Snowmobile Ski-Doo SPORT-UTILITY ACE SERIES. OPERATOR’S GUIDE (2024)

BODY AND SEAT

Installing the Upper Body Module

1. At front, insert the upper body module tabs into the bottom pan

openings.

FRONT HOOD TAB

2. Lower the rear end of the upper body module.

3. Insert the rear end hooks of the upper body module into the slots in

the console.

NOTE:

Make sure the air intake duct is positioned properly connected.

4. Tighten air intake duct clamp.

TIGHTENING TORQUE

Intake duct clamp

1.0 ± 0.2 Nm (9 ± 2 lbf-in)

5. On both sides, install the upper body module retaining screws.

TIGHTENING TORQUE

Upper body screws

1.8 ± 0.2 Nm (16 ± 2 lbf-in)

6. Connect the headlight connectors.

7. Install the storage compartment but leave the cover open.

8. Install gauge, secure with the screws.

153

BODY AND SEAT

TIGHTENING TORQUE

Gauge support screws

2.3 ± 0.2 Nm (20 ± 2 lbf-in)

Seat

400 mm (16 in.) Tunnel Width

Removiing the Seat (tab lock)

From between the fuel tank and the seat front end, pull the locking tab

upwards.

Slide the seat backwards while holding the tab up.

TYPICAL — CROSSCUT VIEW OF SEAT FOAM

1. Pull upwards

2. Slide backwards

Installling the Seat (tab lock)

NOTICE

Riding the vehicle with any objects between the seat and the

fuel tank could damage the fuel tank. NEVER place any objects

between seat and fuel tank.

154

BODY AND SEAT

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

Operator’s Seat

Removiing the Seat

Release the latch at the back of the seat.

Slide seat rearwards to remove it.

Installling the Seat

NOTICE

Riding the vehicle with any objects between the seat and the

fuel tank could damage the fuel tank. NEVER place any objects

between seat and fuel tank.

Place seat over the hooks, then slide it forward.

Securely engage the latch.

WARNING

Make sure seat is securely latched before riding.

156

EQUIPMENT

Some features may not apply to your model or could be optional.

Operator''s Guiide

The Operator's Guide should be stored in the Front Storage

Compartment.

Mountaiin Strap

This handlebar strap shall be used only to provide additional pulling

force when snowmobile is stuck in a slanted position. On an excep-

tional basis it can be used at very slow speed only, when standing on

the right running board to bring the vehicle back on its desired path.

When riding, both hands should remain on the handlebar grips to pro-

vide braking capability, as well proper steering and directional control.

Do not use handlebar strap for towing, lifting or side hilling.

WARNING

Do not use while riding at speed. Steering control is highly re-

duced and brake control is not possible.

Electriic Visor Jack Connector

An electric visor can be connected to the jack connector. A stress re-

lief extension is supplied with the vehicle.

TYPICAL — DRIVER - ELECTRIC VISOR JACK CONNECTOR

LOCATION

160

EQUIPMENT

Driive Belt Guard

Removing the Drive Belt Guard

WARNING

NEVER operate engine:

– Without shields and belt guard securely installed.

– With hood and/or side panels opened or removed.

NEVER attempt to make adjustments to moving parts while en-

gine is running.

NOTE:

Belt guard is purposely made slightly oversize to maintain tension on

its pins and retainers preventing undue noise and vibration. It is impor-

tant that this tension be maintained when reinstalling.

Remove tether cord cap from engine cut-off switch.

Open the LH side panel. See procedure in this section.

Remove retaining pin.

TYPICAL

Lift rear portion of guard then release from front tab.

161

EQUIPMENT

Tools

A part of the drive belt guard is designed to hold the tools allowing for

basic maintenance.

The tools are supplied with the vehicle. They should always be in-

stalled in their proper location and orientation.

TYPICAL - DRIVE BELT GUARD TOOLS LOCATION

1. Suspension adjustment tool

2. Pulley expander and headlight adjustment tool

Install in the following sequence:

CAUTION

Make sure tools are secured properly. Tools may detach and

cause damage to rotating parts.

1. Slide the suspension adjustment tool open end under retaining tab.

167

GAUGE – 4.5” DIGITAL DISPLAY

Multifunctiion Display

Lower Display

May display the following:

- RPM

- Speed

- Engine Temperature

- Fuel Statistics

- Settings

- Messages

- Outside temperature (if equipped)

To change the displayed information, use the gauge LOWER (M) but-

ton, or the Mode button on the handlebar multifunction switch, if

equipped.

The SPEED STAT display shows the maximum and the averaged

speed. Hold LOWER button for 3 seconds to reset.

When the SPEED display is chosen, the RPM is shown in the TRIP

display.

177

GAUGE - 4.5” DIGITAL DISPLAY

Driving Mode Display

The MODE display indicates the selected mode of operation:

- SPORT

- ECO

- STANDARD

NOTE:

When in STANDARD mode, no information is displayed.

A message of the selected mode will be displayed on the lower display

at activation and deactivation as follow:

DRIVING

MESSAGE AT

MODE

ACTIVATION

DEACTIVATION

Sport

Sport OFF

Eco

Eco OFF

Trip Display

This display shows trip informations:

- Cumulative distance odometer

- Trip A hours

179

GAUGE - 4.5” DIGITAL DISPLAY

- Trip A distance (Km or mph)

- Vehicle hour meter

- Clock (If battery equipped)

To change the displayed information, use the gauge UPPER (T) but-

ton, or the Trip button on the handlebar multifunction switch, if

equipped.

Warning Lamps and Indicators

The following indicator lamps will alert you to a vehicle condition that

may become serious. Some lamps will illuminate when starting the ve-

hicle to make sure they work. If any lamps remain on after starting the

vehicle, refer to the respective system warning lamp for further

information.

NOTE:

Some warning indicators appear in the display of the multifunction

gauge and function the same as an indicator lamp but do not display

when starting the vehicle.

Telltale Lights - Lower Bar

Lights

Description

ORANGE - Vehicle malfunction

BLUE - The high beam are selected

RED - The engine temperature is too high.

RED - Parking brake is engaged or malfunction

of the brake system

RED - The battery voltage too low or problem

with the electrical system

RED - Low engine oil pressure (if applicable)

180

GAUGE - 4.5” DIGITAL DISPLAY

Settings

Setup

1. Upper button (Trip)

2. Lower button (Menu)

NOTE: A Trip and a Menu buttons can be found on the handlebar

multifunction switch, if equipped.

Using the LOWER (M) button, select SETTINGS and hold to enter

setting menu.

Reset Stats

Using LOWER button, select RESET STAT and hold to reset.

Unit Selection

This multifunction gauge is factory preset in metric units but it is possi-

ble to change it to imperial units.

Using LOWER button, select UNITS and hold button to change units.

Setting Clock

Using LOWER button, select CLOCK to change the clock.

1. Press LOWER button to select clock display.

2. Push and hold LOWER button for 1 second.

182

GAUGE - 4.5” DIGITAL DISPLAY

3. Press LOWER button to select 12:00 AM PM or 24:00 time base.

4. Push and hold LOWER button to acknowledge selection.

5. Press LOWER button to change hours (hours flash).

6. Push and hold LOWER button to acknowledge hour selection.

7. Press LOWER button to switch to minutes (minutes flash).

8. Push and hold LOWER button to acknowledge minutes selection.

Setting Language

The gauge display language can be changed. Refer to an authorized

BRP snowmobile dealer for language availability and to setup the

gauge to your preference.

183

GAUGE – 7.2” DIGITAL DISPLAY

Mulltiifunction Diispllay

1. Select the upper or center display by using the MENU (M) button

on the multifunction switch. Refer to Secondary Controls for Menu/

Set button location.

2. While the desired display is flashing, navigate through the display,

by using the SET (S) button on the multifunction switch.

Once the desired information is displayed, press the MENU (M)

button or wait 5 seconds to confirm.

To reset

- Average speed

- Top speed

- Total fuel consumption

Press and hold the SET (S) button while display is flashing.

Lower Display

7.2" DIGITAL LOWER DISPLAY

May display the following:

- Settings

184

GAUGE - 7.2” DIGITAL DISPLAY

- Messages

The SPEED display shows the Maximum and the averaged speed.

Hold MENU button for 3 seconds to reset.

Left Lateral Display

The left lateral display includes:

- Fuel level indicator

- Heated Grip level

- Trip distance A and B (Km or mph)

- Cumulative hours

- Speed

- RPM

- Odometer

Right Lateral Display

The right lateral display includes:

- Engine Temperature

- Heated throttle indicator

- Clock

185

GAUGE - 7.2” DIGITAL DISPLAY

NOTE:

When in STANDARD mode, no information is displayed.

A message of the selected mode will be displayed on the lower display

at activation and deactivation as follow:

DRIVING

MESSAGE AT

MODE

ACTIVATION

DEACTIVATION

Sport

Sport OFF

Eco

Eco OFF

Warning Lamps and Indicators

The following indicator lamps will alert you to a vehicle condition that

may become serious. Some lamps will illuminate when starting the ve-

hicle to make sure they work. If any lamps remain on after starting the

vehicle, refer to the respective system warning lamp for further

information.

NOTE:

Some warning indicators appear in the display of the multifunction

gauge and function the same as an indicator lamp but do not display

when starting the vehicle.

188

GAUGE - 7.2” DIGITAL DISPLAY

Telltale Lights - Lower Bar

Lights

Description

ORANGE - Vehicle malfunction

BLUE - The high beam are selected

RED - The engine temperature is too high.

RED - Parking brake is engaged or malfunction

of the brake system

RED - The battery voltage too low or problem

with the electrical system

RED - Low engine oil pressure (if applicable)

ORANGE - Low fuel level

ORANGE

Turn on: Malfunction of the vehicle emissions

control system

Blink: Engine problems, the limp home mode is

activated. Have the vehicle serviced

immediately.

Icons and Indicators - Multifunction Display

Icons and Indicators

Denotes SPORT mode is selected.

Denotes ECO mode is selected.

189

GAUGE - 7.2” DIGITAL DISPLAY

Settings

Setup

Using MENU button, select SETTINGS and hold to enter setting

menu. Various options are available such as swapping the SPEED

and RPM in the Central Display.

Unit Selection

This multifunction gauge is factory preset in metric units but it is possi-

ble to change it to imperial units.

Using MENU button, select UNITS and hold button to change units.

Setting Clock

Using MENU button, select CLOCK and hold to change units.

1. Press MENU button to select clock display.

2. Push and hold MENU button for 1 second.

3. Press MENU button to select 12:00 AM PM or 24:00 time base.

4. Push and hold MENU button or OK button to acknowledge

selection.

5. Press MENU button to change hours (hours flash).

6. Push and hold MENU button or OK button to acknowledge hour

selection

7. Push MENU button to switch to minutes (minutes flash).

8. Press MENU button to change minutes.

Setting Language

The gauge display language can be changed. Refer to an authorized

BRP snowmobile dealer for language availability and to setup the

gauge to your preference.

190

FUEL

Fuel Requiirements

NOTICE

Always use fresh gasoline. Gasoline will oxidize; the result is

loss of octane, volatile compounds, and the production of gum

and varnish deposits which can damage the fuel system.

Alcohol fuel blending varies by country and region. Your vehicle has

been designed to operate using the recommended fuels, however, be

aware of the following:

- Use of fuel containing alcohol above the percentage specified by

government regulations is not recommended and can result in the

following problems in the fuel system components:

- Starting and operating difficulties.

- Deterioration of rubber or plastic parts.

- Corrosion of metal parts.

- Damage to internal engine parts.

- Inspect frequently for the presence of fuel leaks or other fuel sys-

tem abnormalities if you suspect the presence of alcohol in gaso-

line exceeds the current government regulations.

- Alcohol blended fuels attract and hold moisture which may lead to

fuel phase separation and can result in engine performance prob-

lems or engine damage.

Recommended Fuel

Use unleaded gasoline containing MAXIMUM 10% ethanol. The gaso-

line must have the following minimum octane requirements:

Fuel type

Engine

Minimum octane rating

600 ACE

87 AKI (RON+MON)/2

900 ACE

92 RON

Fuel with NO

ethanol

900 ACE Turbo

91 AKI (RON+MON)/2

900 ACE Turbo

95 RON

91 AKI (RON+MON)/2

95 RON

600 ACE

Fuel which may

900 ACE

contain up to 10%

900 ACE Turbo

MAX ethanol

900 ACE Turbo

191

FUEL

NOTICE

Never experiment with other fuels. Engine or fuel system dam-

ages may occur with the use of an inadequate fuel.

NOTICE

Do NOT use fuel from fuel pumps labeled E85.

Use of fuel labeled E15 is prohibited by U.S. EPA Regulations.

Fueling Procedure

WARNING

Always stop engine before refueling.

WARNING

Fuel is flammable and explosive under certain conditions.

Never use an open flame to check fuel level.

Never smoke or allow flame or spark in vicinity.

Always work in a well-ventilated area.

NOTE:

Do not sit or lean on seat when fuel tank cap is not properly installed.

1. Stop engine.

2. Have operator and passenger get off vehicle.

WARNING

Do not allow anyone seated on the vehicle while fueling.

3. Unscrew slowly the fuel reservoir cap counterclockwise to stabilize

pressure before removing it.

NOTE:

A short whistling sound is normal.

192

FUEL

TYPICAL

1. Fuel tank cap

4. Insert the spout into the filler neck.

5. Pour fuel slowly so that air can escape from the tank and prevent

fuel flow back. Be careful not to spill fuel.

6. Stop filling when the fuel reaches the bottom of filler neck. Do not

overfill.

WARNING

Never top up the fuel tank before placing the vehicle in a warm

area. As temperature increases, fuel expands and may

overflow.

7. Fully tighten fuel reservoir cap clockwise.

WARNING

Always wipe off any small fuel spillage from the vehicle. If a ma-

jor spillage occurs, remove side panels to remove fuel vapors

from engine compartment before starting.

NOTE:

Do not sit or lean on seat when fuel tank cap is not properly installed.

193

ENGINE OIL

Recommended Oiil

Rotax^® engines were developed and validated using the XPS™ oil.

BRP recommends the use of its XPS engine oil or an equivalent at all

time. Do not add any oil additives to the recommended engine oil.

Damages caused by the use of an oil not suitable for the engine or by

adding of an oil additives may not be covered by the BRP Limited

Warranty.

XPS RECOMMENDED Engine Oil

4T 0W40 Synthetic oil

IF THE RECOMMENDED XPS ENGINE OIL IS NOT

AVAILABLE

Use a 0W40 4-stroke SAE synthetic engine oil meeting or

exceeding the following lubricant industry specifications.

Always check the API service label certification on the oil container,

it must contain at least the indicated standard.

- API service classification SN

194

DRIVING MODES

WARNING

Whenever changing operating mode, make sure to maintain sit-

uational awareness while riding.

ECO Mode

(Fuel Economy Mode)

When ECO mode is selected (fuel economy mode), vehicle torque

and speed are limited whereby an optimal cruising speed is main-

tained in order to reduce fuel consumption.

Once activated, ECO mode will remain active until it is deactivated by

the operator.

Standard Mode

When in Standard mode, no indicator is in the multifunction gauge.

Sport Mode

WARNING

Ensure passenger is advised to hold on tightly before activating

Sport mode. Sport mode provides increased acceleration.

When selected, Sport mode provides for instant throttle response and

more rapid accelerations than Standard or ECO mode.

Once activated, Sport mode will remain active until it is deactivated by

the operator.

A message of the selected mode will be displayed at activation and

deactivation as follow:

Operating mode

Message at Activation

Sport

SPORT MODE

Standard

STANDARD MODE

Eco

ECO MODE

195

DRIVING MODES

Naviigatiing the Driiviing Modes

Use ECO/ Standard/ Sport Mode switch to navigate between power

levels, from ECO (reduced power) to Standard (full power) to Sport (in-

creased response).

To increase power, press the switch upwards. To decrease power,

press the switch downwards.

TYPICAL

To activate Standard mode when in Sport mode, press bottom end of

switch once.

To activate ECO mode when in Sport mode, press bottom end of

switch twice.

To activate ECO mode when in Standard mode, press bottom end of

switch once.

WARNING

Ensure passenger is advised to hold on tightly before activating

Sport mode. Sport mode provides increased acceleration.

To activate Sport mode when in Standard mode, press top end of

switch once.

To activate Sport mode when in ECO mode, press top end of switch

twice.

196

BREAK-IN PERIOD

Operatiion During Break-In

Engine

During the break-in period:

- Avoid prolonged full throttle operation.

- Avoid sustained accelerations.

- Avoid prolonged cruising speeds.

- Avoid engine overheating.

However, brief accelerations and speed variations contribute to a

good break-in.

During a predetermined period, the engine management system con-

trols some engine parameters.

The duration is based on fuel volume. It will take approximately two

fuel tanks to complete the break-in.

During this period:

- The engine performance and behavior will not be optimal.

- The fuel and oil consumption will be higher.

Drive Belt

A new drive belt requires a break in period of 50 km (30 mi).

During the break-in period:

- Avoid strong acceleration and deceleration.

- Avoid pulling a load.

- Avoid high speed cruising.

If the vehicle creeps, lower the drive belt height from the preliminary

setting. Refer to Drive Belt in maintenance procedure.

198

BASIC PROCEDURES

Engine Startiing Procedure

Procedure

1. Apply parking brake.

2. Recheck throttle control lever operation.

3. Put your helmet on.

4. Ensure that the tether cord cap is installed on the engine cut-off

switch and that the cord is attached to your clothing eyelet.

5. Ensure that the emergency engine stop switch is in the ON position

(up).

WARNING

Never depress throttle while starting engine.

6. Release parking brake.

NOTE:

For an initial cold start, do not release parking brake. Perform the ve-

hicle warm-up procedure as explained below.

7. Depress the START button to engage the electric starter and start

the engine. Release button immediately when engine has started.

NOTICE

Do not engage electric starter for more than 10 seconds at a

time. A rest period should be observed between the cranking

cycles to allow electric starter to cool down.

Emergency Startiing

Do not attempt any emergency starting procedure. Have the battery

charged or replaced.

Vehicle Warm-Up

Before every ride, vehicle has to be warmed up as follows.

1. Start engine as explained in ENGINE STARTING PROCEDURE

(PAGE 199) ENGINE STARTING PROCEDURE above.

2. Allow engine to warm up one or two minutes at idle speed.

NOTE:

Engine will shut down after approximately 12 minutes of idling.

199

BASIC PROCEDURES

3. Disengage parking brake.

4. Apply throttle until drive pulley engages. Drive at low speed the first

two or three minutes.

NOTICE

If vehicle does not move when throttle is applied, stop engine,

remove tether cord cap from the engine cut-off switch, then do

the following.

– Check if skis are stuck on the ground. Lift one ski at a time

by the handle, then put it down.

– Check if track is stuck on the ground. Lift rear of snowmobile

enough to clear track from the ground, then drop.

– Check rear suspension for hard snow or ice accumulation

that could interfere with track rotation. Clean the area.

– Validate that transmission is engaged (not in neutral).

CAUTION

Beware of injuries by using proper lifting techniques, notably

using your legs force. Do not attempt to lift the rear of vehicle if

it is above your limits.

WARNING

Make sure tether cord cap is removed before standing in front

the vehicle, getting close to the track or rear suspension

components.

NOTE:

Warm-up is electronically controlled. During this period (up to 10 mi-

nutes depending on ambient temperature), engine RPM is limited.

Shiiftiing iin Hiigh or Low range

This transmission is designed to accept shifting while moving. How-

ever, shifting while the engine is under heavy load is not

recommended.

NOTICE

Shifting at a speed faster than 30 km/h (19 MPH) may cause

serious damage to the gearbox.

200

BASIC PROCEDURES

High Range

This position selects the high speed range of the gearbox. It is the nor-

mal driving speed range. It allows the vehicle to reach its maximum

speed.

Low Range

This position selects the low speed range of the gearbox. It allows the

vehicle to move slowly with maximum engine torque.

Low range should be used whenever:

- Pulling a cargo carrier or accessory

- Hauling a load

- Crossing obstacles

- Climbing onto trailer

- Hill climbing

It is also recommended to use low range if driving for prolonged peri-

ods at speeds under 24 km/h (15 MPH).

NOTICE

Use the low speed range to pull a cargo carrier, carry heavy

cargo, go over obstacles or drive uphill and downhill.

Shifting in Reverse

1. Bring vehicle to a complete stop.

2. Apply and hold brake. Remain seated, refer to Rider Position (Re-

verse Operation) in Riding the vehicle for posture information.

3. With engine at idle speed, select reverse (R) gear using the re-

verse lever or Start / RER button.

201

BASIC PROCEDURES

WARNING

The reverse speed is not limited. Always proceed with caution

as fast reverse could result in loss of vehicle stability. Come to

complete stop before activating the reverse. Always remain

seated and apply the brake before shifting. Ensure the path be-

hind is clear of obstacles or bystanders before proceeding.

Shifting in Forward from Reverse

1. Bring vehicle to a complete stop.

2. Apply and hold brake.

3. Press and release the RER button or reverse lever.

4. Apply throttle slowly and evenly. Allow drive pulley to engage then

accelerate carefully.

Shuttiing Off the Engine

Release throttle lever and wait until engine has returned to idle speed.

Shut off the engine using either the emergency engine stop switch or

by pulling off the tether cord cap from the engine cut-off switch.

WARNING

Always remove the tether cord cap from engine cut-off switch

when vehicle is not in operation in order to prevent accidental

engine starting or to avoid unauthorized use by children or

others or theft.

203

RIDING CONDITIONS AND YOUR

SNOWMOBILE

Altitude

At factory, your snowmobile was calibrated to be used within an alti-

tude range (relative to sea level).

A new snowmobile has a tag attached to the handlebar indicating its

calibration. Refer to Safety Information on Vehicle.

If for any reason you don't know your snowmobile calibration, contact

an authorized BRP snowmobile dealer.

If your snowmobile is to be used at an altitude outside the specified

range, have it calibrated accordingly by an authorized BRP snowmo-

bile dealer.

NOTICE

An inappropriate altitude calibration would decrease perform-

ance and may cause serious damage to the snowmobile.

Temperature

The engine management of these engines provides the optimum air/

fuel ratio for all temperatures.

Hard Packed Snow

All models covered in this guide which are equipped with a minimum

track profile of 44 mm (1.75 in) are built for deep snow conditions and

should never be used during a prolonged period of time in marginal or

hard packed snow conditions.

In the event you have to ride in these types of conditions:

- Avoid exceeding a speed of 70 km/h (45 mph) in all conditions

- Avoid hard acceleration (over 75% of throttle)

- Ice scratchers should be applied

- Engine temperature should not exceed 75% on the temperature

gauge.

NOTICE

Running these types of tracks at high speed on a trail, on hard

packed surfaces or on ice puts more stress on the lugs, which

tends to heat up as a result. It also could drastically reduce the

life of specific wear parts. To avoid potential degradation, de-

lamination or damages to the track and wear parts, reduce your

speed and minimize the distance that is being ridden on these

types of surfaces.

204

RIDING CONDITIONS AND YOUR SNOWMOBILE

Vehicles Equipped with Ice Scratchers

Ice scratchers are equipped on the vehicle to increase engine cooling

efficiency, to lubricate and to cool track clips and sliders. They must

be used whenever on ice, hard packed snow, or any conditions that

do not lift enough snow particles into the rear suspension and the

tunnel.

NOTICE

Although it is not recommended to ride a snowmobile equipped

with a high lug profile track on trails or hard packed snow condi-

tions, it is highly suggested to combine idler wheels and ice

scratchers on a vehicle used in these conditions.

IMPORTANT

Ridding in these trail conditions puts the reliability of the track and

its warranty at risk

If equipped with the following track profile heights, never exceed the

recommended sustained vehicle speeds listed.

Track Profile Height

Maximum Sustained Speed

57 mm (2.25 in)

110 km/h (70 MPH)

60 mm (2.36 in)

64 mm (2.52 in)

95 km/h (60 MPH)

75 mm (3 in)

205

TUNE YOUR RIDE

Snowmobile handling and comfort depend upon multiple adjustments.

WARNING

Suspension adjustment could affect vehicle handling. Always

take time to familiarize yourself with the vehicle''s behavior after

any suspension adjustment have been made. Always adjust LH

and RH suspension components to the same setting.

Choice of suspension adjustments vary with carrying load, operator's

weight, personal preference, riding speed and field condition.

NOTE:

Some adjustments may not apply to your snowmobile.

WARNING

Before proceeding with any suspension adjustment, remember:

– Park in a safe place.

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

– Use appropriate lifting device or have assistance to share

lifting stress. If a lifting device is not used, use proper lifting

techniques, notably using your legs force.

– Do not attempt to lift the front or rear of vehicle if it is above

your limits.

– Support front of vehicle off the ground with a suitable device

before adjusting suspension.

– Support rear of vehicle off the ground with a wide-base

snowmobile stand with a rear deflector panel.

– Make sure support device is stable and secure.

The best way to set up the suspension is to customize each adjust-

ment one at a time. Various adjustments are interrelated. It may be

necessary to readjust center spring after adjusting front springs for in-

stance. Test run the snowmobile under the same conditions; trail,

speed, snow, operator riding position, etc. Proceed methodically until

you are satisfied.

Following are guidelines to fine-tune suspension. Use suspension ad-

justment tool provided in the tool kit.

206

TUNE YOUR RIDE

Stopper Strap – SC-5M

Stopper strap length has an effect on the amount of weight the center

spring has to carry especially during acceleration, therefore on the

front end uplift.

Stopper straps length also has an effect on center spring travel.

NOTICE

Whenever stopper strap length is changed, track tension must

be checked.

Action

Result

Lighter ski pressure under

acceleration

Increasing stopper strap length

More center spring travel

More bump absorption

capability

Heavier ski pressure under

acceleration

Decreasing stopper strap length

Less center spring travel

Less bump absorption

capability

NOTE:

Stopper strap could be set to position 4, 5 and 6. Below are illustra-

tions for position 4 and 6. Smaller numbers correspond to a longer

strap setting.

208

TUNE YOUR RIDE

Always install the stopper strap bolt as close as possible to the lower

shaft.

NOTE:

Decreasing the stopper strap length may reduce comfort.

When operating the snowmobile in deep snow, it may be necessary to

vary stopper strap length and/or riding position, to change the angle at

which the track rides on the snow. Operator's familiarity with the vari-

ous adjustments as well as snow conditions will dictate the most effi-

cient combination.

Generally, a longer stopper strap setting gives better performance in

deep snow on a flat landscape.

Center Spring

Center spring preload has an effect on steering effort, handling and

bump absorption.

Also, since center spring preload adjustment puts more or less pres-

sure on the front of the track, it has an effect on the performance in

deep snow.

Action

Result

Lighter steering

More bump absorption

capability

Increasing preload

Better deep snow starts

Better deep snow performance

and handling

Heavier steering

Less bump absorption

Decreasing preload

capability

Better trail handling

Cam Type Adjuster

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

cam to increase or decrease the spring preload.

211

TUNE YOUR RIDE

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.

212

TUNE YOUR RIDE

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

213

TUNE YOUR RIDE

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

214

TUNE YOUR RIDE

Cam setting

Result

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

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.

Reduce front suspension spring

Steering feels too heavy

preload.

at steady speeds

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.

Rear of snowmobile

Reduce rear spring preload.

seems too stiff

Rear of snowmobile

Increase rear spring preload.

seems too soft

Rear suspension is

Increase rear spring preload.

frequently bottoming

Increase center spring preload.

–

Lengthen limiter strap.

218

MAINTENANCE SCHEDULE

Maintenance is very important to keep your vehicle in safe operating

condition. The vehicle should be serviced as per the maintenance

schedule.

Proper maintenance is the owner’s responsibility. A warranty claim

may be denied if, among other things, the owner or operator caused

the problem through improper maintenance or use.

Perform periodic checks and follow the maintenance schedule. The

maintenance schedule does not exempt the pre-ride inspection.

WARNING

Failure to properly maintain the vehicle according to the main-

tenance schedule and procedures can make it unsafe to

operate.

EPA Regullatiion - Canadiian and USA Vehiiclles

A repair shop or person of the owner''s choosing may maintain,

replace, or repair emission control devices and systems. These in-

structions do not require components or service by BRP or authorized

BRP snowmobile dealers.

Although an authorized BRP snowmobile dealer has an in-depth tech-

nical knowledge and tools to service your vehicle, the emission-related

warranty is not conditioned on the use of an authorized BRP snowmo-

bile dealer or any other establishment with which BRP has a commer-

cial relationship.

Proper maintenance is the owner’s responsibility. A warranty claim

may be denied if, among other things, the owner or operator caused

the problem through improper maintenance or use.

For emission-related warranty claims, BRP is limiting the diagnosis

and repair of emission-related parts to the authorized BRP snowmo-

bile dealers. For more information, please refer to the US EPA Emis-

sions PERFORMANCE WARRANTY contained in the warranty

section.

You must follow the instructions for fuel requirements in the fueling

section of this manual. Even if gasoline containing greater than ten

volume percent ethanol is readily available, the US EPA issued a pro-

hibition against the use of gasoline containing greater than 10 vol %

ethanol that applies to this vehicle. The use of gasoline containing

greater than 10 vol% ethanol with this engine may harm the emission

control system.

222

MAINTENANCE SCHEDULE

Traill/ Crossover/ Utillity Usage

Whether your vehicle is a Trail, Crossover, or Utility model, these

types of usage require maintenance tasks to be performed between

the regular yearly intervals. These are identified as A + in the chart

below.

If you regularly ride in trails, explore the countryside, or work with

your snowmobile, follow the A+ Trail / Crossover / Utility interval and

perform the tasks outlined in the chart below.

Extreme Cold Condition

An engine that is frequently operated at or below an ambient tempera-

ture of -25 °C (-13 °F) will require an increase in service and mainte-

nance schedule.

Any combustion engine operated at these low ambient temperature

will collect an increased amount of condensation at every startup/

warm-up.

Since the engine is not reaching operating temperatures for extended

periods of time, the oil is starting to be strongly diluted with water and

gas residue (more water content).

An engine needs to reach operating temperature, in order to be able

to evaporate condensate out of the oil.

If daily usage (work or leisure driving cycle) is similar to those men-

tioned below, BRP strongly recommends changing the oil at least

once a month.

Parameters of an increase in service and maintenance schedule:

- Engine not reaching the proper operating temperature during nor-

mal daily usage

- Multiple starts and stops without reaching operating temperature

- Short idle periods

- Low RPM driving cycle in short distances without reaching operat-

ing temperature.

NOTE:

BRP strongly recommends the installation of a block heater to help

warm up the liquids, this will also help to extend the oil lifetime.

223

MAINTENANCE SCHEDULE

Maiintenance Schedulle

Make sure to perform proper maintenance at recommended intervals

as indicated in the tables.

The maintenance chart indicates the items needing to be addressed

based on 2 criteria, whichever happens first:

- Calendar time

- Odometer reading.

Your driving habits determines the factors you shall adhere too. For

example:

- Someone who uses their vehicle every other weekend trail riding

with friends would most likely follow the odometer reading to de-

termine the frequency of his maintenance.

- Someone who uses their vehicle seldomly over the year or only on

a few occasions would follow the calendar time to determine the

frequency of his maintenance.

IMPORTANT: The following tables show the appropriate mainte-

nance application for the first 3 years. For subsequent years, repeat

the same pattern alternatively.

Maiintenance Overviiew

Calendar

Trail/ Cross

Odometer

Time

Over/ Utility

Every

1500 km (1000 mi)

A+

Month

1 Year

3000 km (2000 mi)

Every

4500 km (3000 mi)

A+

Month

2 Years

6000 km (4000 mi)

A and B

Every

7500 km (5000 mi)

A+

Month

224

MAINTENANCE SCHEDULE

600 ACE/ 900 ACE Engines

TRAIL /

CROSSOVER

A+

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

I=Inspect

1500

6000

L=Lubricate

3000 km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

Air and Fuel Delivery

Fuel components (fuel

cap, hoses, clamps and

tank fixation) and

function

In-line fuel filter

Every 5

years

Body and Chassis

Body panels and

I, T

hardware

Pivots, latches, hinges

and key barrels

Engine and Cooling

Engine cooling

components (coolant

concentration, coolant

I, A

level, hose condition,

clamps, leaks)

Engine oil and oil filter

Engine seals and

gaskets

Spark plugs

Every 3

years

225

MAINTENANCE SCHEDULE

TRAIL /

CROSSOVER

A+

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

I=Inspect

1500

6000

L=Lubricate

3000 km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

10 000

(6000

mi)

Engine coolant

Every 5

years

Exhaust and Emissions

Exhaust components

(gaskets, pipes, muffler

condition, leaks)

Exhaust manifold

Brake

Brake components and

I, L

function

Brake fluid

Every

years

Drive

Chaincase drive chain

tension

Gearbox / chaincase oil

level

Track alignment and

I, A

tension

226

MAINTENANCE SCHEDULE

TRAIL /

CROSSOVER

A+

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

I=Inspect

1500

6000

L=Lubricate

3000 km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

Gearbox / chaincase oil

Continuously Variable Transmission (CVT)

CVT components and

C, L

function

CVT drive belt condition

CVT drive belt tension

Drive pulley retaining

screw

Electrical

Battery connections and

condition

Electrical harness

routing

Headlight aim

Modules and applicable

software updates

Operation of control

switches and lighting

Steering and Controls

Ski runners

Gearbox position lever

I, A

operation

Steering alignment

I, A

227

MAINTENANCE SCHEDULE

900 ACE Turbo/ R

TRAIL /

CROSSOVER

A+

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

I=Inspect

1500

6000

L=Lubricate

3000 km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

Air and Fuel Delivery

Fuel components (fuel

cap, hoses, clamps and

tank fixation) and

function

In-line fuel filter

Every 5

years

Body and Chassis

Body panels and

I, T

hardware

Pivots, latches, hinges

and key barrels

Engine and Cooling

Engine cooling

components (coolant

concentration, coolant

I, A

level, hose condition,

clamps, leaks)

Engine oil and oil filter

Engine seals and

gaskets

Spark plugs

Every 3

years

229

MAINTENANCE SCHEDULE

TRAIL /

CROSSOVER

A+

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

I=Inspect

1500

6000

L=Lubricate

3000 km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

10 000

(6000

mi)

Engine coolant

Every 5

years

Exhaust and Emissions

Exhaust components

(gaskets, pipes, muffler

condition, leaks)

Exhaust manifold

Every 3

years

Turbo exhaust gasket

10 000

(6000

mi)

Brake

Brake components and

I, L

function

Brake fluid

Every 2

years

230

MAINTENANCE SCHEDULE

TRAIL /

CROSSOVER

A+

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

I=Inspect

1500

6000

L=Lubricate

3000 km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

Drive

Chaincase drive chain

tension

Gearbox / chaincase oil

level

Track alignment and

I, A

tension

Gearbox / chaincase oil

Continuously Variable Transmission (CVT)

CVT components and

I, C, L

function

CVT drive belt condition

CVT drive belt tension

Drive pulley retaining

screw

Electrical

Battery connections and

condition

Electrical harness

routing

Headlight aim

Modules and applicable

software updates

Operation of control

switches and lighting

231

MAINTENANCE SCHEDULE

TRAIL /

CROSSOVER

A+

/ UTILITY

Every

Every 2

A=Adjust

Every

month

years

C=Clean

year

I=Inspect

1500

6000

L=Lubricate

3000 km

R=Replace

(2000

(1000

(4000

T=Torque

mi)

Steering and Controls

Ski runners

Gearbox position lever

I, A

operation

Steering alignment

I, A

Steering components

and function

Throttle cable

Throttle operation

Suspension

Suspension components

I, L

and function

232

MAINTENANCE PROCEDURES

This section includes instructions for basic maintenance procedures.

WARNING

Turn off the engine, remove tether cord cap and follow these

maintenance procedures when performing maintenance. If you

do not follow proper maintenance procedures you can be in-

jured by hot parts, moving parts, electricity, chemicals or other

hazards.

WARNING

Should removal of a locking device be required (e.g. lock tabs,

self-locking fasteners, etc.) when undergoing disassembly/as-

sembly, always replace with a new one.

Engine Coollant

WARNING

Never open coolant tank cap when engine is hot.

Engine Coolant Level Verification

Open the RH side panel, see Body and Seat.

Check coolant level at room temperature. Liquid should be at cold lev-

el line of coolant tank.

NOTE:

When checking level at low temperature it may be slightly lower than

the mark.

If additional coolant is necessary or if entire system has to be refilled,

refer to an authorized BRP snowmobile dealer, repair shop or person

of your own choosing.

233

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.

234

MAINTENANCE PROCEDURES

Since the engine is not reaching operating temperatures for extended

periods of time, the oil is starting to be strongly diluted with water and

gas residue (more water content).

An engine needs to reach operating temperature, in order to be able

to evaporate condensate out of the oil.

If daily usage (work or leisure driving cycle) is similar to those men-

tioned below, BRP strongly recommends changing the oil at least

once a month.

Parameters of an increase in service and maintenance schedule:

- Engine not reaching the proper operating temperature during nor-

mal daily usage

- Multiple starts and stops without reaching operating temperature

- Short idle periods

- Low RPM driving cycle in short distances without reaching operat-

ing temperature.

NOTE:

BRP strongly recommends the installation of a block heater to help

warm up the liquids, this will also help to extend the oil lifetime.

Recommended Oil

Rotax^® engines were developed and validated using the XPS™ oil.

BRP recommends the use of its XPS engine oil or an equivalent at all

time. Do not add any oil additives to the recommended engine oil.

Damages caused by the use of an oil not suitable for the engine or by

adding of an oil additives may not be covered by the BRP Limited

Warranty.

XPS RECOMMENDED Engine Oil

4T 0W40 Synthetic oil

IF THE RECOMMENDED XPS ENGINE OIL IS NOT

AVAILABLE

Use a 0W40 4-stroke SAE synthetic engine oil meeting or

exceeding the following lubricant industry specifications.

Always check the API service label certification on the oil container,

it must contain at least the indicated standard.

- API service classification SN

235

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.

236

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.

237

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.

240

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.

241

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.

243

MAINTENANCE PROCEDURES

NOTICE

If any exhaust system component is removed, modified or dam-

aged, severe engine damage may result.

Spark Pllugs

Spark plugs inspection or replacement may be performed by an au-

thorized BRP snowmobile dealer, repair shop, or person of your own

choosing. Spark plugs inspection or replacement requires an in-depth

technical knowledge. Though not required, it is recommended that an

authorized BRP snowmobile dealer performs spark plugs inspection

or replacement.

Brake Flluiid

Brake Fluid Level Verification

NOTICE

Vehicle must be on a level surface before checking any fluid

levels.

Check brake fluid (DOT 4) in reservoir for proper level. Add fluid (DOT

4) as required.

244

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

XPS DOT 4 Brake Fluid

Alternative or if not available

DOT 4 Brake Fluid

246

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

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.

247

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.

248

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.

251

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.

253

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.

255

MAINTENANCE PROCEDURES

NOTICE

Overtightening the drive chain could result in severe damage to

the chaincase components.

Drive Belt

Drive Belt Inspection

Remove the drive belt guard. Refer to the procedure in Equipment.

Inspect belt for cracks, fraying or abnormal wear (uneven wear, wear

on one side, missing cogs, cracked fabric). If abnormal wear is noted,

probable cause could be pulley misalignment, excessive RPM with

frozen track, fast starts without warm-up period, burred or rusty

sheave, oil on belt or distorted spare belt. Contact an authorized BRP

snowmobile dealer.

Replacing the Drive Belt

Removiing the Driive Belt

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

2. Remove the LH side panel.

3. Remove the drive belt guard. Refer to Removing the Drive Belt

Guard.

4. Insert the driven pulley expander provided, in the threaded hole on

the adjuster hub as shown.

256

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.

257

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.

258

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)

260

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.

261

MAINTENANCE PROCEDURES

Lift the rear of the snowmobile and support it with a wide-base snow-

mobile mechanical stand with a rear deflector panel. With the engine

off, rotate the track by hand, and inspect condition. If worn or cut, or if

track fibers are exposed, or if missing or defective inserts or guides

are noted; contact an authorized BRP snowmobile dealer.

Snowmobiles Equipped with Traction Enhancing Products

If your snowmobile is equipped with a BRP approved studded track,

PROCEED WITH A VISUAL INSPECTION OF YOUR TRACK BE-

FORE EACH USE.

Look for any defects, such as:

- Perforations in the track

- Tears in the track (particularly around traction holes on studded

tracks)

- Lugs that are broken or torn off, exposing portions of rods

- Delamination of the rubber

- Broken rods

- Broken studs (studded tracks)

- Bent studs (studded tracks)

- Missing studs

- Studs that are torn off the track

- Missing track guide(s)

- Also, ensure that studs nut are tighten to the recommended

torque.

On approved studded tracks, replace broken or damaged studs imme-

diately. If your track shows signs of deterioration, it must be replaced

immediately. When in doubt, ask your dealer.

WARNING

Riding with a damaged track or studs could lead to a loss of

control.

For complete information on traction enhancing products, refer to

TRACTION ENHANCING PRODUCTS in SAFETY INFORMATION at

the beginning of this Operator's Guide.

Track Tension and Alignment

NOTE:

Track tension and alignment are interrelated. Do not adjust one with-

out the other.

262

MAINTENANCE PROCEDURES

WARNING

To prevent serious injury to individuals near the snowmobile:

– NEVER stand behind or near a moving track.

– Always use a wide-base snowmobile stand with a rear de-

flector panel if it is necessary to rotate track.

– When the track is raised off the ground, only run it at the low-

est possible 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, pos-

sibly resulting in the loss of a leg or other serious injury.

Verifying the Track Tensiion

NOTE:

Ride the snowmobile in snow about 15 to 20 minutes prior to adjusting

track tension.

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

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

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.

3. Allow rear suspension to fully extend.

4. Prepare the tensiometer.

Service tool

Tensiometer (P/N 414348200)

1. Set the bottom O-ring as per the Track Deflection from the ap-

plicable vehicle in the Technical Specifications table.

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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.

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MAINTENANCE PROCEDURES

Aliigniing 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.

A01F05A

1. Guides

2. Slider shoes

3. Equal distance

268

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.

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MAINTENANCE PROCEDURES

Tightening Torque

Rear axle screw

48 ± 6 Nm (35 ± 4 lbf-ft)

8. Reposition snowmobile on the ground.

Suspensiion

Rear Suspension Condition

Visually inspect all suspension components including slider shoes,

springs, wheels, etc.

NOTE:

During normal driving, snow will act as a lubricant and coolant for the

slider shoes. Extensive riding on ice or sanded snow, will create ex-

cessive heat build-up and cause premature slider shoe wear.

Suspension Stopper Strap Condition

Inspect stopper straps for wear and cracks, bolt and nut for tightness.

If loose inspect holes for deformation. Replace as required. Tighten

nut to specification.

Tightening Torque

Stopper strap nut

11 ± 1 Nm (97 ± 9 lbf-in)

Suspension Lubrication

Lubricate the following suspension pivots at grease fittings. Refer to

Maintenance Schedule for maintenance frequency.

SERVICE PRODUCT

XPS Synthetic suspension grease

270

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.

276

VEHICLE CARE

Post-Operation Care

Remove snow and ice from rear suspension, track, front suspension,

steering mechanism and skis.

WARNING

Make sure D.E.S.S. key is removed from D.E.S.S. post before

standing in front the vehicle, getting close to the track or rear

suspension components.

Always cover your snowmobile when leaving it outside overnight or

during extended periods of inactivity. This will protect it from frost and

snow as well as help retain its appearance.

Vehiiclle Clleaniing and Protection

Wash snowmobile using water mixed with a mild detergent.

Use only microfiber cloths or an equivalent.

NOTICE

Never use a high pressure washer to clean the vehicle. Use low

pressure only, like a garden hose.

Non Compatible Cleaning Products

Material Type

Non-Compatible Cleaning Products

BRAKE AND PARTS CLEANER

All plastics, vinyls,

painted steel and

ANY PETROLEUM BASE CLEANING

aluminium

PRODUCTS

Compatible Cleaning Products

Material Type

Cleaning Product

All plastics, vinyls,

Automotive type soap with water

painted steel and

XPS Spray Cleaner and Polish

aluminium.

XPS All Purpose Cleaner

For more information and products, Visit the XPS Products website at

www.xpslubricants.com

288

STORAGE

During summer, or when a snowmobile is not in use for more than

three months, proper storage is necessary.

Storage

Clean the vehicle

Add fuel stabilizer to fuel following the product manufacturer

recommendations.

Run the engine after adding the product to the fuel

Lubricate engine

Lubricate brake lever pivot

Lubricate rear suspension

Charge battery monthly to keep it fully charged during storage

Block muffler outlet with rags

Lift rear of vehicle until track is clear of the ground. Do not release

track tension

CAUTION

Use appropriate lifting device or have assistance to share lifting

stress. If a lifting device is not used, use proper lifting techni-

ques, notably using your legs force. Do not attempt to lift the

rear of vehicle if it is above your limits.

NOTICE

The snowmobile has to be stored in a cool and dry place and

covered with an opaque but ventilated tarpaulin. This will pre-

vent sun rays and grime from affecting plastic components and

vehicle finish.

NOTICE

Fuel stabilizer should be added prior to engine lubrication to

ensure carburetor protection against varnish deposits.

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Snowmobile Ski-Doo SPORT-UTILITY ACE SERIES. OPERATOR’S GUIDE (2024) - page 2