Download - Print Preview - Goodwin Performance€¦ · Instruction Sheet P/N 487 801 187 9 / 11. INSTALLATION INSTRUCTIONS This page is intentionally blank 10 / 11 Instruction Sheet P/N 487

CVT Cooling System (Kit P/N 860 200 883)

The following symbols may be used in this document:

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazard situation which, if not avoided, could result in minor or moderate injury.

NOTICE Indicates an instruction which, if not followed, could severely damage vehicle components or other property.

WARNING

– For safety reasons, this kit must be installed by an authorized BRP dealer.

– This kit is designed for specific applicable models only (authorized BRP dealers will confirm model(s)). It is not rec-ommended for units other than the one (those) for which it was sold.

– This instruction sheet MUST be given to the purchaser.

– Should removal of a locking device (e.g. lock tabs, self-locking fasteners, etc.) be required when undergoing dis-assembly/assembly, always replace with a new one.

– Torque wrench tightening specifications must strictly be adhered to.

– Unless otherwise specified, engine must be OFF when performing any operation on the vehicle.

NOTE: The illustrations in this document show typical construction of the different assemblies and maynot reproduce the full detail or exact shape of the parts; however, they represent parts that have thesame or similar function.Installation time is approximately 0.7 hours.

Printed in Canada. (msi2013-088 en AP)©2012 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.

Instruction Sheet P/N 487 801 187 1 / 11®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

PARTS TO BE INSTALLED

PARTS TO BE INSTALLEDITEM DESCRIPTION PART NUMBER QTY

P1 Cooling duct 417 300 439 1

P2 Front bracket 417 300 423 1

P3 AVEX rivet (short) 390 909 200 4

P4 3/16 Pop rivets(short - BLACK) 293 150 103 6

P5 Front support 417 300 422 1

P6 3/16 Pop rivets(long - BLACK) 293 150 104 3

P7 Flat washer 517 225 900 3

P8 Reinforcement plate 417 300 421 1

P9 AVEX rivet (long) 390 909 100 2

P10 Notice label (English) 516 004 542 1

P11 Notice label (French) 516 004 594 1

P12 Cap 502 007 251 1

P13 M6 X 20 Torx screw 250 000 128 2

P14 Stopper plate 417 300 445 1

P15 M5 X 14 screw 250 000 145 4

2 / 11 Instruction Sheet P/N 487 801 187

INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONSVehicle Preparation1. Remove the following parts:

– LH side panel– Drive belt guard.

2. Remove 2 rivets securing drive belt guard frontbracket.

NOTE: Depending on suspension configuration, itcould be easier to remove inner rivet from insideengine compartment.

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1. Rivets to be removed

3. Discard bracket.

Front Support AssemblySecure reinforcement plate [P8] to front support[P5] with AVEX rivets (long) [P9].

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1. AVEX rivets (long)[P9]2. Reinforcement plate [P8]3. Front support [P5]

Front Support Installation1. Secure the top of front support assembly using

two 3/16 Pop rivets (long - BLACK) [P6] and 2washers [P7] in the top holes.

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EXTERIOR VIEW1. Rivets at the top of front support

Instruction Sheet P/N 487 801 187 3 / 11


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INTERIOR VIEW1. Flat washers [P7]2. 3/16 Pop rivets (long - BLACK)[P6]3. Front support [P5]

2. Using a pick, pierce through the bottom pan us-ing the lower hole of the bracket as a guide.

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1. Pick2. Front support

3. From the outside, drill a 7 mm (17/64 in) in thehole pierced at the previous step.

NOTE: A drill size "J" can be used.4. Secure the bottom of front support assembly

using a 3/16 Pop rivet (long - BLACK) [P6] anda washer [P7] in the bottom hole.

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EXTERIOR VIEW1. Rivet at the bottom of front support

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INTERIOR VIEW1. 3/16 Pop rivet (long - BLACK) [P6]2. Flat washer [P7]3. Front support [P5]

Stopper Plate Installation (2009to 2012 Models with AluminumToe Hold Only)NOTE: This procedure is not applicable to vehi-cles with a plastic toe hold.

Remove the drive belt guard rear bracket. Discardscrews.Using the provided template (see at the end of thisdocument), drill two holes of 5 mm (13/64 in).



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1. New drilled holes

Install the stopper plate [P14] on bracket and se-cure it using AVEX rivets (short) [P3].

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1. Stopper plate [P14]2. AVEX rivets (short) [P3]3. Drive belt guard rear bracket

Reinstall drive belt guard rear bracket on vehicleusing NEW M5 x 14 Torx screws.

TIGHTENING TORQUE

Stopper plate bolts 3 N•m to 3.5 N•m(27 lbf•in to 31 lbf•in)

Drive Belt Guard Disassembly1. Remove and keep the tool kit support from the

drive belt guard.NOTE: Unlock the tab from underneath the pulleyguard and pull on the tool kit support upwards torelease it.

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1. Tool kit support2. Locking tab3. Drive belt guard

2. Drill the 3 rivets holding the drive belt guard re-inforcement.

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1. Rivets to drill2. Drive belt guard reinforcement

3. Remove and discard lateral protector fromdrive belt guard by drilling the 5 rivets asshown. Keep the remaining of drive belt guard.



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1. Lateral protector2. Rivets X 5

Drive Belt Guard Assembly1. Install front bracket [P2] with AVEX rivets (short)

[P3] on kept drive belt guard.

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1. Front bracket [P2]2. AVEX rivets (short) [P3]3. Kept drive belt guard

2. Install cooling duct [P1] on drive belt guard with3/16 Pop rivets (short - BLACK) [P4].

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1. Cooling duct [P1]2. 3/16 Pop rivets (short - BLACK) [P4]3. Drive belt guard

3. Clean surface where label must be installedwith isopropyl alcool and affix notice label [P10]on drive belt guard assembly as illustrated.

NOTE: This product comes with the following no-tice label containing important information. Thenotice label should be considered a permanentpart of this product. If the notice label comesoff or becomes hard to read, please contact anauthorized BRP Ski-Doo dealer for replacement.

Any person who intends to use this productshould read and understand the information con-tained on the label before doing so.



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1. Notice label [P10] location

4. Reinstall the tool kit support on the drive beltguard.

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1. Tool kit support

5. Reinstall Drive belt.

Drive Belt Guard Installation1. Insert drive belt guard tab in front support slot.

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1. drive belt guard tab2. Front support slot

2. Push drive belt guard toward engine then to-ward front of vehicle.

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3. Position the grommet over the retaining rod.



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1. Retaining rod

4. Position rear portion of the drive belt guard overthe retainer and secure it using the retainingpin.

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1. Retaining pin

Cap Installation(800R E-TEC only)Hood Removal

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1. Hood

1. Stand in front of vehicle.

2. Pull outwards on both sides of hood aft section.

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3. Slide hood forwards.4. Remove hood from vehicle.

Cap Installation1. Remove and discard illustrated M6 screws.

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1. Cap retaining screws

2. Install cap [P12] between bottom pan coverand console with screw holes over bottom pancover and under console. Secure cap with M6x 20 Torx screws [P13], see image for details.



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1. Cap [P12]2. Console3. Bottom pan cover4. Bottom pan edge5. M6 X 20 Torx screw [P13]

NOTE: Make sure cap groove is well inserted intobottom pan edge, see image.

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CROSS SECTION VIEW1. Bottom pan edge2. Cap groove3. Cap

3. Torque M6 x 20 Torx screws.

TIGHTENING TORQUE

M6 x 20 Torx screws 2.25 N•m ± 0.25 N•m(20 lbf•in ± 2 lbf•in)

4. Reinstall hood and lateral panel.



This page is

intentionally blank



3 in/po

50 mm

Ensure template is to scale/S’assurer que le gabarit est à l’échelle

50 mm

3 in/po

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