BRP SKI-DOO MX Z X 600RS 2016 User manual

PRE-DELIVERY
BULLETIN
SKI-DOO®
September 2015 Subject: MX Z X 600RS Predelivery Inspection No. 2016-5
THE MX Z X 600RS 2016 IS FOR RACE APPLICATION ONLY
There is no limited warranty available
YEAR MODEL MODEL NUMBER PREDELIVERY KIT P/N
2016 MX Z X 600RS BMGA / BMGB 549 011 447
TABLE OF CONTENTS
Page Page
IMPORTANT NOTICE ........................ 2
UPDATE SUMMARY ......................... 3
PREDELIVERY KIT . .... ... .... ... .... ... ... ... 3
UNCRATING ................................... 4
Crate Cover....................................... 4
Crate Brackets ................................... 4
Crate Disposal.................................... 4
Rear Suspension Shipping Hook(s) .......... . 5
Shipping Brackets ............................... 5
PARTS TO BE INSTALLED.................. 5
Front Shock Absorber........ .... ............... 5
Skis ................................................ 6
Handlebar......................................... 6
Handlebar Wind Deflector........ .... ......... . 7
Steering Pad...................................... 8
Snow Guard ...................................... 8
Rear Bumper..................................... 8
Exhaust Deflector ............................... 8
Drive Belt ......................................... 9
Grip Plates (if needed) ................. .... .... 10
Reinforcement Bracket .... .... ................ 10
FINAL PREPARATION........... ............ 10
Engine Oil........................................ 10
Brake Fluid Level ........... .... ................ 10
Track Tension and Alignment ... .... .......... 11
Track Studding .................................. 12
Speedometer.................................... 12
Vehicle Cleaning ................................ 13
DELIVERY TO CUSTOMER .... .... .... .... 13
Break-in Period.................................. 13
Rear Suspension Adjustments ....... ........ 13
French Warning Labels ............. ......... .. 13
Vehicle Delivery................................. 13
Warranty ......................................... 13
Printed in Canada. (mbl2016-006 en ML MS)
©2015 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
1 / 13
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

IMPORTANT NOTICE
IMPORTANT NOTICE
This bulletin must be used in conjunction with check list enclosed in bag with OPERATOR’S GUIDE . Make
sure that PREDELIVERY CHECK LIST is completed and signed by customer and dealer.
WARNING
To obtain limited warranty coverage, predelivery procedures must be performed by an autho-
rized BRP Ski-Doo snowmobile dealer/distributor. Apply all necessary torques as indicated.
NOTE: The information and components/system descriptions contained in this document are correct at
time of publication. Bombardier Recreational Products Inc. (BRP) however, maintains a policy of contin-
uous improvement of its products without imposing upon itself any obligation to install them on products
previously manufactured.
Due to late changes, there might be some differences between manufactured product and descriptions
and/or specifications in this document. BRP reserves the right at any time to discontinue or change spec-
ifications, designs, features, models or equipment without incurring obligation.
The illustrations in this document show typical construction of different assemblies and may not repro-
duce full detail or exact shape of parts. However, they represent parts that have same or similar function.
Content of this bulletin is designed as a guideline only. All mechanics performing predelivery proce-
dures should have attended current model year service training.
Further information or inquiries should be directed to your distributor service representative and/or spe-
cific SERVICE MANUAL
sections.
Please complete PREDELIVERY CHECK LIST for each snowmobile and retain a customer signed copy.
Make sure customer receives OPERATOR’S GUIDE , PREDELIVERY CHECK LIST signed copy and
SAFETY DVD .
There is a tag attached to ignition key, only customer must remove it. This label will remind cus-
tomer to ask dealer/distributor to perform suspension adjustments according to riding style and
vehicle load.
WARNING
Torque wrench tightening specifications must strictly be adhered to. Where specified, install new
locking devices (e.g. lock tabs, elastic stop nuts). If the efficiency of a locking device is impaired,
it must be renewed.
2 / 13 2016-5 PREDELIVERY

PREDELIVERY KIT
UPDATE SUMMARY
This summary highlights updates to the Predelivery Inspection for MY 2016. It does not supersede pro-
cedures detailed further in this publication.
IMPORTANT: Technicians should read and apply all procedures in this PDI bulletin as applicable to model.
APPLICABLE TO UPDATE DESCRIPTION REFERENCE
No stabilizer bar Parts to be installed
No windshield Parts to be intalledAll Models
No idler wheels Parts to be installed
PREDELIVERY KIT
Parts List (P/N 549 011 447)
SECTION WHERE USED DESCRIPTION P/N QTY
Rear Bumper Screw M6 x 18 250 000 779 6
Ski stopper 505 072 594 2
Washer 503 192 496 2Skis
Elastic nut M10 233 201 464 2
Front Shock Absorbers Elastic nut M10 233 201 464 4
Pop rivet 4.8 mm (3/16 in) 293 150 104 4
Snow Guard
Washer 517 225 900 4
Pop rivet 4.8 mm (3/16 in) 293 150 104 3
Exhaust Deflector
Washer 517 124 300 3
Reinforcement Bracket Hemlok rivet 6.4 mm (1/4 in) 293 150 147 3
PREDELIVERY 2016-5 3 / 13

UNCRATING
UNCRATING
Crate Cover
1. Carefully lay crate on its bottom.
NOTICE
Allowing crate to drop may cause se-
rious damage to vehicle.
2. Remove all screws retaining crate top to side-
walls.
mbl2015-002-001_a
3. Remove screws securing sidewalls to crate
base.
4. Unscrew sidewalls one at the time.
mbl2015-002-002_a
5. Remove polyethylene foam sheets.
NOTICE
Do not remove protective wrapping
until delivery to customer.
6. Remove parts to be installed from vehicle or
crate base.
Crate Brackets
CAUTION
Make sure vehicle is properly
supported before removing ski legs and rear
suspension from crate brackets.
1. Remove ski leg wood protectors (if applicable).
2. Detach ski legs from crate shipping brackets.
3. Discard shipping bolts and shipping inserts.
Keep spacers for ski installation.
mbl2011-005-001_a
1. Shipping bolts (discard)
2. Shipping inserts (discard)
3. Spacers (keep)
Discard shipping bracket.
4. Using a pry bar, remove wood blocks retaining
track to crate base.
mbl2010-003-001_a
1. Track
2. Wood block
5. Remove vehicle from crate base.
Crate Disposal
NOTE: The ECO crate is designed to be disassem-
bled easily in order to be stacked with very low
height or to be disposed as per environmental reg-
ulations.
1. Pull canvas off top and sidewall wood struc-
tures.
2. Stack or dispose as per local environmental reg-
ulations.
4 / 13 2016-5 PREDELIVERY

PARTS TO BE INSTALLED
Rear Suspension Shipping
Hook(s)
NOTICE
Shipping hooks must be removed to
have snowmobile suspension operational.
1. Apply parking brake.
2. Standing on footrests, apply pressure onto rear
suspension and ask someone to remove rear
hook.
NOTICE
To avoid any damage to seat, always
sit on seating surface.
12
mbl2008-009-003_a
TYPICAL
1. Apply pressure
2. Rear hook
3. Lift rear of vehicle so that a block or a box can
be positioned under front part of rear suspen-
sion.
4. Ask another person to apply pressure onto rear
suspension.
NOTICE
To avoid any damage to seat, always
sit on seating surface.
5. Remove front hook(s) from suspension.
Shipping Brackets
To access the shock upper bolts, remove the up-
per body module. Refer to BODY subsection in
the appropriate shop manual.
1. Remove and discard plastic washers.
2. Keep washer, upper M10 x 65 and lower M10
x 55 bolts for front shock absorbers installation.
4
2
2
3
1
mbl2015-006-001_a
1. Shipping brackets
2. Plastic washers
3. Washers and upper bolt
4. Lower bolt
3. Remove and discard shipping brackets.
PARTS TO BE INSTALLED
Front Shock Absorber
Install front shock absorbers using the previously
removed M10 screws and washer, and new M10
flanged nuts (predelivery kit). Refer to following
table in order to place the reservoirs inward and
towards front.
mbl2011-003-200_b
1. Reservoir (inwards and towards front)
SHOCK ABSORBERS
SHOCK P/N VEHICLE SIDE
(P/N 505 073 966) LH
(P/N 505 073 965) RH
NOTICE
If shock absorbers are installed back-
wards, interference will occur and serious
damage may happen to suspension and shock
absorbers.
1. Tighten bolts to specification.
PREDELIVERY 2016-5 5 / 13

PARTS TO BE INSTALLED
TIGHTENING TORQUE
Shock absorber retaining
nuts 48 N•m (35 lbf•ft)
Skis
Ensure ski leg bushings are still on ski legs.
1. Install ski stopper on the ski.
NOTE: Position indicator at front and make sure
the bump in the ski is in the groove of the ski stop-
per.
mmr2008-049-028_a
TYPICAL
1. Ski stopper
2. Bushings
2. Install ski on ski leg using the hardware as
shown.
mbl2015-002-012_a
TYPICAL - EXCEPT ADJUSTABLE STANCE
1. Ski stopper (predelivery kit)
2. M10 x 130 bolt (previously removed)
3. M10 flat washer (predelivery kit)
4. M10 flanged nut (predelivery kit)
5. Ski axle
Tighten flanged nut to specification.
TIGHTENING TORQUE
Ski retaining nuts 48 N•m (35 lbf•ft)
Handlebar
1. Remove the tape securing the handlebar
wiring.
2. Loosen the lower steering extension retaining
screws.
mbl2012-008-012_a
1. Steering extension
2. Retaining screws
3. Tighten steering extension lower screws to
specification.
TIGHTENING TORQUE
Steering extension
lower screws 24 N•m (18 lbf•ft)
4. If necessary, adjust handlebar so that brake
fluid reservoir is level, tighten steering exten-
sion upper screws to specification.
TIGHTENING TORQUE
Steering extension
upper screws 24 N•m (18 lbf•ft)
5. Tighten steering electrical harness locking tie,
then cut exceeding strip.
mbl2014-007-004_a
FRONT OF HANDLEBAR
1. Locking tie
6 / 13 2016-5 PREDELIVERY

PARTS TO BE INSTALLED
Handlebar Wind Deflector
On each side:
1. Insert arm into deflector.
msi2015-004-001_b
2. Position trim tab inside slot on deflector.
msi2015-004-002_b
3. Slide trim into place along deflector and over
arm.
msi2015-004-003_b
4. Secure deflector assembly using K50 x 20 Torx
screw.
msi2015-004-004_b
5. Cut the handlebar wiring locking ties.
6. Place the arm against the handlebar.
7. Install the clamp with screws but do not tighten
yet.
mbl2015-002-005_a
8. Set the deflector horizontally and tighten
screws to specification.
mbl2015-002-006_a
TIGHTENING TORQUE
Wind deflector screws 3.5 N•m (31 lbf•in)
9. Secure handlebar wiring with new locking ties.
WARNING
Turn handlebar completely from side to side
making sure that wind deflectors do not inter-
fere with handlebar controls and accessories
(throttle lever, brake lever, emergency engine
stop switch, windshield, etc).
PREDELIVERY 2016-5 7 / 13

PARTS TO BE INSTALLED
Steering Pad
1. Insert the steering pad tab through riser block.
NOTE: Make sure to wrap all wires and cables.
mbl2009-008-012
2. Snap steering pad in place.
mbl2009-008-011_a
1. Snaps
Snow Guard
1. Insert snow guard between tunnel and rear
plastic trim.
2. Fasten snow guard with 4.8 mm (3/16 in) pop
rivets and washers (from predelivery kit).
mbl2014-007-001_a
1. Plastic trim
2. Snow guard
3. Rivet
4. Washer
Rear Bumper
1. Align holes of rear bumper with frame holes.
2. Secure rear bumper to frame using 6 M6 x 18
hexagonal screws (predelivery kit).
3. Tighten to specification.
TIGHTENING TORQUE
Bumper screws 16 N•m ± 1 N•m
(142 lbf•in ± 9 lbf•in)
Exhaust Deflector
1. Remove muffler.
2. From underneath snowmobile, position ex-
haust deflector with 4.8 mm (3/16 in) pop rivets
(predelivery kit).
8 / 13 2016-5 PREDELIVERY

PARTS TO BE INSTALLED
mbl2009-008-008_a
A. View from front
B. View from right side
1. Pop rivets
2. Exhaust deflector
3. From inside engine compartment, place 3
washers (predelivery kit) on rivets.
mbl2009-008-009_a
1. Washers on rivets
4. Pop the rivets.
5. Reinstall muffler.
Drive Belt
1. Remove drive belt guard.
2. Loosen the lock nut on the set screw.
3. Completely open the driven by turning the set
screw clockwise.
4. Clean drive and driven pulleys using PULLEY
FLANGE CLEANER (P/N 413 711 809) .
5. Install drive belt is with arrows in the direction
of rotation.
mmo2011-002-006_a
TYPICAL
1. To be pointed in the direction of rotation
6. To adjust drive belt, turn the set screw 1/4 turn
at a time, then rotate the driven pulley to prop-
erly set the belt between the pulley sheaves.
7. Measure belt deflection using a straight edge
and the TENSIOMETER (P/N 414 348 200) .
414348200
8. Adjust drive belt deflection as per specification.
DRIVE BELT DEFLECTION
Deflection27 mm to 37 mm
(1.06 in to 1.46 in)
Force applied 11.3 kg (25 lb)
NOTE: Turn the set screw in (clockwise) to in-
crease the distance between the sheaves and
out (counter-clockwise) to decrease the distance.
Tighten the lock nut after the belt adjustment has
been made.
A32D34A
JAM NUT
PREDELIVERY 2016-5 9 / 13

FINAL PREPARATION
NOTE: This setting is correct as a preliminary ad-
justment. In some cases, when starting the en-
gine, the vehicle could creep, indicating that the
belt is too tight. If the vehicle creeps, lower the
belt, install the belt guard and side panel, then
start engine. Repeat until creeping stops.
Reinstall side panels.
Grip Plates (if needed)
1. Secure grip plates using 4.8 mm (3/16 in) pop
rivets.
mbl2009-008-007_a
1. Pop rivets
2. Grip plate
Reinforcement Bracket
1. Lift and support front of vehicle.
2. Install a stopper such as a rubber hose on a
6.4 mm (1/4 in) drill in order to allow a drilling
depth of maximum 15 mm (.59 in).
NOTICE
Exceeding drilling depth would dam-
age cooling system or engine.
3. Drill through all three bracket holes, then into
the chassis. The bracket holes were purposely
made smaller than 6.4 mm (1/4 in).
mbl2010-006-001_a
UNDERNEATH FRONT OF CHASSIS
1. Reinforcement bracket
2. Reinforcement bracket holes
3. Front of vehicle
4. Secure the front of bracket using provided
Hemlok rivets (predelivery kit).
NOTE: Hemlok rivets require an heavy duty or
compressed air powered riveting machine. If
such equipment is not available, the bracket can
be secured using 6 mm (1/4 in) bolts.
FINAL PREPARATION
Engine Oil
NOTE: This vehicle has no oil pump, oil must be
mixed with fuel at the ratio of 33:1 in a jerrycan
then, be poured in the fuel tank.
Refer to PREMIX FUEL/OIL RATIO
table below as
a guideline to properly premix oil with fuel.
NOTICE
Never experiment with other fuel/oil
ratios. Use only oil that can flow at -40°C
(-40°F).
Premix Fuel/Oil Ratio
PREMIX FUEL/OIL RATIO
33:1
METRIC (SI)
33 L of fuel + 1 L of oil = 33:1
IMPERIAL
7.2 imp. gal of fuel + 35 imp. oz of oil = 33:1
7.2 imp. gal of fuel + 1 L of oil = 33:1
UNITED STATES
8.8 U.S. gal of fuel + 34 U.S. oz of oil = 33:1
8.8 U.S.gal of fuel + 1 L of oil = 33:1
Recommended Oil
RECOMMENDED OIL
600RS XPS SYNTHETIC 2-STROKE OIL
(P/N 293 600 132)
NOTICE
The engine of this snowmobile has
been developed and validated using the XPS
SYNTHETIC 2-STROKE OIL (P/N 293 600 132) . BRP
strongly recommends the use of either lubri-
cant at all times.
Brake Fluid Level
Check brake fluid in reservoir for proper level.
10 / 13 2016-5 PREDELIVERY

FINAL PREPARATION
mmo2006-005-013_a
TYPICAL
1. Level mark
Add brake fluid (DOT 4) as required.
– Use BRAKE FLUID GTLMA DOT4 (P/N 293 600
131) .
NOTICE
Use only (DOT 4) brake fluid from a
sealed container. Do not store or use a partially
used bottle of brake fluid.
Track Tension and Alignment
1. Remove the tether cord cap.
2. Lift rear of vehicle and support it off the ground.
3. Allow rear suspension to fully extend.
4. Loosen the rear idler wheel axe retaining
screws.
mbl2014-007-002_a
TRACK REMOVED FOR CLARITY
5. Move track in order to align adjustment screws
with track openings.
6. Tighten both adjustment screws equally to in-
crease track tension a little.
mbl2014-007-003_a
7. Use the TENSIOMETER (P/N 414 348 200) .
414348200
8. Set deflection between using bottom O-ring.
BOTTOM O-RING SETTING
3.2 cm (1-1/4 in)
mmr2009-133-003_b
DEFLECTION SETTING
1. Bottom O-ring
9. Place upper O-ring to 0 kgf (0 lbf).
10. Position the tensiometer on track, halfway be-
tween front and rear idler wheels.
11. Push the tensiometer downwards until bot-
tom O-ring (deflection set earlier) be aligned
with the bottom of slider shoe.
mmr2009-133-001_a
PREDELIVERY 2016-5 11 / 13

FINAL PREPARATION
mmr2009-133-002_a
1. Deflection O-ring aligned with slider shoe
12. Read load recorded by the upper O-ring on the
tensiometer.
mmr2009-133-003_a
LOAD READING
1. Upper O-ring
13. Load reading must be as per the following ta-
ble.
TRACK ADJUSTMENT SPECIFICATION
Track deflection setting 3.2 cm (1-1/4 in)
Track load reading 6 kg to 8.5 kg
(13 lb to 19 lb)
14. Tighten both adjustment screws until speci-
fied tension is obtained.
15. Tighten rear idler wheel retaining screws to
specification.
TIGHTENING TORQUE
Rear idler wheel
retaining screws
48 N•m ± 6 N•m
(35 lbf•ft ± 4 lbf•ft)
Check track alignment as follows:
16. Start engine and accelerate slightly so that
track slowly turns. This must be done in a
short period of time (15 to 20 seconds).
17. Check that the track is well centered; equal
distance on both sides between edges of
track guides and slider shoes.
A01F05A
1
2
3
1. Guides
2. Slider shoes
3. Equal distance
18. To correct track alignment:
18.1 Stop engine.
18.2 Remove tether cord cap.
18.3 Loosen rear wheel retaining screws.
18.4 Tighten adjustment screw on the side
where the slider shoe is the farthest
from the track insert guides.
19. Tighten rear idler wheel retaining screws to
specification.
TIGHTENING TORQUE
Rear idler wheel
retaining screws
48 N•m ± 6 N•m
(35 lbf•ft ± 4 lbf•ft)
20. Repeat procedure until alignment is correct.
Recheck tension.
Track Studding
WARNING
Never stud a track that has not been ap-
proved for studs. Installing studs on an
unapproved track could increase risks of
track tearing or severing, possibly resulting
in serious injuries or death.
WARNING
For track studding, always refer to the IN-
STRUCTION SHEET
supplied with stud kits
that are APPROVED by BRP for models cov-
ered in this PREDELIVERY BULLETIN .
Speedometer
To change the speedometer units to SAE custom
units or metric, use the latest B.U.D.S. software.
Look in Settings then in Cluster.
12 / 13 2016-5 PREDELIVERY

DELIVERY TO CUSTOMER
Vehicle Cleaning
1. Wash and dry vehicle.
NOTICE
Never use a high pressure washer to
clean vehicle. High pressure can cause electri-
cal or mechanical damages.
2. Clean exterior of vehicle using flannel clothes
or microfiber cloth with XPS ALL PURPOSE
CLEANER (P/N 219 701 709) .
NOTICE
It is necessary to use flannel or mi-
crofiber clothes on plastic parts to avoid dam-
aging surfaces. Never clean plastic parts with
strong detergent, paint thinner, acetone, prod-
ucts containing chlorine, etc.
To clean metallic parts use
BRP HEAVY DUTY
CLEANER (P/N 293 110 001)
.
Painted parts which are damaged should be prop-
erly repainted to prevent rust.
DELIVERY TO
CUSTOMER
Break-in Period
It is imperative for engine reliability to perform a
complete break-in period.
For the first fuel tank 26 L (7 U.S. gal.), use:
— PREMIUM UNLEADED GASOLINE
— Pre-mix fuel using XPS INJECTION OIL
(P/N 293 600 117) 33:1
— Factory installed main jets.
NOTICE
If the break-in is not performed ac-
cording to those recommendations severe en-
gine failure will occur.
Rear Suspension Adjustments
The best way to set up the suspension is to start
from factory settings, then customize each adjust-
ment one at a time.
Please refer to OPERATOR'S GUIDE for all spec-
ifications.
French Warning Labels
1. Underneath seat, a package containing French
version of all warning labels found on vehicle is
available for French customers.
2. After vehicle is washed and dried, remove back-
ing from each label and apply it on correspond-
ing English label.
Vehicle Delivery
1. Complete PRE DELIVERY CHECK LIST .
2. Test ride vehicle.
3. Give OPERATOR’S GUIDE
and SAFETY DVD to
customer.
4. Customer and dealer must read and sign PRE
DELIVERY CHECK LIST
.
Warranty
The 2016 MX Z X 600RS is designed exclusively
for competition and is exempt from emission stan-
dards and related requirements under the United
States Environmental Protection Agency 40 CFR
1051.620 and Environment Canada SOR/2011-10
5.(4).
This vehicle including the engine is classified as
a competition snowmobile and should never be
used on a public trails.
The 2016 MX Z X 600RS is shipped from the fac-
tory with no limited warranty.
For further information refer to
WARRANTY sec-
tion and the back cover page of the 2016 MX Z X
600RS operator's guide.
PREDELIVERY 2016-5 13 / 13