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Snowmobile Ski-Doo CROSSOVER ACE SERIES. OPERATOR’S GUIDE (2024) - page 3

TUNE YOUR RIDE

STOPPER STRAP POSITION 6 (6TH HOLE)

1. Free holes

2.

6th hole from end

3. Towards rear

4. Tip of strap touching strap axis

5. Two holes left open between screw head and nut

6. Towards front

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1. Increase preload

2. Decrease preload

Ring Type Adjuster

Grab and turn the ring and the spring to increase or decrease the

spring preload.

1. Increase preload

2. Decrease preload

Rear Spring

Rear spring preload has an effect on comfort, ride height and load

compensation.

Also, adjusting rear spring preload shifts more or less weight to the

snowmobile front end. As a result, more or less weight is applied to

the skis. This has an effect on performance in deep snow, steering ef-

fort and handling.

Slight suspension bottoming occurring under the worst riding condi-

tions indicates a good choice of spring preload.

NOTE:

Ensure to adjust suspension when hauling cargo.

NOTE:

Remove cargo load to ease preload adjustment.

243

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Action

Result

Firmer rear suspension

Higher rear end

Increasing preload

More bump absorption

capability

Heavier steering

Softer rear suspension

Lower rear end

Less bump absorption

Decreasing preload

capability

Lighter steering

Better performance and

handling in deep snow

Refer to the following to determine if preload is correct.

TYPICAL - PROPER ADJUSTMENT

- A = Suspension fully extended

- B = Suspension has collapsed with operator, passenger and load

added

- C=Distancebetweendimension“A”and“B”,seetablebelow

244

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C

What to do

50 to 75 mm (2 to 3 in)

No adjustment required

More than

Adjusted too soft. Increase

75 mm (3 in)

preload

Less than

Adjusted too firm. Decrease

50 mm (2 in)

preload

NOTE:

If the specification is unattainable with the original springs, see an au-

thorized BRP snowmobile dealer for other available springs.

NOTICE

To increase spring preload, always turn the left side adjustment

cam in a clockwise direction, and the right side cam in a coun-

terclockwise direction.

CAUTION

Never set preload cams directly from position 5 to 1 or directly

from position 1 to 5.

The adjustment cams have 5 different settings, 1 being the softest.

TYPICAL — LH SIDE

1. Adjust spring preload

245

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TYPICAL — RH SIDE

1. Adjust spring preload

Rear Shock Absorber

Rear Shock Compressiion Damping (If Equipped)

NOTE:

Both low and high speed compression damping are adjusted

simultaneously.

Low speed compression damping controls how the shock absorber re-

acts to a low suspension velocity (slow compression strokes, in most

cases when riding at lower speeds).

High speed compression damping controls how the shock absorber

reacts to a high suspension velocity (quick compression strokes, in

most cases when riding at higher speeds).

Result on big and

Turning

Action

small bumps

Increasing

Firmer compression

Clockwise

compression

damping

damping force

Decreasing

Counter

Softer compression

compression

Clockwise

damping

damping force

246

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To adjust, turn the adjuster button located on the oil reservoir on shock

clockwise to increase compression damping force and counterclock-

wise to decrease compression damping force.

TYPICAL - WITH PIGGYBACK RESERVOIR

1. Compression damping adjustment button

247

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rMotion With Quick Adjust

Turn the right side knob to adjust the shock compression speed.

TYPICAL - RMOTION WITH QUICK ADJUST - RH SIDE

1. Knob to adjust low/high speed compression damping

CMOTION

1. Compression damping adjustment button

248

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Rear Suspension Extension Spring Preload (SC-5U)

Adjust by turning the preload cam.

1. Preload cam

ACTION

RESULT

More track surface on the ground

Increasing preload

Less extension lift

Better reverse capability especially in

deep snow

Decreasing preload

More extension lift

Rear Suspension Extension Stabilizer Cam

To change stabilizer cam setting, pull lock off, then turn cam.

Ensure the lock if fully pushed-in when locked.

249

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1. Stop block

2. Stabilizer cam

3. Lock

POSITION 1

250

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POSITION 2

Cam setting

Result

Allows free movement of the

suspension extension on its

entire stroke

Away from upper stop block

(Position 2)

General use

Good reverse capability

Locks the suspension extension

in line with the suspension rails

Leaning on both stop blocks

Better traction, full track contact

(Position 1)

surface

Better towing capability

Rear Shock Absorber (ACS)

The operator can adjust the comfort and ride height by adjusting the

air pressure inside the air shock absorber.

To adjust, proceed as follows:

Modell with 7.2“Digital Diisplay

1. Start engine.

2. Press and hold MODE (M) button until requested setting starts

flashing.

251

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When the air suspension mode is selected, AIR_SUSP is dis-

played. The display also shows the actual suspension setting (a

number from 1 to 5, 1 being the softest setting).

3. Depress the heated throttle lever switch as shown to increase or

decrease air pressure.

4. The desired set point appears on the display. To confirm, press the

MENU (M) button or wait 5 seconds.

ACS SETTING 3

Model with the Large Panoramiic 7.8” Wide LCD

Display

1. Start engine.

2. Press the Vehicle Data button, to the bottom left of the rotary

control.

When the air suspension mode is selected, AIR_SUSP is dis-

played. The display also shows the actual suspension setting (a

number from 1 to 5, 1 being the softest setting).

3. Turn the knob modify the suspension setting.

252

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4. The desired set point appears on the display. To confirm, press on

the knob or wait 5 seconds.

ACS SETTING 3

Front Suspensiion Adjustments

Ski Stance

Skis can be set to three different widths.

To obtain the different widths, place the spacers:

- Inside the skis leg (narrowest ski stance setting: easiest to initiate

turn on sidehills), or

- Outside the skis leg (widest ski stance setting: most stable on cor-

ners), or

- On each side (central setting: best steering accuracy on deep

snow).

253

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1. Spacers

2. Axle

3. Stopper

4. Screw

5. Washer

6. Nut

TIGHTENING TORQUE

48 ± 6 Nm

Ski nut

(35 ± 4 lbf-ft)

Front Springs

Front spring preload has an effect on front suspension firmness.

Front spring preload also has an effect on the steering behavior.

Action

Result

Firmer front suspension

Higher front end

Increasing preload

More precise steering

More bump absorption

capability

254

TUNE YOUR RIDE

Action

Result

Softer front suspension

Lower front end

Decreasing preload

Lighter steering

Less bump absorption

capability

WARNING

Adjust both springs to the same preload. Uneven adjustment

can cause poor handling and loss of stability, and/or control,

and increase the risk of an accident.

Cam Type Adjuster

Using the suspension adjustment tool provided in the tool kit, turn the

cam to increase or decrease the spring preload.

1. Increase preload

2. Decrease preload

Ring Adjuster – Type 1

Grab and turn the ring and the spring to increase or decrease the

spring preload.

255

TUNE YOUR RIDE

1. Increase preload

2. Decrease preload

Ring Adjuster – Type 2

Grab and turn the ring and the spring to increase or decrease the

spring preload.

1. Increase preload

2. Decrease preload

Adjjustment Tips Accordiing to Vehicle Behavior

Problem

Corrective measures

Check ski alignment.

- Reduce front suspension spring

Front suspension darting

preload.

- Increase center spring preload.

- Reduce rear spring preload.

Steering feels too heavy

- Reduce front suspension spring

at steady speeds

preload.

256

TUNE YOUR RIDE

Problem

Corrective measures

-

Increase center spring preload.

Steering feels too heavy

-

Reduce rear spring preload.

during acceleration

–

Lengthen limiter strap.

Too much ski lift during

-

Shorten limiter strap.

cornering or acceleration

–

Increase rear spring preload.

-

Reduce rear spring preload.

Rear of snowmobile

–

Reduce compression damping

seems too stiff

adjustment

if equipped

Rear of snowmobile

-

Increase rear spring preload.

seems too soft

–

Increase compression damping

adjustment

Rear suspension is

if equipped.

frequently bottoming

-

Increase rear spring preload.

–

Increase center spring preload.

–

Lengthen limiter strap.

-

Reduce center spring preload.

–

Increase rear spring preload.

Snowmobile seems to

-

Increase front suspension spring

pivot around its center

preload.

-

Shorten limiter strap.

-

Reduce rear spring preload.

Track spins too much at

-

Increase center spring preload.

start

–

Lengthen limiter strap.

257

MAINTENANCE SCHEDULE

600 ACE/ 900 ACE Engines

TRAIL /

CROSSOVER

A+

A

B

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

or

or

I=Inspect

or

1500

6000

L=Lubricate

3000 km

km

km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

mi)

mi)

Air and Fuel Delivery

Fuel components (fuel

cap, hoses, clamps and

I

tank fixation) and

function

R

In-line fuel filter

Every 5

years

Body and Chassis

Body panels and

I, T

hardware

Pivots, latches, hinges

L

and key barrels

Engine and Cooling

Engine cooling

components (coolant

concentration, coolant

I, A

level, hose condition,

clamps, leaks)

Engine oil and oil filter

R

Engine seals and

I

gaskets

R

Spark plugs

Every 3

years

263

MAINTENANCE SCHEDULE

TRAIL /

CROSSOVER

A+

A

B

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

or

or

I=Inspect

or

1500

6000

L=Lubricate

3000 km

km

km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

mi)

mi)

or

10 000

km

(6000

mi)

R

Engine coolant

Every 5

years

Exhaust and Emissions

Exhaust components

(gaskets, pipes, muffler

I

condition, leaks)

Exhaust manifold

T

Brake

Brake components and

I, L

function

R

Brake fluid

Every

2

years

Drive

Chaincase drive chain

A

A

tension

Gearbox / chaincase oil

I

I

level

Track alignment and

A

I, A

tension

264

MAINTENANCE SCHEDULE

TRAIL /

CROSSOVER

A+

A

B

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

or

or

I=Inspect

or

1500

6000

L=Lubricate

3000 km

km

km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

mi)

mi)

Gearbox / chaincase oil

R

Continuously Variable Transmission (CVT)

CVT components and

I,

C, L

function

CVT drive belt condition

I

CVT drive belt tension

A

A

Drive pulley retaining

T

screw

Electrical

Battery connections and

I

condition

Electrical harness

I

routing

Headlight aim

A

Modules and applicable

I

software updates

Operation of control

I

switches and lighting

Steering and Controls

Ski runners

I

I

Gearbox position lever

I, A

operation

Steering alignment

I, A

265

MAINTENANCE SCHEDULE

TRAIL /

CROSSOVER

A+

A

B

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

or

or

I=Inspect

or

1500

6000

L=Lubricate

3000 km

km

km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

mi)

mi)

Steering components

I

and function

Throttle cable

A

Throttle operation

I

Suspension

Suspension components

I, L

and function

266

MAINTENANCE SCHEDULE

900 ACE Turbo/ R

TRAIL /

CROSSOVER

A+

A

B

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

or

or

I=Inspect

or

1500

6000

L=Lubricate

3000 km

km

km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

mi)

mi)

Air and Fuel Delivery

Fuel components (fuel

cap, hoses, clamps and

I

tank fixation) and

function

R

In-line fuel filter

Every 5

years

Body and Chassis

Body panels and

I, T

hardware

Pivots, latches, hinges

L

and key barrels

Engine and Cooling

Engine cooling

components (coolant

concentration, coolant

I, A

level, hose condition,

clamps, leaks)

Engine oil and oil filter

R

Engine seals and

I

gaskets

R

Spark plugs

Every 3

years

267

MAINTENANCE SCHEDULE

TRAIL /

CROSSOVER

A+

A

B

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

or

or

I=Inspect

or

1500

6000

L=Lubricate

3000 km

km

km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

mi)

mi)

or

10 000

km

(6000

mi)

R

Engine coolant

Every 5

years

Exhaust and Emissions

Exhaust components

(gaskets, pipes, muffler

I

condition, leaks)

Exhaust manifold

T

R

Every 3

years

or

Turbo exhaust gasket

10 000

km

(6000

mi)

Brake

Brake components and

I, L

function

R

Brake fluid

Every 2

years

268

MAINTENANCE SCHEDULE

TRAIL /

CROSSOVER

A+

A

B

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

or

or

I=Inspect

or

1500

6000

L=Lubricate

3000 km

km

km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

mi)

mi)

Drive

Chaincase drive chain

A

A

tension

Gearbox / chaincase oil

I

I

level

Track alignment and

A

I, A

tension

Gearbox / chaincase oil

R

Continuously Variable Transmission (CVT)

CVT components and

I, C, L

function

CVT drive belt condition

I

CVT drive belt tension

A

A

Drive pulley retaining

T

screw

Electrical

Battery connections and

I

condition

Electrical harness

I

routing

Headlight aim

A

Modules and applicable

I

software updates

Operation of control

I

switches and lighting

269

MAINTENANCE SCHEDULE

TRAIL /

CROSSOVER

A+

A

B

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

or

or

I=Inspect

or

1500

6000

L=Lubricate

3000 km

km

km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

mi)

mi)

Steering and Controls

Ski runners

I

I

Gearbox position lever

I, A

operation

Steering alignment

I, A

Steering components

I

and function

Throttle cable

A

Throttle operation

I

Suspension

Suspension components

I, L

and function

270

MAINTENANCE PROCEDURES

1. Coolant reservoir

2. COLD line

Recommended Engine Coolant

RECOMMENDED COOLANT

XPS Extended life pre-mixed coolant

IF THE RECOMMENDED XPS COOLANT IS NOT

AVAILABLE

Distilled water and antifreeze solution (50% distilled water, 50%

antifreeze)

NOTICE

Always use ethylene-glycol antifreeze containing corrosion in-

hibitors specifically for internal combustion aluminum engines.

Engiine Oiil

Extreme Cold Condition

An engine that is operated in -25°C/-13°F and below environment will

require an increase in service and maintenance schedule.

Any combustion engine operated in such a low load and rather cold

operating temperature collects an increased amount of condensation

at every startup/warm-up.

272

MAINTENANCE PROCEDURES

Verifying the Engine Oil Level

NOTICE

Check level before each ride and refill if necessary. Do not

overfill. Operating the engine with an improper level may se-

verely damage engine. Wipe off any spillage.

Place vehicle on a level surface and proceed as follows to check oil

level:

1. Start engine and let it reach its normal operating temperature. En-

gine is at normal temperature when rear radiator gets warm, indi-

cating that the thermostat is open.

2. Let engine run at idle for 30 more seconds.

3. Stop engine.

4. Open the LH side panel. Refer to Body and Seat.

5. Remove the drive belt guard, refer to Drive Belt Guard.

6. Remove dipstick from the filler tube, then wipe it clean.

7. Completely insert dipstick in the filler tube.

8. Remove dipstick and check the oil level. Oil level should be be-

tween the MIN and MAX marks as shown, add if necessary.

1. Oil level between MIN. and MAX.

CAUTION

Engine oil can be very hot.

WARNING

Wipe off any oil spills. Oil is highly flammable when heated.

274

MAINTENANCE PROCEDURES

Replacing the Engine Oil

CAUTION

The engine oil can be very hot. Wait until engine oil is warm.

NOTICE

Engine oil and oil filter must be replaced at the same time.

1. Bring engine to its normal operating temperature.

2. Place vehicle on a level surface.

3. Remove the LH side panel.

4. Remove dipstick.

LH SIDE OF VEHICLE

1. Oil tank dipstick

5. Remove the oil filter. Refer to the procedure in this subsection.

6. From underneath the vehicle, access the drain plug:

1. Remove one access cover retaining screw and loosen the

other.

275

MAINTENANCE PROCEDURES

1. Drain plugs access cover

PIVOT THE ACCESS COVER

1. Retaining screws

2. Pivot the access cover to clear the bottom pan opening.

7. Clean drain plug area.

8. Place a drain pan under the bottom pan opening.

276

MAINTENANCE PROCEDURES

9. Remove engine drain plugs in the following order.

UNDERNEATH THE ENGINE

1. Main drain plug

2. Secondary drain plug

10. Allow oil to drain completely.

11. Install NEW sealing washers on oil drain plugs.

NOTICE

Never use a sealing washer a second time. Always replace with

a new one.

277

MAINTENANCE PROCEDURES

1. Sealing washer

2. Oil drain plug

12. Install drain plugs and tighten to specification.

Tightening Torque

15 ± 2 Nm

Drain plugs

(133 ± 18 lbf-in)

13. Install a new oil filter. Refer to procedure in this subsection.

14. Refill oil tank at the proper level with the recommended oil.

Approximate Engine Oil Capacity (with filter)

600 ACE

2.1 l (2.22 qt(liq.,US))

900 ACE

900 ACE Turbo

3.3 l (3.5 qt(liq.,US))

900 ACE Turbo R

15. Reinstall dipstick in oil tank and properly tighten it.

16. Start engine and let it idle for a few minutes.

17. Ensure there are no leaks.

18. Stop engine and check oil level as explained in this subsection. Re-

fill if necessary.

19. Dispose oil and filter as per your local environmental regulations.

278

MAINTENANCE PROCEDURES

Engine Oill Fillter

Engine Oil Filter Replacement

Removing the Oiil Fiilter

1. Remove the RH side panel.

2. Clean oil filter area.

3. Remove:

- Oil filter cover screws

- Oil filter cover with O-ring

- Oil filter.

1. Oil filter cover screws

2. Oil filter cover

3. O-ring

4. Oil filter

4. Dispose filter as per your local environmental regulations.

Installliing the Oill Fiilter

1. Check the oil filter inlet and outlet orifices inside oil filter receptacle

(integrated part of magneto cover) for dirt and contaminations.

279

MAINTENANCE PROCEDURES

1. Oil inlet orifice from the oil pressure pump

2. Oil outlet orifice to the engine lubrication system

3. Oil filter receptacle

2. Install a new O-ring on oil filter cover.

3. Install the new filter into the cover.

4. Lubricate filter seal and cover O-ring with engine oil.

280

MAINTENANCE PROCEDURES

1. Lubricate with engine oil

NOTICE

Pay attention to avoid pinching the O-ring during filter and cov-

er installation.

5. Install the oil filter cover.

6. Tighten oil filter cover screws to specification.

Tightening Torque

Oil filter cover screws

10 ± 1 Nm (89 ± 9 lbf-in)

7. Wipe off any oil spillage on engine.

Exhaust System

Exhaust System Verification

The muffler tail pipe should be centered with the exit hole in the bottom

pan. Exhaust system must be free of rust or leaks. Make sure that all

parts are securely in place.

Check retaining springs and heat shields condition and replace if

necessary.

The exhaust system is designed to reduce noise and to improve the

total performance of the engine. Modification may be in violation of lo-

cal laws.

281

MAINTENANCE PROCEDURES

TYPICAL

1. Brake fluid reservoir

283

MAINTENANCE PROCEDURES

TYPICAL

1. Minimum

2. Maximum

3. Operating range

CAUTION

Avoid getting brake fluid on skin or eyes - it may cause severe

burns. In case of contact with the skin, wash thoroughly. In

case of contact with the eyes, immediately rinse with plenty of

water for at least 10 minutes and then consult a doctor

immediately.

Recommended Brake Fluid

Recommended Brake Fluid

XPS DOT 4 Brake Fluid

Alternative or if not available

DOT 4 Brake Fluid

284

MAINTENANCE PROCEDURES

Use only DOT 4 brake fluid from a sealed container. An opened con-

tainer may be contaminated or may have absorbed moisture from the

air.

WARNING

Use only DOT 4 brake fluid from a sealed container. To avoid

serious damage to the braking system, do not use fluids other

than the recommended one, nor mix different fluids for topping

up.

Chaincase Oiil

Recommended Chaincase Oil

Recommended Chaincase Oil

XPS Synthetic chaincase oil

Alternative or if not available

75W140 gear oil that meets the API GL-5 specification

NOTICE

If the recommended XPS chaincase oil is not available, use a

75W140 gear oil that meets the API GL-5 specification. The

chaincase of this snowmobile has been developed and vali-

dated using the XPS™ Synthetic chaincase oil. BRP strongly

recommends the use of its XPS Synthetic chaincase oil at all

times. Damages caused by oil which is not suitable for the

chaincase will not be covered by the BRP limited warranty.

Verifying the Chaincase Oil Level

With the vehicle on a level surface, check the oil level by removing the

check plug.

285

MAINTENANCE PROCEDURES

CHECK PLUG

Oil level must reach the threaded hole.

If level is correct, reinstall check plug and tighten to the specified

torque.

Tightening Torque

Check plug

6 ± 1 Nm (53 ± 9 lbf-in)

If level is insufficient, refer to Chaincase Filling Procedure.

Replacing the Chaincase Oil

Draining the Chaincase Oill

1. Place the vehicle on a level surface.

2. Place a drain pan under the chaincase drain plug area.

3. Remove filler cap.

4. Remove the drain plug located at the bottom of the chaincase.

286

MAINTENANCE PROCEDURES

5. Wait a while to allow all oil to drain out of the chaincase.

6. Install drain plug and tighten to specification.

Tightening Torque

Chaincase drain plug

6 ± 1 Nm (53 ± 9 lbf-in)

Fillliing the Chaiincase

1. Open the RH side panel. Refer to Equipment.

2. Remove the check plug.

287

MAINTENANCE PROCEDURES

CHECK PLUG

3. Remove the filler cap.

TYPICAL - TOP OF CHAINCASE

1. Filler cap

4. Pour recommended oil in the filler hole until oil comes out by the

check plug hole.

5. Reinstall check plug and tighten to specification.

288

MAINTENANCE PROCEDURES

Tightening Torque

Check plug

6 ± 1 Nm (53 ± 9 lbf-in)

Reinstall the filler cap.

Gearbox Oiil

Recommended Gearbox Oil

XPS RECOMMENDED Chaincase Oil

XPS™ Synchromesh Transmission Synthetic Oil

IF THE RECOMMENDED XPS OIL IS NOT

AVAILABLE

Use a 75W140 gear oil that meets the API GL-5 specification

NOTICE

The gearbox of this snowmobile has been developed and vali-

dated using the XPS synchromesh transmission synthetic oil.

BRP strongly recommends the use of its synchromesh trans-

mission synthetic oil at all times. Damages caused by oil which

is not suitable for the gearbox will not be covered by the BRP

limited warranty.

Gearbox Oil Level

With the vehicle on a level surface, check the oil level by removing the

check plug on the left side of gearbox.

Oil level must reach the threaded hole's lower edge.

289

MAINTENANCE PROCEDURES

CHECK PLUG

To add oil, proceed as follows:

1. Remove the filler plug.

FILLER PLUG

2. Pour recommended oil in gearbox by the filler hole until oil comes

out by the check plug hole.

3. Reinstall check and filler plug and tighten to specifications.

290

MAINTENANCE PROCEDURES

TIGHTENING TORQUE

Check plug

6 ± 1 Nm (53 ± 9 lbf-in)

Filler plug

8 ± 1 Nm (71 ± 9 lbf-in)

Replacing the Gearbox Oil

Gearbox Oiil Drainiing

1. Place the vehicle on a level surface.

2. Place a drain pan under gearbox drain plug area.

3. Remove filler cap.

4. Remove the drain plug located at the bottom of gearbox.

5. Wait a while to allow all oil to drain out of gearbox.

6. Install drain plug and tighten to specification.

Tightening Torque

Gearbox drain plug

6 ± 1 Nm (53 ± 9 lbf-in)

Gearbox Oiil Fillliing

NOTE:

Vehicle must be on a level surface.

291

MAINTENANCE PROCEDURES

1. Remove the filler plug.

2. Remove oil level check plug.

FILLER PLUG

CHECK PLUG

3. Pour recommended oil into gearbox through the filler hole.

292

MAINTENANCE PROCEDURES

NOTE:

Oil level is correct when it just begins to come out of the check plug

orifice.

4. Reinstall check plug and tighten to specification.

tightening torque

Oil level check plug

6 ± 1 Nm (53 ± 9 lbf-in)

Driive Chain

Access to Chaincase

Open RH side panel, refer to Equipment.

Drive Chain Adjustment

Using the Torx end of the driven pulley expander, GENTLY turn ten-

sioner clockwise to eliminate the play.

TYPICAL

Do not force the tensioner in.

NOTE:

Do not remove the hair cotter pin.

293

MAINTENANCE PROCEDURES

TYPICAL - PULLEY EXPANDER INSTALLED ON ADJUSTER

HUB

5. Open the driven pulley by screwing the tool in.

6. Remove the drive belt by slipping it over the edge of the driven pul-

ley, then over the drive pulley.

Installliing the Drive Belt

The driven pulley must be expanded. Refer to Removing the Drive

Belt.

1. Slip the belt over the drive pulley, then over the driven pulley.

NOTICE

Do not force or use tools to pry the belt into place, as this could

cut or break the cords in the belt.

NOTE:

The maximum drive belt life span is obtained when belt is installed

with arrows in the direction of rotation.

295

MAINTENANCE PROCEDURES

1. To be pointed in the direction of rotation

2. Unscrew and remove the driven pulley expander from the pulley.

3. Rotate the driven pulley several times to properly set the belt be-

tween the sheaves.

4. If a new belt was installed, an adjustment will be required for the

proper belt height. Refer to Adjusting the Drive Belt Height.

5. Install belt guard.

6. Close side panel.

Adjusting the Drive Belt Height

Remove the tether cord cap from engine cut-off switch.

Remove the LH side panel.

Remove the drive belt guard.

1. Loosen the clamping bolt.

296

MAINTENANCE PROCEDURES

2. Using the suspension adjustment tool provided, turn the ring 1/4

turn at a time then rotate the driven pulley to properly set the drive

belt between the pulley sheaves.

297

MAINTENANCE PROCEDURES

NOTE:

The adjustment ring has left hand treads.

Repeat step 4 until the lowest portion of the cogs on the external

surface of drive belt is even with the driven pulley edge.

TYPICAL - PRELIMINARY SETTING

1. Lowest portion of cogs even with external surface of drive belt

NOTE:

Turning the ring counterclockwise lowers the drive belt in the pulley.

Turning the ring clockwise raises the drive belt in the pulley.

3. Firmly tighten the clamping bolt. If possible, tighten to specified tor-

que using a torque wrench.

TIGHTENING TORQUE

Clamping bolt

5.5 ± 0.5 Nm (49 ± 4 lbf-in)

298

MAINTENANCE PROCEDURES

4. Install belt guard, refer to Installing the Drive Belt Guard.

5. Install LH side panel.

6. Start engine and check if vehicle creeps.

7. If vehicle does not creep, adjustment is complete.

8. If vehicle creeps, check the drive belt deflection.

Reverse Activation (if equiipped)

Reverse may not activate or may be harder to activate if the belt is

positioned too high in the driven pulley. If reverse activation does not

work properly, ensure the drive belt is properly adjusted.

Adjust the drive belt lower in the driven pulley if needed.

Track

Track Condition

WARNING

Remove tether cord cap from engine cut-off switch before per-

forming any maintenance or adjustment, unless otherwise

specified. Vehicle must be parked in a safe place, away from

the trail.

Remove tether cord cap from engine cut-off switch.

299

MAINTENANCE PROCEDURES

1. Bottom O-ring

2. Place the upper O-ring to 0 kgf (0 lbf).

1. Upper O-ring

5. Position the tensiometer on track, halfway between front and rear

idler wheels.

6. Push the tensiometer downwards until bottom O-ring (deflection

set earlier) be aligned with the bottom of slider shoe.

TYPICAL

302

MAINTENANCE PROCEDURES

TYPICAL

1. Deflection O-ring aligned with slider shoe

7. Read load recorded by the upper O-ring on the tensiometer.

TYPICAL - LOAD READING

1. Upper O-ring

8. Load reading must be as per the track deflection in the Technical

Specifications.

9. If load reading is not in accordance with the specification, adjust

track tension. Refer to Track Tension Adjustment.

Adjusting the Track Tension

1. Remove tether cord cap from engine cut-off switch.

303

MAINTENANCE PROCEDURES

CAUTION

Use proper lifting techniques, notably using your legs force. Do

not attempt to lift the rear of vehicle if it is above your limits.

2. Remove wheel caps.

3. Loosen the rear axle screws on both sides.

4. Tighten or loosen both adjustment screws (equally) to increase or

decrease track tension.

SC-5U

1. Remove cap

2. Loosen the axle screw or nut

3. Tighten or loosen adjustment screws

5. If correct tension is unattainable, contact an authorized BRP snow-

mobile dealer.

6. Retighten the rear axle fasteners to specification.

TIGHTENING TORQUE

Rear idler wheel retaining

48 ± 6 Nm (35 ± 4 lbf-ft)

screws

7. Check track alignment as described below.

304

MAINTENANCE PROCEDURES

Alligning the Track

WARNING

Before checking track alignment, ensure that the track is free of

all particles which could be thrown out while track is rotating.

Keep hands, tools, feet and clothing clear of track. Always lift

the snowmobile on a wide-base stand with a rear deflector pan-

el. Ensure no one is standing in close proximity to the snowmo-

bile, especially at the rear of the track. Never rotate track at

high speed.

Centrifugal force could cause debris, damaged or loose studs,

pieces of torn track, or an entire severed track to be violently

thrown backwards out of the tunnel with tremendous force.

1. Lift rear of vehicle and support it off the ground.

CAUTION

Use proper lifting techniques, notably by using the force of your

legs . Do not attempt to lift the rear of vehicle if it is above your

limits.

2. Start engine and accelerate slightly so that track slowly turns. This

must be done in a short period of time (15 to 20 seconds).

3. Check that the track is well centered; equal distance on both sides

between edges of track guides and slider shoes.

1

2

3

A01F05A

1. Guides

2. Slider shoes

3. Equal distance

305

MAINTENANCE PROCEDURES

4. To correct track alignment:

1. Guides

2. Slider shoes

3. Tighten on this side

1. Stop engine.

2. Remove tether cord cap from engine cut-off switch.

WARNING

Remove tether cord cap from engine cut-off switch before per-

forming any maintenance or adjustment, unless otherwise

specified. Vehicle must be parked in a safe place, away from

the trail.

3. Loosen the rear axle nut.

4. Tighten adjustment screw on side where the slider shoe is the

farthest from the track insert guides.

5. Tighten the rear axle nut.

WARNING

Properly tighten wheel retaining bolt, otherwise wheel may

come off and cause track to “lock”.

6. Restart engine and rotate track slowly to recheck alignment.

7. Tighten the rear axle nut to specified torque.

306

MAINTENANCE PROCEDURES

SC-5U

1. Grease fittings

SC-5U

1. Grease fittings

Steering and Front Suspension Condition

Visually inspect steering and front suspension for tightness of compo-

nents (steering arms, control arms and links, tie rods, ball joints, ski

bolts, ski legs, etc.). If necessary, contact an authorized BRP snowmo-

bile dealer.

308

MAINTENANCE PROCEDURES

Skis

Wear and Condition of Skis and Runners

Check the condition of the skis and ski runner carbides. If worn, con-

tact an authorized BRP snowmobile dealer.

WARNING

Excessively worn skis and/or ski runners will adversely affect

snowmobile control.

Fuses

Access to Fuse Block

Open RH side panel, refer to Body and Seat.

Fuses Location

TYPICAL – FA

309

MAINTENANCE PROCEDURES

TYPICAL – FUSE BOX 1 (FB1)

TYPICAL – RELAY BLOCK - IF EQUIPPED

310

MAINTENANCE PROCEDURES

TYPICAL – FUSE BOX 2 (FB2) - IF EQUIPPED

Refer to Technical Specification for relay and fuse identification.

Fuse Inspection

Check fuse condition and replace it if necessary.

To remove fuse from holder, pull fuse out. Check if filament is melted.

1. Fuse

2. Check if melted

311

MAINTENANCE PROCEDURES

WARNING

Do not use a higher rated fuse.

WARNING

If fuse has burnt out, source of malfunction should be deter-

mined and corrected before restarting. See an authorized BRP

snowmobile dealer for servicing.

Headllights

Headlights Bulb Replacement

1. Remove the windshield. Refer to Removing the Windshield in Body

and Seat subsection.

2. Open the storage compartment.

TYPICAL

3. Remove the gauge support retaining screws.

312

MAINTENANCE PROCEDURES

4. Lift the front of the gauge support, then slide it forward to remove it.

313

MAINTENANCE PROCEDURES

5. Set gauge support aside.

6. Remove the storage compartment.

7. Disconnect 12V power outlet connectors to remove (if equipped).

8. Disconnect bulb connector.

9. Unlock bulb by turning it counterclockwise.

10. Pull bulb out.

NOTE:

Ensure bulb seal stays in place.

314

MAINTENANCE PROCEDURES

1. Bulb

2. Bulb seal

Install a new bulb using the reverse of the removal procedure.

NOTICE

Never touch glass portion of an halogen bulb with bare fingers,

it shortens its operating life. If glass is touched, clean it with

isopropyl alcohol which will not leave a film on the bulb.

Check headlights operation.

Headlights Beam Aiming

Open the storage compartment.

315

MAINTENANCE PROCEDURES

TYPICAL

Turn the adjustment screw to reach desired beam height.

Battery

400 mm (16 in.) Tunnel Width

Removiing the Battery

1. Remove the seat.

2. Remove the battery cover.

316

MAINTENANCE PROCEDURES

TYPICAL

3. Disconnect the negative terminal first, then the positive terminal.

NOTICE

Battery BLACK ( – ) cable must always be disconnected first

and connected last.

4. Remove the battery hold down bracket.

317

MAINTENANCE PROCEDURES

5. Remove the battery.

Installling the Battery

NOTICE

Battery BLACK ( – ) cable must always be disconnected first

and connected last.

The installation is the reverse of the removal procedure. However, pay

attention to the following details.

318

MAINTENANCE PROCEDURES

500 and 600 mm (20 and 24 in.) Tunnel Width

Removiing the Battery

1. Remove the passenger seat and backrest, if equipped.

2. Open the cargo box, remove the battery cover and all mounting

screws.

LH SIDE SCREW SHOWN

3. Remove the cargo box.

320

MAINTENANCE PROCEDURES

4. Disconnect the negative terminal first, then the positive terminal.

NOTICE

Battery BLACK ( – ) cable must always be disconnected first

and connected last.

1. Disconnect negative

2. Disconnect positive

5. Remove the battery hold down bracket.

321

MAINTENANCE PROCEDURES

6. Remove the battery.

Installling the Battery

The installation is the reverse of the removal procedure. However, pay

attention to the following details.

322

VEHICLE IDENTIFICATION

Vehiiclle Descriiptiion Decal

Vehicle description decal is located on right hand side of tunnel.

TYPICAL

FOR NORTH AMERICAN MARKET

336

VEHICLE IDENTIFICATION

520002459

FOR EUROPEAN MARKET

Identificatiion Numbers

The main components of your snowmobile (engine and frame) are

identified by different identification numbers. It may sometimes be-

come necessary to locate these numbers for warranty purposes or to

trace your snowmobile in the event of loss. These numbers are re-

quired by the authorized BRP snowmobile dealer to complete war-

ranty claims properly. We strongly recommend that you take note of

all the identification numbers on your snowmobile and supply them to

your insurance company.

Vehicle Identification Number (VIN)

VIN is scribed on vehicle description decal. See above. It is also en-

graved on tunnel near vehicle description decal.

Model number and model year are part of the information found in the

VIN. See illustration.

2BP

S

LSAB

9

A

V

000001

2BP = Canada

Serial

Model number

YH2 = Finland

number

Factory

S = Ski-Doo

V = Valcourt

L = Lynx

R = Rovaniemi

Numeric or

Alphabetic

Model year: P = 2023

Q = 2024

R=2025etc.

337

VEHICLE IDENTIFICATION

Engine Identification Number Location

338

COMPLIANCE LABELS

EPA Complliance Label

EPA COMPLIANCE LABEL

TYPICAL

339

COMPLIANCE LABELS

SSCC Labell

Safety standards for snowmobiles have been adopted by the Snow-

mobile Safety and Certification Committee (SSCC) of which BRP is a

proud participating member. Assurance that your snowmobile meets

these standards is easily checked by locating the Certification Label

on a right vertical portion of the vehicle.

The following label shows that an independent testing laboratory has

verified compliance with the SSCC safety standards.

SSCC LABEL

TYPICAL

340

COMPLIANCE LABELS

Yelllowstone Natiionall Park Complliance Labell

YELLOWSTONE NATIONAL PARK - COMPLIANCE LABEL

LABEL LOCATION

341

COMPLIANCE LABELS

Regullatiion (EU) 2016/1628 appllicablle for

Non-Road Mobiile Machineries

Vehicles who comply to Regulation (EU) 2016/1628 (NRMM) are iden-

tified on the engine valve cover.

TYPICAL

NRMM IDENTIFICATION ON ENGINE

342

COMPLIANCE LABELS

Depending on your particular vehicle configuration, an additional

NRMM identification decal may be installed on the tunnel, near the

gearbox.

TYPICAL - ON RH SIDE OF TUNNEL

Bombardier Recreational

Products Inc.

565 de la Montagne,

Valcourt,QC, Canada

J0E 2L0

BRP-Rotax GmbH Co. KG

Rotaxstrasse 1

Gunskirchen, A-4623

Austria

Rotax

NRMM IDENTIFICATION ON VEHICLE

343

NOISE EMISSION AND VIBRATION VALUES

MODEL

600 ACE

900 ACE

NOISE EMISSION AND VIBRATION VALUES¹

90,4 dB @ 3625

91,2 dB @ 3625

Sound power level

Noise

RPM (Uncertainty

RPM (Uncertainty

(LWA)

(Kwa) 3 dB)

(Kwa) 3 dB)

<2.5 m/s² @

3.15 m/s² @

Hand-arm system

3625 RPM

3625 RPM

Vibration

Whole body at

<0.5 m/s² @

<0.5m/s² @ 3625

seat

3625 RPM

RPM

¹: Noise emission and Vibration values are measured in accordance

with Annexes A and B of ISMA 1 regulation on a snow covered or

grass surface in neutral or without belt.

900 ACE Turbo (130 hp) and Turbo

MODEL

R (180 hp)

NOISE EMISSION AND VIBRATION VALUES¹

Sound power level

99 dB @ 3625 RPM (Uncertainty

(LWA)

(Kwa) 3 dB)

Noise

Sound pressure

92 dB @ 3625 RPM (Uncertainty

(LpA)

(Kpa) 3 dB)

Hand-arm system

<2.5 m/s² @ 3625 RPM

Vibration

Whole body at

<0.5m/s² @ 3625 RPM

seat

¹: Noise emission and Vibration values are measured in accordance

with Annexes A and B of ISMA 1 regulation on a snow covered or

grass surface in neutral or without belt.

344

ENGINE

600 ACE

ENGINE

600 ACE

Rotax 600, liquid

cooled, 4-stroke,

Engine type

D.O.H.C., dry

sump.

Number of cylinder

2

Bore

74 mm (2.91 in)

Stroke

69.7 mm (2.74 in)

Displacement

600 cm³ (36.6 in³)

Maximum power engine speed

7250 RPM

FUEL SYSTEM

Multi point EFI, 46

Fuel delivery

mm heated

throttle body

At ECO Mode

1500 ± 200 RPM

(not adjustable)

Idle speed

STD/ Sport Mode

1700 ± 200 RPM

(not adjustable)

ELECTRICAL SYSTEM

30 A @ 14.5 V

Total system output

420 W to 650 W

@ 6000 RPM

NGK MR7BI-8 or

Type

equivalent

Spark

600 ACE

plug⁽¹⁾

Not adjustable 0.7

Gap

to 0.8 mm (.028 to

.031 in)

356

ENGINE

LUBRICATION SYSTEM

4T 0W40

Type

Synthetic oil

Engine oil⁽²⁾

Oil change and

Quantity

600 ACE

filter, 2.1 l (2.22

qt(liq.,US))

900 ACE

ENGINE

900 ACE

Rotax 903, liquid

cooled, 4-stroke,

Engine type

D.O.H.C., dry

sump

Number of cylinder

3

Bore

74 mm (2.9 in)

Stroke

69.7 mm (2.74 in)

Displacement

899 cm³ (54.9 in³)

Maximum power engine speed

7250 ± 200 RPM

FUEL SYSTEM

Multi point EFI, 46

Fuel delivery

mm heated

throttle body

Standard and

1300 ± 200 RPM

ECO mode

Idle speed (not adjustable)

Sport mode

1500 ± 200 RPM

357

ENGINE

ELECTRICAL SYSTEM

30 A @ 14.5 V

Total system output

650 W @ 6000

RPM

NGK MR8BI-8 or

Type

equivalent

Spark plug⁽¹⁾

Gap

Not adjustable 0.7

to 0.8 mm (.028 to

.031 in)

LUBRICATION SYSTEM

XPS 4T 0W40

Type

Synthetic oil

Engine oil⁽²⁾

Oil change with

Quantity

filter: 3.3 l (3.5

qt(liq.,US))

900 ACE Turbo

900 ACE Turbo

ENGINE

(130 hp)

Rotax 903, liquid

cooled, 4-stroke,

Engine type

D.O.H.C., dry

sump, turbo

without intercooler

Number of cylinder

3

Bore

74 mm (2.9 in)

Stroke

69.7 mm (2.74 in)

Displacement

899 cm³ (54.9 in³)

Maximum power engine speed

7400 ± 200 RPM

358

ENGINE

FUEL SYSTEM

Multi point EFI, 46

Fuel delivery

mm heated

throttle body

Standard and

1300 ± 200 RPM

ECO mode

Idle speed (not adjustable)

Sport mode

1650 ± 200 RPM

ELECTRICAL SYSTEM

30 A @ 14.5 V

Total system output

650 W @ 6000

RPM

NGK

Type

LMAR9AI-8D or

equivalent

Spark plug⁽¹⁾

Gap

Not adjustable 0.7

to 0.8 mm (.028 to

.031 in)

LUBRICATION SYSTEM

XPS 4T 0W40

Type

Synthetic oil

Engine oil⁽²⁾

Oil change with

Quantity

filter: 3.3 l (3.5

qt(liq.,US))

359

ENGINE

900 ACE Turbo R

900 ACE Turbo

ENGINE

R (180 hp)

Rotax 903, liquid

cooled, 4-stroke,

Engine type

D.O.H.C., dry

sump, turbo with

intercooler

Number of cylinder

3

Bore

74 mm (2.9 in)

Stroke

69.7 mm (2.74 in)

Displacement

899 cm³ (54.9 in³)

Maximum power engine speed

7900 ± 200 RPM

FUEL SYSTEM

Multi point EFI, 46

Fuel delivery

mm heated

throttle body

Standard and

1300 ± 200 RPM

ECO mode

Idle speed (not adjustable)

Sport mode

1650 ± 200 RPM

ELECTRICAL SYSTEM

30 A @ 14.5 V

Total system output

650 W @ 6000

RPM

NGK

Type

LMAR9AI-8D or

equivalent

Spark plug⁽¹⁾

Gap

Not adjustable 0.7

to 0.8 mm (.028 to

.031 in)

360

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