Ski-Doo 861 002 700 User manual

1+1 SEAT
(BLACK / BLACK) (Kit P/N 861 002 700)
(BLACK / SILVER) (Kit P/N 861 002 900)
(BLACK / YELLOW) (Kit P/N 861 002 800)
WARNING
For safety reasons, this kit must be installed by an authorized Ski-Doo®snowmobile dealer. Should
removal of a locking device (e.g. lock tabs, self-locking fasteners, etc.) be required when undergoing
disassembly/assembly, always replace with a new one. Torque wrench tightening specifications
must strictly be adhered to. This instruction sheet must be given to the purchaser. This kit is
designed for (a) specific applicable model(s) only (authorized Ski-Doo snowmobile dealers will
confirm model(s)). It is not recommended for units other than the one (those) for which it was sold.
N
NN
NO
OO
OT
TT
TE
EE
E:
::
:The following table is to be consulted for tightening torques when not specified in the text.
FASTENER GRADE/TORQUE
FASTENER
SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
M4 1.5—2N•m
(13 — 18 lbf•in)
2.5—3N•m
(22 — 27 lbf•in)
3.5 — 4 N•m
(31 — 35 lbf•in)
4—5N•m
(35 — 44 lbf•in)
M5 3—3.5N•m
(27 — 31 lbf•in)
4.5 — 5.5 N•m
(40 — 47 lbf•in)
7—8.5N•m
(62 — 75 lbf•in)
8—10N•m
(71 — 89 lbf•in)
M6 6.5—8.5N•m
(58 — 75 lbf•in)
8—12N•m
(71—106lbf•
in)
10.5 — 15 N•m
(93—133lbf•
in)16 N•m (142 lbf•in)
M8 15 N•m (11 lbf•ft) 24.5 N•m (18 lbf•ft) 31.5 N•m (23 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) 72.5 N•m (53 lbf•ft)
M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105N•m(77lbf•ft) 127.5 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)
N
NN
NO
OO
OT
TT
TE
EE
E:
::
:The illustrations in this document show typical construction of the different assemblies and
may not reproduce the full detail or exact shape of the parts; however, they represent parts that have
the same or similar function.
Notice
This Instruction Sheet uses the following symbols:
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in serious injury or
death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle
components.
N
NN
NO
OO
OT
TT
TE
EE
E:
::
:Indicates supplementary information needed to fully complete an instruction.
Printed in Canada. (msi2006-006 PM) Instruction Sheet P/N 415 129 086 1/ 6
©2005 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
®™Trademarks of Bombardier Recreational Products Inc. or its affiliates.
* Trademark of Bombardier Inc. used under license.

N
NN
NO
OO
OT
TT
TE
EE
E:
::
:Installation time is approximately 0.7 hour.
PARTS TO BE INSTALLED
P4 P9 P12 P1
P6 P2 P3 P11 P10
P7P8
P5
A33H21T
ITEM 861 002 700
(black/black)
861 002 900
(black/silver)
861 002 800
(black/yellow) DESCRIPTION QTY
P1 510 004 220 Seat Support 1
P2 207 562 044 M6 x 20 Flanged Hexagonal Bolt 2
P3 232 581 414 M8 Elastic Stop Nut 2
P4 510 004 703 510 004 705 510 004 704 Seat Assembly 1
P5 510 001 435 Footrest 2
P6 293 150 087 4.8 mm (3/16 in) Rivet 4
P7 516 001 745 Warning Label (French) 1
P8 516 001 746 Warning Label (English) 1
P9 510 004 699 Handle 2
P10 205 406 086 M10x60SocketHeadBolt 2
P11 233 201 414 M10 Flanged Elastic Nut 2
P12 510 004 109 Handle Cap 2
2 / 6 Instruction Sheet P/N 415 129 086

INSTRUCTION
INSTRUCTION
Seat Preparation
Install both handles [
[[
[P9]
]]
] onto seat assembly [
[[
[P4]
]]
]
with handle caps [
[[
[P12]
]]
].
N
NN
NO
OO
OT
TT
TE
EE
E:
::
:There is only one possible handle position.
Secure handles using M10 x 60 socket head bolts
[
[[
[P10]
]]
] and M10 flanged elastic nuts [
[[
[P11]
]]
]. Torque
to7N•m(62lbf•in).
WARNING
Make sure that both handles are properly
fastened to the seat base.
N
NN
NO
OO
OT
TT
TE
EE
E:
::
:Install nut from inside lining.
Seat Support Installation
2
31
A33H2JB
Remove storage cover and set it aside.
N
NN
NO
OO
OT
TT
TE
EE
E:
::
:Storage cover can be used should
1 + 1 seat not be needed.
Unscrew trunk [
[[
[2]
]]
], remove latch screw [
[[
[3]
]]
],
remove storage tray [
[[
[1]
]]
] and trunk.
Cut storage tray as shown.
WARNING
Always wear eye protection and gloves when
using power tools.
N
NN
NO
OO
OT
TT
TE
EE
E:
::
:Picture shows right side but left side also
needs the same cut.
Remove and discard both driver's seat rear anchor
M8 hexagonal nuts, keep flat washers.
Install seat support [
[[
[P1]
]]
] and secure it using new
M8 elastic stop nuts [
[[
[P3]
]]
]atdriver'sseatrear
anchors and M6 x 20 flanged hexagonal bolts [
[[
[P2]
]]
]
at tunnel anchors at rear.
Instruction Sheet P/N 415 129 086 3 / 6

INSTRUCTION
Installation of the Warning Labels
N
NN
NO
OO
OT
TT
TE
EE
E:
::
:
•it is very important to properly install the
warning labels as described below. This will
help ensure the safety of any occupants as well
as bystanders.
•The French warning labels are required by
law in the Province of Québec.
Clean surfaces with isopropyl alcohol and apply
warning labels [
[[
[P7]
]]
]and[
[[
[P8]
]]
] onto storage tray as
shown.
Reinstall trunk, storage tray and latch screw.
A33H6NA
A
C
B
Trim trunk upper edge on both sides as per
measurements shown on photo, where
-[
[[
[A]
]]
]equals50mm(1–31/32 in),
-[
[[
[B]
]]
] equals 170 mm (6–11/16 in) and
-[
[[
[C]
]]
]equals16mm(5/8in).
A33H6OA
1
2
Round off corners [
[[
[1]
]]
] and also, smoothen inner
and outer edges [
[[
[2]
]]
], all along, to avoid fingers or
seat material from suffering cuts.
1+1SeatInstallation
Hook-up seat assembly onto seat support lugs.
Push on seat and rotate downward around lugs to
latch seat assembly in place.
Slide both seat lining eyelets onto trunk lugs.
WARNING
Make sure the optional seat is properly locked
in place before using snowmobile.
Footrest Installation
1
1
Lean footrest [
[[
[P5]
]]
] against roller [
[[
[1]
]]
]asshown.
4 / 6 Instruction Sheet P/N 415 129 086

INSTRUCTION
1
Measure 584.2 mm (23 in) from bottom of driver's
footrest [
[[
[1]
]]
].
FRONT
Align center of rear hole of passenger's footrest
with that mark.
1
WARNING
Always wear eye protection and gloves when
using power tools.
Model(s): REV Platform
Drill 5 mm (3/16 in) holes [
[[
[1]
]]
], using footrests as
templates and secure using rivets [
[[
[P6]
]]
].
A33H5KA
Model(s): RT Platform
Hammer down the spikes on footrest where foot
peg will rest.
2
A33H5LA
3
Drill rear center 5 mm (3/16 in) hole [
[[
[2]
]]
], and
another 5 mm (3/16 in) hole [
[[
[3]
]]
] centered on inner
front surface, using foot peg as template, as
shown, then secure using rivets [
[[
[P6]
]]
].
Installation is now complete.
Instruction Sheet P/N 415 129 086 5 / 6

INSTRUCTION
1+1 Seat Removal
Slide out seat lining eyelets from trunk lugs; push
on latch button (where it says so on lining) and
lift seat.
Install storage cover (should seat not be used).
WARNING
Make sure the optional seat is properly locked
in place before using snowmobile.
Warning Labels
This product comes with the following label(s)
containing important safety information.
A33H66A
English Label (P8)
(P/N 516 001 746)
A33H66A
French Label (P7)
(P/N 516 001 745)
Location of Labels
On the left: English Label (P8)
On the right: French Label (P7)
The label(s) should be considered permanent part of
this product. If the label(s) comes off or becomes
hard to read, please contact an authorized dealer
for replacement.
Any person who intends to use this product should
read and understand this information before doing
so.
6 / 6 Instruction Sheet P/N 415 129 086