800R E-TEC - Piston Replacement 2012-22 (For vehicles …

1 Campaign no.: 2012 0022. August 15, 2013 Subject: 800R E-TEC - Piston Replacement No. 2012 -22. (For vehicles used at an Altitude Below 1200m (4000ft)). YEAR MODEL PACKAGE MODEL NUMBER SERIAL NUMBER. 137 VACA, VACB, VACC, VACD, VACE. VBCA, VBCB, VBCC, VBCD, 146. Freeride 800R E-TEC VBCE. VCCA, VCCB, 154 VCCC, VCCD, VCCE. VDCA (racing). GSX 800R E-TEC SE DPCA, DPCB. TNT UCCB, UCCC. MZCB, MZCC, MZCD, MZCE, X. MX Z 800R E- TEC MZCF, MZCG, MZCH, MZCJ. MXCA, MXCB, MXCC, MXCD, X-RS MXCE, MXCF, MXCH, MXCJ, MXCK. 2012 Adrenaline UFCA, UFCB See list attached Back Country UGCA, UGCB. Renegade 800R E-TEC .

2 Back UKCA, UKCB, UKCC, UKCE, Country X UKCF, UKCG, UKCH, UKCJ. X BACA, BACB, BACC, BACD. CTCA, CTCC. SP CUCB, CUCD. CWCA, CWCC. UNCA, UNCB, Summit 800R E-TEC . UNCC, UNCD, UNCE. X UPCA, UPCB, UPCC, UPCD, UPCE. URCA, URCB, URCC, URCD. Printed in Canada. (mbg2012-028 en AP). 2013 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved. 1 / 14. and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates. PROBLEM PROCEDURE. Under certain sea-level riding conditions, the pis- PROCEDURE HIGHLIGHTS. ton ring groove may wear prematurely leading to performance loss and possible engine damage.

3 Replace Piston as described in the appropriate shop manual Perform Piston projection measurement SOLUTION. Perform a fuel system leak test Replace pistons, if the vehicle meets both of the following requirements: Erase fault codes Vehicle used generally at an altitude below Re-initialization engine break-in 1 200 m (4,000 ft). Vehicle has reached 5 000 km (3,125 mi). Piston Replacement REQUIRED PARTS For Piston Replacement procedure, refer to appro- priate shop manual. Inside North America SHOP MANUAL PART NUMBER. PART. DESCRIPTION QTY 2012 Shop Manual NUMBER (P/N 219 100 561).

4 REV-XP/REV-XR. Piston Kit 415 129 844 1. Coolant 219 700 362 4 liters Piston Projection Measurement Outside North America REQUIRED TOOLS. PART Piston PROJECTION. DESCRIPTION QTY. NUMBER (P/N 529 036 215). Piston Kit 619 400 097 1. TDC DIAL INDICATOR. Coolant 619 590 183 4 liters (P/N 295 000 143). Parts need to be ordered through regular chan- nels. 1. Install the TDC dial indicator on the Piston pro- NOTE: The Piston Kit includes enough gaskets to jection tool. repair the majority of vehicles . If different thick- 2. Place Piston projection tool on a flat steel sur- ness are required, you need to order them sepa- face.

5 Rately. 3. Rotate dial indicator face to position the 0 in line GASKET PART INCLUDED IN with needle. THICKNESS NUMBER THE KIT. mm 420 430 080 NO. mm 420 430 081 NO. mm 420 430 082 YES. mm 420 430 083 YES. mm 420 430 084 YES. mm 420 430 085 YES. mm 420 430 086 NO. mm 420 430 087 NO. mmr2011-010-002_a SETTING THE ZERO. 4. Install tool on PTO cylinder. 2 / 14 2012 -22 WARRANTY CAMPAIGN. 5. Center tool with cylinder to ensure that dial in- dicator reads Piston dome. mmr2011-010-004. TYPICAL. 8. Check if Piston projection is according to spec- ification. mmr2011-010-003. TOOL PROPERLY CENTERED Piston PROJECTION SPECIFICATION.

6 6. Ensure that PTO Piston is set to TDC. ENGINE BLOCK. MODEL SERVICE LIMIT IDENTIFICATION. 7. Read dial indicator as follows: NUMBER. Calculate the number of notches the Freeride pointer traveled. (CAN/USA) mm to mm 6413041. NOTE: The gauge pointer will move clock- Summit (.072 in to .076 in). wise. Read the pointer travel, NOT the (CAN/USA). number where the pointer stops. mm to mm All Other 6413046. Note measurement. (.064 in to .068 in). Example: The cylinder block identification number is located on the intake flange of cylinder block. mmr2012-021-001_a mmr2012-035-004_b 1.

7 Identification number NOTICE Take care to use the proper specifica- 1. Pointer travel: 64 notches, which means .064 inch tion according to the type of engine and the NOTE: In the example above, the correct measure model of vehicle. is .064 inch, (NOT .036 inch). 9. If Piston projection is out of specification, re- place base gasket. WARRANTY CAMPAIGN 2012 -22 3 / 14. NOTE: A thicker base gasket will lower the Piston projection measurement. Refer to CYLINDER BASE GASKET table in TOP. END (800R ENGINES) subsection of the 2012 . SHOP MANUAL REV-XP/REV-XR. 10. Reinstall engine parts.

8 Fuel System Leak Test REQUIRED TOOLS. FUEL HOSE ADAPTER. (P/N 529 036 023). mmr2008-030-003. PRESSURE GAUGE PRESSURE GAUGE WITH FUEL HOSE ADAPTER. (P/N 529 035 709). 1. Ensure there is enough gas in fuel tank. 2. Install a rag under the ECM hose quick connect to catch fuel spillage. 3. Disconnect fuel supply hose from ECM. mmr2009-071-003_a TYPICAL. 1. ECM. 2. Fuel pressure hose fitting 3. Fuel hose adapter to ECM fitting 4. Fuel hose adapter to pressure gauge WARNING. mmr2009-071-002_a When carrying out this test, ensure fuel is not TYPICAL. 1. ECM leaking from test equipment onto electrical 2.

9 Fuel pressure hose components. 3. Release button, quick disconnect fitting 4. Install the fuel hose adapter and the pressure NOTE: The pump should be activated for 15 sec- gauge between fuel pressure hose and ECM. onds to ensure proper bleeding of the system. 5. Connect the emergency engine stop switch ( post) to the vehicle. 6. Install the tether cord cap ( key) on the emergency engine stop switch. 7. Connect vehicle to the latest version of 8. Perform calibration or software update if asked for. 9. Select the ECM and Activation tabs. 10. Click on the Fuel Pump (Click/Hold) button in the Activate field.

10 4 / 14 2012 -22 WARRANTY CAMPAIGN. 18. Reinstall the fuel pressure hose on ECM and gently but firmly pull on hose to ensure quick disconnect fitting is properly locked and se- cure on the ECM. Fault Codes Erasing 1. Connect vehicle to the latest applicable version of , refer to the COMMUNICATION. TOOLS AND subsection. 2. Select the Faults tab. 3. Click on Clear Occurred Faults. mmr2009-071-001_b 1. Activation tab 2. Fuel Pump (Click/Hold) button Engine Break-in NOTE: The fuel pump will run as long as you hold Re-Initialization the Fuel Pump (Click/Hold) button in IMPORTANT: Re-Initialize break-in period in 11.