Can-Am Roadster RT-622 2010 User manual

2010
Service Manual
Roadster
RT-622 Trailer

Legal deposit:
National Library of Quebec
National Library of Canada 2010
All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc. (BRP)
©Bombardier Recreational Products Inc. (BRP) 2010
Printed in Canada
Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt (Quebec) Canada

TABLE OF CONTENTS
SAFETY NOTICE ........................................................................................................ III
INTRODUCTION......................................................................................................... IV
GENERAL INFORMATION........................................................................................... IV
TRAILER INFORMATION............................................................................................. IV
MANUAL INFORMATION............................................................................................ IV
01 MAINTENANCE
01 – MAINTENANCE SCHEDULE.................................................................................... 1
02 – STORAGE AND PRESEASON PREPARATION............................................................... 3
02 CHASSIS
01 – WHEELS AND WHEELS HUBS ................................................................................ 5
GENERAL ...................................................................................................... 6
PROCEDURES................................................................................................. 6
WHEELS .................................................................................................... 6
WHEEL BEARINGS ......................................................................................... 6
WHEEL HUBS .............................................................................................. 7
TIRES ....................................................................................................... 7
02 – SUSPENSION..................................................................................................... 9
GENERAL .................................................................................................... 10
ADJUSTMENT.............................................................................................. 10
SPRING PRELOAD ADJUSTMENT ....................................................................... 10
PROCEDURES............................................................................................... 10
SHOCK ABSORBERS ..................................................................................... 10
SPRING ................................................................................................... 11
TRAILING ARM ........................................................................................... 11
03 – BODY............................................................................................................. 13
GENERAL .................................................................................................... 17
TRAILER CARE ........................................................................................... 17
PROCEDURES............................................................................................... 17
DECALS................................................................................................... 17
ROCK GUARD ............................................................................................ 17
LATCHES.................................................................................................. 17
LATCH CABLES........................................................................................... 17
LOCK PINS................................................................................................ 20
INNER FASCIAS .......................................................................................... 20
FRONT ACCESS COVER.................................................................................. 21
REAR ACCESS COVER ................................................................................... 22
KEY BARREL.............................................................................................. 22
BODY ..................................................................................................... 27
04 – FRAME ........................................................................................................... 31
GENERAL .................................................................................................... 32
PROCEDURES............................................................................................... 32
TONGUE .................................................................................................. 32
COUPLER ................................................................................................. 34
FRAME.................................................................................................... 34
03 ELECTRICAL SYSTEM
01 – LIGHTS AND HARNESS ...................................................................................... 35
GENERAL .................................................................................................... 38
PROCEDURES............................................................................................... 38
TAILLIGHT ................................................................................................ 38
POSITION LIGHT ......................................................................................... 38
TURN SIGNAL LIGHTS AND BACKUP LIGHTS........................................................... 38
I

TABLE OF CONTENTS
03 ELECTRICAL SYSTEM (cont’d)
01 – LIGHTS AND HARNESS (cont’d)
PROCEDURES (cont’d)
LICENSE PLATE LIGHT ................................................................................... 39
HARNESS ................................................................................................. 39
04 TECHNICAL SPECIFICATIONS
01 – RT-622 TRAILER SPECIFICATIONS.......................................................................... 41
II

SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to cor-
rectly service the Roadster RT-622 trailer as de-
scribed in the model list in the
INTRODUCTION .
This edition was primarily published to be used by
mechanical technicians who are already familiar
with all service procedures relating to BRP prod-
ucts. Mechanical technicians should attend train-
ing courses given by BRPTI.
Please note that the instructions will apply only
if proper hand tools and special service tools are
used.
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.
It is understood that this manual may be trans-
lated into another language. In the event of any
discrepancy, the English version shall prevail.
The contents of this manual depicts parts and pro-
cedures applicable to a particular product at the
time of writing. Service and Warranty Bulletins
may be published to update the content of this
manual. Dealer modifications that were carried
out after manufacturing of the product, whether
or not authorized by BRP, are not included.
The use of BRP parts is most strongly recom-
mended when considering replacement of any
component. Dealer assistance should be sought
in case of doubt.
This manual emphasizes particular information
which is denoted by the following wording and
symbols:
WARNING
Indicates a potential hazard, if not avoided,
could result in serious personal injury includ-
ing the possibility of 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 result in severe damage to
trailer components.
NOTE: Indicates supplementary information re-
quired to fully complete an instruction.
Although the mere reading of such information
does not eliminate the hazard, your understand-
ing of the information provided will promote its
correct use. Always use common shop safety
practices.
BRP disclaims liability for all damages and/or in-
juries resulting from the improper use of the con-
tents of this publication. We strongly recommend
that any services be carried out and/or verified by
a highly skilled professional mechanic.
rmr2010-061 III

INTRODUCTION
INTRODUCTION
GENERAL INFORMATION
The information and component/system descrip-
tions contained in this manual are correct at time
of writing. BRP however, maintains a policy of
continuous improvement of its products without
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.
This Service Manual covers the following BRP
Roadster RT-622 trailers.
MODEL COLOR MODEL NUMBER
Timeless Black T1AA, T1AE, T1AF
Orbital Blue T1AB, T1ADRT-622
Full Moon Silver T1AC
TRAILER INFORMATION
TRAILER IDENTIFICATION
The trailer is identified by a serial number. It may
sometimes become necessary to locate this num-
ber for warranty purposes or to trace the trailer in
the event of theft.
The serial number is located on the frame and can
be seen from the LH rear wheel housing.
704902071
rmo2010-005-006_a
WHEEL REMOVED FOR CLARITY PURPOSE ONLY
1. Trailer serial number
MANUAL INFORMATION
MANUAL PROCEDURES
As many of the procedures in this manual are
interrelated, we suggest that before undertaking
any task, you read and thoroughly understand the
entire section or subsection in which the proce-
dure is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before undertaking
any procedure, be sure that you have on hand all
required tools, or approved equivalents.
This manual uses technical terms which may be
different from the
PARTS CATALOG .
When ordering parts always refer to the
PARTS
CATALOG
.
MANUAL LAYOUT
The manual is divided into many major sections as
you can see in the main table of contents at the
beginning of the manual.
Each section is divided in various subsections, and
again, each subsection has one or more division.
The illustrations show the typical construction 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.
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INTRODUCTION
NEW
WHEELS AND WHEEL HUBS
Section 02 CHASSIS
Subsection 01 (WHEELS AND WHEEL HUBS)
105 Nm
(77 lbfft)
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INTRODUCTION
YPICAL PAGE
Subsection 01 (WHEELS AND IRES)
Indicates component
procedures apply to.
Reference to a specific
section or subsection.
Call-outs pertaining
to above illustration.
TYPICAL
indicates a general vie
hich may not represent
exact details.
Illustration al ays
follo s text to hich
it applies.
Indicates specific
procedure to be
carried out.
Tittle in bold indicates
category of information
to be carried out.
Section 01 CHASSIS
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INTRODUCTION
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in exploded views and/or text. When they are not specified, refer
to following table.
WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic stop nuts, cotter pins, etc.) must be replaced.
In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the following pro-
cedure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply the half of the recommended torque value.
3. Torque to the recommended torque value.
NOTICE Be sure to use the proper tightening torque for the proper strength grade.
NOTE: When possible, always apply torque on the nut.
NOTE: Always torque screws, bolts and/or nuts in a criss-cross sequence.
A00A8BS
Property
class and
head
markings
Property
class and
nut
markings
5
5
8
8
10
10
12
12
4.8
4.8
4.8
8.8
8.8
8.8
9.8
9.8
9.8
10.9
10.9
10.9
12.9
12.9
12.9
12.9
FASTENER GRADE/TORQUE
FASTENER
SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
M4 1.5 – 2 N•m
(13 – 18 lbf•in)2.5 – 3 N•m (22 – 27 lbf•in)N•m 3.5 – 4 N•m (31 – 35 lbf•ft) 4–5N•m (35 – 44 lbf•ft)
M5 3–3.5N•m
(27 – 31 lbf•ft) 4.5 – 5.5 N•m (40 – 47 lbf•ft) 7–8.5N•m (62 – 75 lbf•ft) 8–10N•m (71 – 89 lbf•ft)
M6 6.5 – 8.5 N•m
(58 – 75 lbf•ft) 8–12N•m (71 – 106 lbf•ft) 10.5 – 15 N•m (93 – 133 lbf•in)16 N•m (142 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)
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VIII rmr2010-061