BRP EXPEDITION User manual

2006
Shop Manual
2005
Shop Manual
REV SERIES
BOMBARDIER RECREATIONAL PRODUCTS INC.

TABLE OF CONTENTS
SAFETY NOTICE ................................................................................... XI
INTRODUCTION .................................................................................. XII
VEHICLE IDENTIFICATION NUMBER........................................................................... XIV
ENGINE SERIAL NUMBER....................................................................................... XIV
LIST OF ABBREVIATIONS USED IN THIS MANUAL......................................................... XIV
ARRANGEMENT OF THIS MANUAL........................................................................... XVI
GENERAL INFORMATION...................................................................................... XVIII
ILLUSTRATIONS AND PROCEDURES ....................................................................... XVIII
SELF-LOCKING FASTENERS PROCEDURE ................................................................. XVIII
LOCTITE APPLICATION PROCEDURE.......................................................................... XIX
THREADLOCKER .................................................................................................. XIX
STRIPPED THREAD REPAIR ..................................................................................... XX
GASKET COMPOUND............................................................................................ XXI
MOUNTING ON SHAFT .......................................................................................... XXI
CASE-IN COMPONENTS........................................................................................ XXII
TIGHTENING TORQUE ......................................................................................... XXIII
01 MAINTENANCE
01 – MAINTENANCE CHART....................................................................................... 1
02 – STORAGE ....................................................................................................... 3
GENERAL.............................................................................................................. 3
ENGINE ................................................................................................................ 3
FUEL SYSTEM......................................................................................................... 4
DRIVE SYSTEM ....................................................................................................... 4
STEERING/FRONT SUSPENSION ................................................................................... 5
SUSPENSION.......................................................................................................... 5
ELECTRICAL........................................................................................................... 5
VEHICLE ............................................................................................................... 5
03 – PRESEASON PREPARATION................................................................................. 7
ENGINE ................................................................................................................ 7
FUEL SYSTEM......................................................................................................... 7
DRIVE SYSTEM ....................................................................................................... 8
ELECTRICAL SYSTEM................................................................................................ 8
VEHICLE ............................................................................................................... 8
02 TROUBLESHOOTING
01 – ENGINE .......................................................................................................... 9
02 – FUEL AND OIL SYSTEMS .................................................................................. 21
03 – DRIVE AND BRAKE SYSTEMS............................................................................. 25
DRIVE SYSTEM ...................................................................................................... 25
BRAKE SYSTEM...................................................................................................... 32
04 – ELECTRICAL SYSTEM....................................................................................... 33
05 – STEERING AND SUSPENSION ............................................................................ 43
03 ENGINES
01 – LEAK TEST .................................................................................................... 47
PREPARATION ....................................................................................................... 47
PROCEDURE......................................................................................................... 48
FINALIZING REASSEMBLY.......................................................................................... 49
ENGINE LEAK VERIFICATION FLOW CHART ..................................................................... 50
I

TABLE OF CONTENTS
02 – EXHAUST SYSTEM.......................................................................................... 51
377 AND 552 ENGINES ..................................................................................... 52
593, 593 HO, 593 HO SDI AND 793 HO ENGINES ...................................................... 53
TUNED PIPE.......................................................................................................... 54
MANIFOLD ........................................................................................................... 55
MUFFLER............................................................................................................. 55
03 – ENGINE REMOVAL AND INSTALLATION................................................................ 57
REMOVAL FROM VEHICLE......................................................................................... 59
INSPECTION.......................................................................................................... 63
INSTALLATION ....................................................................................................... 63
REMOVAL FROM VEHICLE......................................................................................... 65
INSPECTION.......................................................................................................... 69
INSTALLATION ....................................................................................................... 69
04 – MAGNETO SYSTEM......................................................................................... 71
GENERAL............................................................................................................. 76
MAGNETO FLYWHEEL.............................................................................................. 76
STATOR............................................................................................................... 78
CPS/TRIGGER COIL.................................................................................................. 78
05 – TOP END....................................................................................................... 81
TROUBLESHOOTING................................................................................................ 84
CLEANING............................................................................................................ 84
DISASSEMBLY ....................................................................................................... 84
INSPECTION.......................................................................................................... 86
ASSEMBLY ........................................................................................................... 86
TROUBLESHOOTING................................................................................................ 98
COMPONENT REMOVAL WITH THE ENGINE INSTALLED ...................................................... 98
CLEANING............................................................................................................ 98
RAVE VALVE BASIC OPERATION................................................................................... 98
DISASSEMBLY ....................................................................................................... 98
INSPECTION........................................................................................................ 103
ASSEMBLY ......................................................................................................... 104
06 – BOTTOM END ............................................................................................... 109
CLEANING.......................................................................................................... 112
DISASSEMBLY ..................................................................................................... 112
INSPECTION........................................................................................................ 113
ASSEMBLY ......................................................................................................... 113
BREAK-IN........................................................................................................... 118
CLEANING.......................................................................................................... 122
DISASSEMBLY ..................................................................................................... 122
INSPECTION........................................................................................................ 123
ASSEMBLY ......................................................................................................... 123
BREAK-IN........................................................................................................... 128
07 – ENGINE MEASUREMENT ................................................................................. 129
CYLINDER HEAD WARPAGE ..................................................................................... 129
CYLINDER TAPER.................................................................................................. 129
CYLINDER OUT OF ROUND ...................................................................................... 129
COMBUSTION CHAMBER VOLUME MEASUREMENT........................................................ 130
USED PISTON MEASUREMENT.................................................................................. 131
CYLINDER/PISTON CLEARANCE................................................................................. 131
RING/PISTON GROOVE CLEARANCE............................................................................ 133
RING END GAP..................................................................................................... 133
CRANKSHAFT DEFLECTION...................................................................................... 133
II

TABLE OF CONTENTS
CONNECTING ROD BIG END AXIAL PLAY...................................................................... 134
CHECKING CRANKSHAFT ALIGNMENT .. ...... ...... .... ..... ... .... ..... ... ..... ... .... ..... ... .... ........ ... 134
08 – COOLING SYSTEM ......................................................................................... 135
COOLING FAN REMOVAL AND INSTALLATION ................................................................ 138
COOLING FAN BEARING REPLACEMENT ...................................................................... 138
FAN BELT REPLACEMENT AND DEFLECTION ADJUSTMENT................................................ 139
LIQUID COOLING SYSTEM....................................................................................... 142
COOLING SYSTEM LEAK TEST................................................................................... 145
INSPECTION........................................................................................................ 145
DRAINING THE SYSTEM.......................................................................................... 145
DISASSEMBLY AND ASSEMBLY ................................................................................. 145
COOLING SYSTEM REFILLING PROCEDURE................................................................... 146
09 – REWIND STARTER.......................................................................................... 147
INSPECTION........................................................................................................ 150
REMOVAL .......................................................................................................... 150
ROPE REPLACEMENT............................................................................................. 150
DISASSEMBLY ..................................................................................................... 151
ASSEMBLY ......................................................................................................... 151
INSTALLATION ..................................................................................................... 154
10 – OIL INJECTION SYSTEM .................................................................................. 155
GENERAL........................................................................................................... 158
OIL TYPE............................................................................................................ 158
OIL SYSTEM LEAK TEST.......................................................................................... 158
OIL PUMP IDENTIFICATION ...................................................................................... 159
CLEANING.......................................................................................................... 159
CHECKING OPERATION........................................................................................... 159
DISASSEMBLY ..................................................................................................... 160
ASSEMBLY ......................................................................................................... 161
BLEEDING PROCEDURE.......................................................................................... 162
ADJUSTMENT...................................................................................................... 162
04 FUEL SYSTEM
01 – FUEL TANK AND FUEL PUMP ............................................................................ 165
IN-TANK FUEL FILTER ............................................................................................. 168
IN-LINE FUEL FILTER.............................................................................................. 168
FUEL TANK ......................................................................................................... 169
FLOAT-TYPE FUEL LEVEL GAUGE ............................................................................... 170
ELECTRIC FUEL LEVEL SENSOR................................................................................. 171
FUEL SYSTEM PRESSURIZATION................................................................................ 171
DIAPHRAGM FUEL PUMP................................................................................. 172
REMOVAL .......................................................................................................... 174
PUMP VERIFICATION.............................................................................................. 174
CLEANING AND INSPECTION .................................................................................... 174
INSTALLATION ..................................................................................................... 174
02 – CARBURETORS, THROTTLE AND CHOKE CABLES................................................... 175
CARBURETOR — VM TYPE ............................................................................... 176
IDENTIFICATION ................................................................................................... 177
REMOVAL .......................................................................................................... 177
CLEANING AND INSPECTION .................................................................................... 177
DISASSEMBLY AND ASSEMBLY ................................................................................. 177
CARBURETOR ADJUSTMENTS .................................................................................. 178
INSTALLATION ..................................................................................................... 181
III

TABLE OF CONTENTS
CHOKE.............................................................................................................. 182
CARBURETOR TM TYPE................................................................................... 184
IDENTIFICATION ................................................................................................... 185
REMOVAL .......................................................................................................... 185
CLEANING AND INSPECTION .................................................................................... 187
DISASSEMBLY AND ASSEMBLY ................................................................................. 187
INSTALLATION ..................................................................................................... 189
CARBURETOR ADJUSTMENTS .................................................................................. 189
CHOKE CABLE ..................................................................................................... 191
03 – DPM SYSTEM ............................................................................................... 193
OVERVIEW ......................................................................................................... 195
SYSTEM TESTING ................................................................................................. 195
PARTS REMOVAL AND INSTALLATION.......................................................................... 195
DPM MANIFOLD TESTING........................................................................................ 196
05 ENGINE MANAGEMENT (POWER TEK)
01 – OVERVIEW ................................................................................................... 199
OPERATING PRINCIPLE.................................................................................... 200
FUEL DELIVERY SYSTEM .. ... ..... ..... ..... .... ..... ..... ..... ..... .. ... .. ..... ..... ..... .. ... .. ..... ... ... .. .. . 200
ENGINE MANAGEMENT SYSTEM (EMS)........................................................................ 200
EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS....................................................... 201
POWER DISTRIBUTION........................................................................................... 202
IGNITION SYSTEM................................................................................................. 202
ELECTRONICALLY CONTROLLED RAVE ........................................................................ 202
DIGITALLY ENCODED SECURITY SYSTEM (DESS)............................................................. 202
ROTAX ELECTRONIC REVERSE (RER)........................................................................... 203
MONITORING SYSTEM ........................................................................................... 203
DIAGNOSTIC MODE............................................................................................... 203
02 – DIAGNOSTIC PROCEDURES.............................................................................. 205
GENERAL........................................................................................................... 205
TROUBLESHOOTING ............................................................................................. 205
EMS FAULT CODES ............................................................................................... 206
VCK (VEHICLE COMMUNICATION KIT).......................................................................... 209
03 – COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT ................................ 213
GENERAL..................................................................................................... 213
ELECTRICAL SYSTEM............................................................................................. 213
FUEL SYSTEM...................................................................................................... 215
ENGINE MANAGEMENT SYSTEM....................................................................... 216
ENGINE CONTROL MODULE (ECM)............................................................................. 216
POWER RELAY..................................................................................................... 216
THROTTLE POSITION SENSOR (TPS)............................................................................ 217
AIR TEMPERATURE SENSOR (ATS).............................................................................. 221
COOLANT TEMPERATURE SENSOR (CTS)...................................................................... 222
AIR PRESSURE SENSOR (APS)................................................................................... 223
KNOCK SENSOR (KS).............................................................................................. 224
E-RAVE SOLENOID ................................................................................................ 225
DPM SOLENOID................................................................................................... 226
IGNITION COIL..................................................................................................... 226
ENGINE START/RER SWITCH..................................................................................... 227
DIGITALLY ENCODED SECURITY SYSTEM (DESS)............................................................. 228
IV

TABLE OF CONTENTS
06 ENGINE MANAGEMENT (SDI)
01 – OVERVIEW ................................................................................................... 231
OPERATING PRINCIPLE.................................................................................... 232
CHARGING SYSTEM............................................................................................... 232
IGNITION SYSTEM................................................................................................. 232
AIR INDUCTION.................................................................................................... 232
FUEL DELIVERY SYSTEM .. ... ..... ..... ..... .... ..... ..... ..... ..... .. ... .. ..... ..... ..... .. ... .. ..... ... ... .. .. . 233
ENGINE MANAGEMENT SYSTEM (EMS) .............................................................. 234
ECM — GENERAL FUNCTIONS .................................................................................. 235
EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS....................................................... 237
ELECTRONIC FUEL INJECTION.................................................................................. 237
IGNITION TIMING.................................................................................................. 238
ELECTRONICALLY CONTROLLED RAVE ........................................................................ 238
KNOCK SENSOR................................................................................................... 238
ENGINE MODES OF OPERATION................................................................................ 238
FLOODED ENGINE (DROWNED MODE) ........................................................................ 238
MONITORING SYSTEM ........................................................................................... 238
LIMP HOME MODES.............................................................................................. 238
DIAGNOSTIC MODE............................................................................................... 239
ROTAX ELECTRONIC REVERSE (RER)........................................................................... 239
02 – DIAGNOSTIC PROCEDURES.............................................................................. 241
GENERAL........................................................................................................... 241
TROUBLESHOOTING ............................................................................................. 241
VCK (VEHICLE COMMUNICATION KIT).......................................................................... 245
2-TEC SYSTEM FAULT CODES ................................................................................... 247
03 – COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT ................................ 249
GENERAL..................................................................................................... 249
FUEL SYSTEM............................................................................................... 249
ELECTRICAL SYSTEM...................................................................................... 250
RESISTANCE MEASUREMENT................................................................................... 251
ENGINE CONNECTORPIN-OUTS ................................................................................ 252
RELAY............................................................................................................... 253
AIR INDUCTION SYSTEM ................................................................................. 254
THROTTLE BODY.................................................................................................. 254
FUEL DELIVERY ............................................................................................. 257
ELECTRIC FUEL PUMP............................................................................................ 258
FUEL RAIL .......................................................................................................... 261
FUEL INJECTORS.................................................................................................. 262
ELECTRONIC MANAGEMENT ............................................................................ 265
ECM REPLACEMENT.............................................................................................. 265
ENGINE WIRING HARNESS....................................................................................... 265
THROTTLE POSITION SENSOR (TPS)............................................................................ 266
CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 268
AIR TEMPERATURE SENSOR (ATS).............................................................................. 269
COOLANT TEMPERATURE SENSOR (CTS)...................................................................... 270
AIR PRESSURE SENSOR (APS)................................................................................... 271
EXHAUST GAS TEMPERATURE SENSOR (EGTS)............................................................... 271
KNOCK SENSOR (KS).............................................................................................. 272
E-RAVE SOLENOID ................................................................................................ 273
DOUBLE IGNITION COIL.......................................................................................... 273
IGNITION TIMING.................................................................................................. 275
BATTERY............................................................................................................ 275
V

TABLE OF CONTENTS
CAPACITOR......................................................................................................... 275
ENGINE START/RER SWITCH VERIFICATION................................................................... 276
DESS POST VERIFICATION....................................................................................... 277
07 ELECTRICAL SYSTEM
01 – IGNITION SYSTEM ......................................................................................... 279
GENERAL........................................................................................................... 279
IGNITION TIMING.................................................................................................. 282
SPARK PLUG ....................................................................................................... 291
DESIGN SYMBOLS USED IN NGK SPARK PLUGS.................................................... 292
02 – CHARGING SYSTEM ....................................................................................... 293
GENERAL........................................................................................................... 293
CHARGING GENERATOR COIL (STATOR) ....................................................................... 293
VOLTAGE REGULATOR/RECTIFIER .............................................................................. 294
BATTERY............................................................................................................ 295
CABLE TERMINAL INSTALLATION............................................................................... 297
03 – STARTING SYSTEM ........................................................................................ 299
TROUBLESHOOTING.............................................................................................. 301
04 – ACCESSORIES............................................................................................... 307
GENERAL........................................................................................................... 307
12-VOLT POWER OUTLET (CIGARETTE-LIGHTER TYPE) ...................................................... 308
BEEPER (REVERSE ALARM)...................................................................................... 308
ENGINE TEMPERATURE GAUGE................................................................................. 309
ELECTRIC FUEL GAUGE .......................................................................................... 310
HEADLAMP......................................................................................................... 310
HEADLAMP BEAM AIMING ...................................................................................... 311
HEATING ELEMENTS.............................................................................................. 312
RELAY............................................................................................................... 312
SPEEDOMETER.................................................................................................... 313
SPEED SENSOR.................................................................................................... 313
TACHOMETER ..................................................................................................... 314
TAILLIGHT .......................................................................................................... 314
VISOR OUTLET..................................................................................................... 315
08 DRIVE SYSTEM
01 – DRIVE BELT .................................................................................................. 317
APPLICATION CHART ............................................................................................. 317
INSPECTION........................................................................................................ 317
CHECKING NEUTRAL FUNCTION................................................................................ 317
ROTATION DIRECTION............................................................................................ 317
DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT .................................................. 318
DRIVE BELT DEFLECTION MEASUREMENT (REFERENCE ONLY)............................................ 320
02 – DRIVE PULLEY............................................................................................... 323
BOMBARDIER LITE ......................................................................................... 324
GENERAL........................................................................................................... 325
REMOVAL .......................................................................................................... 325
DISASSEMBLY ..................................................................................................... 325
CLEANING.......................................................................................................... 326
INSPECTION........................................................................................................ 326
ASSEMBLY ......................................................................................................... 326
INSTALLATION ..................................................................................................... 327
TRA III......................................................................................................... 328
VI

TABLE OF CONTENTS
GENERAL........................................................................................................... 329
REMOVAL .......................................................................................................... 329
DISASSEMBLY ..................................................................................................... 329
CLEANING.......................................................................................................... 331
INSPECTION........................................................................................................ 331
ASSEMBLY ......................................................................................................... 333
INSTALLATION ..................................................................................................... 337
DRIVE PULLEY ADJUSTMENT ................................................................................... 337
03 – DRIVEN PULLEY ............................................................................................ 339
FORMULA RER AND FORMULA VSA-R......................................................................... 340
REMOVAL .......................................................................................................... 341
DISASSEMBLY ..................................................................................................... 341
CLEANING.......................................................................................................... 341
INSPECTION........................................................................................................ 341
BUSHING REPLACEMENT........................................................................................ 342
ASSEMBLY ......................................................................................................... 342
INSTALLATION ..................................................................................................... 343
ADJUSTMENT...................................................................................................... 344
HPV VSA ............................................................................................................ 345
REMOVAL .......................................................................................................... 346
DISASSEMBLY ..................................................................................................... 346
CLEANING.......................................................................................................... 346
INSPECTION........................................................................................................ 346
ASSEMBLY ......................................................................................................... 346
INSTALLATION ..................................................................................................... 347
ADJUSTMENT...................................................................................................... 347
04 – PULLEY ALIGNMENT ...................................................................................... 349
GENERAL........................................................................................................... 349
MEASURING PROCEDURE ....................................................................................... 349
ALIGNMENT PROCEDURE........................................................................................ 351
05 – BRAKE ........................................................................................................ 353
HYDRAULIC BRAKE ........................................................................................ 354
BRAKE FLUID ...................................................................................................... 355
MASTER CYLINDER............................................................................................... 355
CALIPER ............................................................................................................ 355
BRAKE PADS ....................................................................................................... 356
BRAKE DISC........................................................................................................ 357
COUNTERSHAFT BEARING....................................................................................... 357
COUNTERSHAFT................................................................................................... 358
BRAKE LIGHT SWITCH............................................................................................ 358
BLEEDING.......................................................................................................... 359
06 – CHAINCASE.................................................................................................. 361
GENERAL........................................................................................................... 363
CHAINCASE OIL LEVEL ........................................................................................... 363
OIL CHANGE ....................................................................................................... 363
DRIVE CHAIN ADJUSTMENT..................................................................................... 364
REMOVAL AND DISASSEMBLY .................................................................................. 364
INSPECTION........................................................................................................ 365
INSTALLATION AND ASSEMBLY ................................................................................. 365
SILENT CHAIN...................................................................................................... 365
07 – DRIVE AXLE.................................................................................................. 367
REMOVAL .......................................................................................................... 371
VII

TABLE OF CONTENTS
ASSEMBLY ......................................................................................................... 372
LUBRICATION...................................................................................................... 373
ADJUSTMENT...................................................................................................... 373
08 – TRACK ........................................................................................................ 375
TRACK TYPE APPLICATION....................................................................................... 375
GENERAL........................................................................................................... 375
INSPECTION........................................................................................................ 375
REMOVAL .......................................................................................................... 375
INSTALLATION ..................................................................................................... 375
ADJUSTMENT...................................................................................................... 375
TRACK CLEAT ...................................................................................................... 377
TRACTION ENHANCING PRODUCTS (STUDS).................................................................. 377
09 REAR SUSPENSION
01 – SC SUSPENSION ........................................................................................... 381
AXLE SELF-LOCKING SCREWS REMOVAL ..................................................................... 386
REAR AXLE REMOVAL............................................................................................ 386
REAR AXLE INSTALLATION....................................................................................... 386
REAR SHOCK ABSORBER REMOVAL ........................................................................... 386
REAR SHOCK ABSORBER INSTALLATION...................................................................... 387
FRONT SHOCK ABSORBER REMOVAL ......................................................................... 387
FRONT SHOCK ABSORBER INSTALLATION .................................................................... 387
REAR SPRING REMOVAL......................................................................................... 388
REAR SPRING INSTALLATION.................................................................................... 388
SLIDER SHOE VERIFICATION .................................................................................... 388
SLIDER SHOE REMOVAL ......................................................................................... 389
SLIDER SHOE INSTALLATION.................................................................................... 390
SUSPENSION REMOVAL.......................................................................................... 390
SUSPENSION INSTALLATION .................................................................................... 391
FRONT ARM REMOVAL........................................................................................... 391
FRONT ARM INSTALLATION ..................................................................................... 391
REAR ARM/PIVOT ARM REMOVAL.............................................................................. 392
REAR ARM INSTALLATION....................................................................................... 392
STOPPER STRAP................................................................................................... 392
RIDE ADJUSTMENT............................................................................................... 393
LUBRICATION...................................................................................................... 393
02 – SC 3 SUSPENSION ......................................................................................... 395
AXLE SELF-LOCKING SCREWS REMOVAL ..................................................................... 399
REAR AXLE REMOVAL............................................................................................ 399
REAR AXLE INSTALLATION....................................................................................... 399
REAR SHOCK ABSORBER REMOVAL ........................................................................... 399
REAR SHOCK ABSORBER INSTALLATION...................................................................... 400
FRONT SHOCK ABSORBER REMOVAL ......................................................................... 400
FRONT SHOCK ABSORBER INSTALLATION .................................................................... 400
REAR SPRING REMOVAL......................................................................................... 400
REAR SPRING INSTALLATION.................................................................................... 401
SLIDER SHOE VERIFICATION .................................................................................... 402
SLIDER SHOE REMOVAL ......................................................................................... 402
SLIDER SHOE INSTALLATION.................................................................................... 403
SUSPENSION REMOVAL.......................................................................................... 403
SUSPENSION INSTALLATION .................................................................................... 404
FRONT ARM REMOVAL........................................................................................... 404
VIII

TABLE OF CONTENTS
FRONT ARM INSTALLATION ..................................................................................... 405
REAR ARM/PIVOT ARM REMOVAL.............................................................................. 405
REAR ARM/PIVOT ARM INSTALLATION......................................................................... 405
STOPPER STRAP................................................................................................... 406
RIDE ADJUSTMENT............................................................................................... 406
LUBRICATION...................................................................................................... 406
03 – SC 4 SUSPENSION ......................................................................................... 409
AXLE SELF-LOCKING SCREW REMOVAL....................................................................... 413
REAR AXLE REMOVAL............................................................................................ 413
REAR AXLE INSTALLATION....................................................................................... 413
REAR SHOCK ABSORBER REMOVAL ........................................................................... 413
REAR SHOCK ABSORBER INSTALLATION...................................................................... 414
FRONT SHOCK ABSORBER REMOVAL ......................................................................... 414
FRONT SHOCK ABSORBER INSTALLATION .................................................................... 415
REAR SPRING REMOVAL......................................................................................... 415
REAR SPRING INSTALLATION.................................................................................... 416
SLIDER SHOE VERIFICATION .................................................................................... 416
SLIDER SHOE REMOVAL ......................................................................................... 417
SLIDER SHOE INSTALLATION.................................................................................... 418
SUSPENSION REMOVAL.......................................................................................... 418
SUSPENSION INSTALLATION .................................................................................... 418
FRONT ARM REMOVAL........................................................................................... 418
FRONT ARM INSTALLATION ..................................................................................... 419
REAR ARM/PIVOT ARM REMOVAL.............................................................................. 419
REAR ARM/PIVOT ARM INSTALLATION......................................................................... 419
BLOCK INSTALLATION............................................................................................ 420
IDLER WHEELS INSTALLATION.................................................................................. 420
STOPPER STRAP................................................................................................... 420
RIDE ADJUSTMENT............................................................................................... 420
LUBRICATION...................................................................................................... 421
04 – SHOCK ABSORBER INSPECTION AND SERVICING .................................................. 423
SPRING REMOVAL ................................................................................................ 423
SHOCK ABSORBER INSPECTION................................................................................ 424
DISASSEMBLY AND ASSEMBLY ................................................................................. 425
10 STEERING/FRONT SUSPENSION
01 – STEERING SYSTEM ........................................................................................ 433
DISASSEMBLY AND ASSEMBLY ................................................................................. 437
INSPECTION........................................................................................................ 440
ADJUSTMENT...................................................................................................... 440
STEERING ADJUSTMENT (SKIS) ................................................................................. 444
LUBRICATION...................................................................................................... 446
02 – FRONT SUSPENSION...................................................................................... 447
GENERAL INSPECTION ........................................................................................... 450
DISASSEMBLY ..................................................................................................... 450
INSPECTION........................................................................................................ 454
INSTALLATION ..................................................................................................... 455
11 BODY/FRAME
01 – BODY.......................................................................................................... 461
INSTALLATION AND ADJUSTMENT .................................................................... 461
DECAL .............................................................................................................. 461
IX

TABLE OF CONTENTS
WINDSHIELD....................................................................................................... 461
GUARD.............................................................................................................. 461
WIRING HARNESS................................................................................................. 461
CABLES............................................................................................................. 462
TUBING ............................................................................................................. 462
PLASTIC MAINTENANCE AND REPAIR ................................................................. 462
MAINTENANCE .................................................................................................... 462
REPAIR.............................................................................................................. 462
02 – FRAME........................................................................................................ 463
FRAME CLEANING ................................................................................................ 463
FRAME WELDING ................................................................................................. 463
FRAME COMPONENT REPLACEMENT ......................................................................... 463
12 TECHNICAL DATA
01 – FAN COOLED MODELS .................................................................................... 465
02 – LIQUID COOLED MODELS................................................................................. 471
03 – LIQUID COOLED (SDI) MODELS.......................................................................... 479
13 WIRING DIAGRAM
01 – WIRING DIAGRAMS........................................................................................ 485
WIRING DIAGRAM LEGEND...................................................................................... 485
WIRE COLORS..................................................................................................... 485
CONNECTOR HOUSING AREA................................................................................... 485
HOUSING REFERENCE PER AREA............................................................................... 486
WIRE LOCATION IN CONNECTOR HOUSING .................................................................. 486
SYMBOLS DESCRIPTION......................................................................................... 488
UNPLUGING CONNECTORS...................................................................................... 489
TAB AND RECEPTACLE CONNECTORS REMOVAL ............................................................ 489
TAB AND RECEPTACLE CONNECTORS INSTALLATION....................................................... 495
X

INTRODUCTION
MODEL ENGINE MODEL NUMBER
EXPEDITION 550F FJ5A, FJ5B
380F DG5B
550F DF5A
500 SS DC5A, DC5B
600 HO DB5A, DB5B
600 HO SDI DD5A, DD5B, DE5A, DE5B
GSX
800 HO DPM Power Tek DA5A, DA5B
380F EM5A, EM5B
550F EL5A, EL5B
500 SS ED5A, ED5B, ED5C
600 HO EC5A, EC5B
600 HO SDI EH5A, EH5B, EJ5A, EJ5B, EJ5C
GTX
800 HO DPM Power Tek EA5A, EA5B, EA5C
380F BR5A, BR5B, BR5C
550F BP5A, BP5B, BP5C
500 SS BF5A, BF5B, BF5C, BF5G, BF5H, BF5J, BF5L, BH5B,
BH5C, BH5D, BH5A, BH5E
600 HO BC5A, BC5C, BC5F, BC5G, BC5H, BC5J, BC5K, BC5L,
BC5M, BE5A, BE5B, BE5C, BE5G, BE5H, BE5J, BE5K, BE5L,
BE5M,BE5N,BG5A,BG5B,BV5A,BV5B,BV5C,BV5D
MX Z
600 HO SDI
BK5A, BK5B, BK5C, BK5D, BK5F, BK5G, BK5H, BK5J, BK5K,
BK5L, BK5M, BK5N, BL5A, BL5B, BL5C, BL5G, BL5H, BL5J,
BL5K, BL5L, BL5M, BW5C, BW5F, BW5G, BW5H, BW5J,
BW5K, BW5L, BW5M, BX5C, BX5D, BX5E, BX5F, BX5G
MX Z (Adrenaline) 800 HO BD5A, BD5B, BD5C, BD5G, BD5H, BD5J,
BD5K, BD5L, BD5M
MX Z 800 HO DPM Power Tek
BB5A, BB5B, BB5C, BB5D, BB5F, BB5G, BB5H,
BB5J, BB5K, BB5L, BB5M, BB5N, BS5C, BS5D,
BS5E, BS5F, BS5G, BS5H, BS5J, BS5K, BS5L, BS5M,
BS5N, BU5A, BU5B, BU5C, BU5D
550F CM5A, CM5B
SUMMIT
800 HO DPM CG5A, CG5B, CG5C, CG5D, CH5A, CH5B, CH5C,
CH5D, CJ5A, CJ5B, CJ5C, CK5A, CK5B, CL5A, CL5B,
CL5C, CP5A, CP5B, CP5C, CP5D
mmr2005-059 XIII

INTRODUCTION
VEHICLE IDENTIFICATION
NUMBER
Vehicle Identification Number Location
1
A33H01A
TYPICAL
1. Vehicle identification number
Identification Number Meaning
A00A8HA
2 B P S B X 5 A 9 Y 1 0 0 0 0 0 1
Model number Serial number
Model year: y = 2000
1 = 2001
2 = 2002
e c.
ENGINE SERIAL NUMBER
Engine Serial Number Location
A03A0BA
1
TYPICAL — 2–STROKE FAN-COOLED ENGINES
1. Engine serial number
1
A32C01B
TYPICAL — 2–STROKE LIQUID-COOLED ENGINES
1. Engine serial number
LIST OF ABBREVIATIONS USED
IN THIS MANUAL
ABBREVIATION MEANING
Aampere
amp ampere
A•h ampere-hour
AC alternate current
ACM acceleration and control
modulator
AMG absorbed glass mat
BDC bottom dead center
BTDC before top dead center
°C degree Celsius
cc cubic centimeter
CDI capacitor discharge ignition
CTR center
cm centimeter
cm²square centimeter
cm³cubic centimeter
DC direct current
DESS digitally encoded security
system
DPM digital performance
management
XIV
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INTRODUCTION
ABBREVIATION MEANING
°F degree Fahrenheit
FC fan cooled
fl. oz fluid ounce
ft foot
GRD ground
H.A.C. high altitude compensator
hal. halogen
HI high
IFP internal floating piston
imp. oz imperial ounce
in inch
in²square inch
in³cubic inch
kkilo (thousand)
kg kilogram
km/h kilometer per hour
kPa Kilopascal
Lliter
lb pound
lbf pound (force)
lbf/in²pound per square inch
LH left hand
LO low
LT long track
mmeter
MAG magneto
Max. maximum
Min. minimum
mL milliliter
mm millimeter
M.E. millennium edition
MPEM multi-purpose electronic
module
MPH mile per hour
Nnewton
ABBREVIATION MEANING
N.A. not applicable
no. number
0continuity
0.L open line (open circuit)
O.D. outside diameter
OPT optional
oz ounce
P/N part number
PSI pound per square inch
PTO power take off
Rrectangular
RH right hand
R.A.S. response angle suspension
RAVE Rotax adjustable variable
exhaust
RER Rotax electronic reverse
RPM revolution per minute
RMS root mean square
RRIM reinforced reaction injection
molding
SDI semi-direct injection
Sp. Gr. specific gravity
ST semi-trapez
TDC top dead center
TRA total range adjustable
U.S. oz ounce (United States)
Vvolt
Vac volt (alternative current)
VSA variable sheave angle
mmr2005-059 XV

INTRODUCTION
ARRANGEMENT OF THIS MANUAL
Section 07 REAR SUSPENSION
Subsec ion 01 (SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN)
SUSPENSION SC-10 SPORT,
TOURING AND MOUNTAIN
A-Series and B-Series
56
MMR2000_042_00-02A.FM
A03F24S
Short track models only
Long track
models only
SLE
only
Loc i e
271
Loc i e
271
Loc i e
271
Loc i e
271
Loc i e
271
Loc i e
271
Loc i e
271
Loc i e
271
Low
emp.
grease
6
5
6
7
4
3
2
1
6
1
Low
emp.
grease
8
16
Low
emp.
grease
11
12
13
14
15
11
11
11
16
20 18
10
17
11
18 Nm
(160 lbfin)
4 Nm
(35 lbfin)
Page heading
indicates section
and subsection
detailed.
Bold face number
indicates special
procedure concerning
this part.
Tightening torque nearby
fastener. In this case, nut
must be torqued to
4 Nm or 3 lbfin.
This Shop Manual uses technical terms wich may be
slightly different from the ones in the parts catalog.
Exploded view
assists you in
identifying parts and
related positions.
TYPICAL PAGE
A00A7XS
Illustration number
for publishing
process.
Subsection title
indicates
beginning of the
subsection.
Drop represents
a service
product to be
applied to
a surface.
In this case
Loctite 271 to
screw threads.
Dotted box contains
parts of a particular
model in this case
the short track
models only.
Page number
Italic subtitle above
exploded view
indicates
pertaining models.
CAUTION: Pay a en ion o orque
specifi
ca ions. Some of hese are
in
lbf  in ins ead of lbf  f . Use appro-
pria e orque wrench.
Document
number for
publishing
process.
XVI
mmr2005-059

INTRODUCTION
MMR2000_042_00-02A.FM
A16D0IA
1
2
A
1
A-Series and B-Series Only
Should installation procedure be required, refer
to BRAKE then look for Brake Disc and Coun ershaf
Bearing Adjus men .
All Models
Check end play of driven pulley on countershaft by
pushing pulley towards outer housing so that the inner
shims (P/N 04 108 200) contact it. Measure end play
at the mounting screw end between shim(s) and puley.
See illustration.
TYPICAL  TOP VIEW
1. Shim (P/N 504 108 200) (as required)
2. Conta t
A. 0 to 1 mm (0 to 3/64 in)
Torque retaining screw no. 13 to 2 Nm (18 lbfft).
ADJUSTMENT
Refer to PULLEY DISTANCE AND ALIGNMENT to adjust
pulley distance. Adjust drive belt height be-
tween pulley halves to obtain specified belt
deflection.
Reinstall the pulley on the countershaft by rever-
sing the removal procedure.
CAUTION: Always apply an i-seize lubrican (P/N
413 701 000) on he coun ershaf before final pulley
ins alla ion.
57
Turn puller handle and sliding half at once to extract
the bushing. INSTALLATION
Coun ershaf
IMPORTANT: Large bushing retaining screws and
washers must be removed before small bushing
installation.
Coat bushing outside diameter with Loctite 609
(P/N 413 703 100).
Install bushing as following photo.
A03D1YA
529 031 300
529 031 200
A03D1ZA
529 031 300
529 031 200
Cam
Coat cam no. 18 interior with anti-seize lubricant.
ASSEMBLY
Came Slider Shoe
Section 05 TRANSMISSION
Subsec ion 03 (DRIVEN PULLEY)
When replacing slider shoes no. 4, always install a new
set (3 shoes) to maintain equal pressure on the cam.
Assemble driven pulley components by reversing
the disassembly procedure.
A00A7YS
Title indicates
main procedure
to be carried-out.
Reference to look
up a certain section
and subsection.
In this case it concerns
pulleys adjustment.
Italic bold face setting
in this case indicates
that particular
procedure for
A and B-Series is
finished, so from
this point, all models
are concerned.
Illustration always
follows text to which
it pertains.
Subtitle indicates
a particular procedure
for the named part.
Bold face number following part
name refers to exploded view
at beginning of subsection.
Call-outs for
above illustration.
Italic bold face type
setting indicates a
particular procedure
concerning a model.
TYPICAL caption
indicates a general
view which does
not represent full
detail.
TOP VIEW
caption helps you
in understanding
illustration.
TYPICAL PAGE
mmr2005-059 XVII

INTRODUCTION
GENERAL INFORMATION
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. BRP however, maintains a policy
of continuous improvement of its products with-
out imposing upon itself any obligation to install
them on products previously manufactured.
Due to late changes, it may have some differences
between the manufactured product and the de-
scription 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.
ILLUSTRATIONS AND
PROCEDURES
Illustrations and photos show the typical construc-
tion of the different assemblies and, in all cases,
may not reproduce the full detail or exact shape of
the parts shown. However, they represent parts
which have the same or a similar function.
CAUTION: Most components of those 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
could cause damage to the vehicle or possible
personal injury.
As many of the procedures in this manual are inter-
related, we suggest, that before undertaking any
task, you read and thoroughly understand the en-
tire section or subsection in which the procedure
is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before commenc-
ing any procedure, be sure that you have on hand
all the tools required, or approved equivalents.
The use of RIGHT and LEFT indications in the text,
always refers to driving position (when sitting on
vehicle).
A33A2BA
12
TYPICAL
1. Left
2. Right
SELF-LOCKING FASTENERS
PROCEDURE
A00A6LA
TYPICAL —SELF-LOCKING FASTENER
The following describes the most common appli-
cation procedures when working with self-locking
fasteners.
Use a metal brush or a tap to clean the hole prop-
erly then use a solvent (Methyl-Chloride), let act
during 30 minutes and wipe off. The solvent uti-
lization is to ensure the adhesive works properly.
XVIII
mmr2005-059

INTRODUCTION
LOCTITE APPLICATION
PROCEDURE
The following describes the most common ap-
plication procedures when working with Loctite
products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this shop manual.
THREADLOCKER
Uncovered Holes (bolts and nuts)
A00A3LA
1
2
1. Apply here
2. Do not apply
–Clean threads (bolt and nut) with solvent.
–Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
–Choose proper strength Loctite threadlocker.
–Fit bolt in the hole.
–Apply a few drops of threadlocker at proposed
tightened nut engagement area.
–Position nut and tighten as required.
Blind Holes
A00A3MA
1
2
1. On threads
2. On threads and at the bottom of hole
–Clean threads (bolt and hole) with solvent.
–Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
–Choose proper strength Loctite threadlocker.
–Apply several drops along the threaded hole and
at the bottom of the hole.
–Apply several drops on bolt threads.
–Tighten as required.
Stud in Blind Holes
A00A3NA
2
13
1. On threads
2. On threads and in the hole
3. Onto nut threads
–Clean threads (stud and hole) with solvent.
–Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
–Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
mmr2005-059 XIX

INTRODUCTION
–Apply several drops of proper strength Loctite
on stud threads.
–Install stud.
–Install cover, etc.
–Apply drops of proper strength Loctite on un-
covered threads.
–Tighten nuts as required.
Preassembled Parts
A00A3OA
1
2
1. Apply here
2. Do not apply
–Clean bolts and nuts with solvent.
–Assemble components.
–Tighten nuts.
–Apply drops of proper strength Loctite on
bolt/nut contact surfaces.
–Avoid touching metal with tip of flask.
NOTE: For preventive maintenance on exist-
ing equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.
Adjusting Screw
A00A3PA
12
1. Apply here
2. Plunger
–Adjust screw to proper setting.
–Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces.
–Avoid touching metal with tip of flask.
NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C(450°F)).
STRIPPED THREAD REPAIR
Stripped Threads
A00A3QA
5
8
6
7
1
2
3
4
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tape
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker
Standard Thread Repair
–Follow instructions on Loctite FORM-A-
THREAD 81668 package.
XX
mmr2005-059

INTRODUCTION
–If a plate is used to align bolt:
–Apply release agent on mating surfaces.
–Put waxed paper or similar film on the sur-
faces.
–Twist bolt when inserting it to improve thread
conformation.
NOTE: NOT intended for engine stud repairs.
Repair of Small Holes/Fine Threads
Option 1: Enlarge damaged hole, then follow
STANDARD THREAD REPAIR procedure.
Option 2: Apply FORM-A-THREAD on the screw
and insert in damaged hole.
Permanent Stud Installation (light duty)
–Use a stud or thread on desired length.
–DO NOT apply release agent on stud.
–Do a STANDARD THREAD REPAIR.
–Allowtocurefor30minutes.
–Assemble.
GASKET COMPOUND
All Parts
A00A3SA
2
1
13
1
1. Proper strength Loctite
2. Loctite Primer N (P/N 413 708 100) and Gasket Eliminator
515 (P/N 413 702 700) on both sides of gasket
3. Loctite Primer N only
–Remove old gasket and other contaminants
with Loctite Chisel remover (P/N 413 708 500).
Use a mechanical mean if necessary.
NOTE: Avoid grinding.
–Clean both mating surfaces with solvent.
–Spray Loctite Primer N on both mating surfaces
and on both sides of gasket. Allow to dry 1 or
2minutes.
–Apply GASKET ELIMINATOR 515 (P/N 413 702
700) on both sides of gasket, using a clean ap-
plicator.
–Place gasket on mating surfaces and assemble
immediately.
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite in the hole and on
threads. Tighten.
If holes are sunken, apply proper strength Loctite
on bolt threads.
–Tighten as usual.
MOUNTINGONSHAFT
Mounting with a Press
A00A3UA
1
2
3
1. Bearing
2. Proper strength Loctite
3. Shaft
Standard
–Clean shaft external part and element internal
part.
–Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
NOTE: Retaining compound is always forced out
whenappliedonshaft.
–DO NOT use anti-seize Loctite or any similar
product.
–No curing period is required.
Mounting in Tandem
–Apply retaining compound on internal element
bore.
–Continue to assemble as shown above.
mmr2005-059 XXI