parts to be installed - goodwin performance · electric starter (kit p/n 860 200 627) 600 ho e-tec,...

ELECTRIC STARTER (Kit P/N 860 200 627)600 HO E-TEC, 800R Power TEK, 800R E-TEC

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.

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.NOTE: Installation time is approximately 1.3 hours.

PARTS TO BE INSTALLED

ITEM DESCRIPTION PART NUMBER QTY

P1 Electric Starter 515 177 389 1

P2 M8 x 25 Bolt 250 000 248 2

P3 M8 x 35 Bolt 207 583 544 1

P4 M8 Flat Washer 250 200 008 1

P5 Spacer 515 176 500 1

P6 Starter Cable 515 177 208 1

P7 M6 Nut 232 561 434 3

P8 M6 Flat Washer 234 061 410 1

P9 Battery Support 515 177 264 1

P10 M6 Nut 233 261 414 4

P11 M6 x 20 Bolt 207 662 044 2

P12 M6 Flat Washer (18 mm OD) 250 200 082 2

P13 Battery 296 000 295 1

P14 Battery Strip 515 177 266 1

P15 Starter Solenoid 278 003 012 1

P16 M6 x 16 Bolt 207 661 644 3

P17 BLACK Battery Cable 515 176 358 1

P18 M6 Lock Washer 250 200 041 1

P19 RED Battery Cable 515 176 535 1

P20 Fuse Wire 515 176 744 1

P21 Solenoid wiring Harness (long) Not availableseparately 1

P22 90° Protector Cap (red) 710 000 495 2

Printed in Canada. (msi2014-064 en JT)©2013 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.

Instruction Sheet P/N 487 801 505 1 / 15®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

PARTS TO BE INSTALLED

ITEM DESCRIPTION PART NUMBER QTY

P23 Locking Tie 414 115 200 5

P24 Locking Tie (with tie-mount) 293 750 009 2

P25 M8 x 25 Bolt 207 682 534 1

P26 M8 x 30 Bolt 207 683 044 1

P27 M6 x 12 Bolt 207 661 244 1

P28 M6 x 25 Bolt 207 562 544 3

P29 M14 Spring Washer 250 200 006 1

P30 Solenoid wiring harness (short) Not availableseparately 1

P31 Shrink tube 60 mm (2.5 in) (not included)Not available

separately 1

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INSTRUCTIONSNOTE: Prior to installation, please verify if a re-vised version of this instruction sheet is availableon BOSSWeb.

Battery ActivationActivate battery as per manufacturer's instruc-tions.

Vehicle PreparationEngine Compartment Access

XP ModelsRemove:– Hood– Side panels– Bottom pan cover

2 / 15 Instruction Sheet P/N 487 801 505

INSTRUCTIONS

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HOODStep 1: Release retaining pinsStep 2: Slide hood towards the front

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TYPICAL — RH SIDE PANEL SHOWN1. Latches

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BOTTOM PAN COVER1. Remove screws

XS/XM ModelsRemove:– Side panels– Upper body module– Bottom pan coverNOTE: Keep screws for reinstallation.

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TYPICAL — LH SIDE PANEL SHOWN1. Latches2. Stud location

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UPPER BODY MODULE

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BOTTOM PAN COVER

Primary Air Intake Silencer Removal

E-TEC XP 2009 to 2013 Models1. Remove primary air intake silencer as follows:

1.1 Unlock connector tube by lifting tab on rearsection of connector tube.

Instruction Sheet P/N 487 801 505 3 / 15

INSTRUCTIONS

1.2 Twist tube counter clockwise and pullslightly forward.

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Step 1: Lift tabStep 2: Twist tubeStep 3: Pull forward

1.3 Push securing tab of primary air intakesilencer and pull silencer out of adapterplate.

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1. Primary air intake silencer2. Securing tab

Drive Pulley Removal

All Models1. Remove belt guard.2. To hold drive pulley for removal, use the DRIVE

PULLEY HOLDER (P/N 529 035 674):

529035674

2.1 Install holder on a sliding sheave arm.

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1. Sliding sheave2. Drive pulley holder

2.2 Remove the drive pulley bolt and discardconical spring washer.

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1. Drive pulley bolt2. Discard conical spring washer

2.3 Thread the DRIVE PULLEY PULLER (P/N 529000 064) in drive pulley.

529000064

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1. Drive pulley holder2. Drive pulley puller

2.4 Tighten the puller to extract drive pulley.2.5 Pull out the drive pulley and belt.


INSTRUCTIONS

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Tuned Pipe and Muffler Removal

E-TEC models1. Disconnect the Exhaust Gas Temperature Sen-

sor (EGTS) from muffler and/or exhaust tunedpipe.

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RH SIDE1. EGTS connector

All Models1. Use SPRING INSTALLER/REMOVER (P/N 529 035

983) and remove:

529035983

– Tuned pipe– Muffler

Electric Starter Installation1. Remove and discard the M8 bolt from LH front

engine support.

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1. LH front engine support bolt

2. Remove and discard the M8 bolt from LH rearengine support.

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1. LH rear engine support bolt

3. Remove and discard the three M6 bolts secur-ing engine stopper.

4. Remove engine stopper.

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1. M6 bolts2. Engine stopper

5. Bring starter to its location and position its elec-tric post toward front of vehicle.

6. Loosely install a bolt [P2] as shown.


INSTRUCTIONS

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1. Bolt [P2]

600 HO E-TEC7. Install spacer [P5] as shown.8. Loosely install a bolt [P3] and washer [P4] to

starter.

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TYPICAL1. Starter

Other Models9. Loosely install a bolt [P3] and washer [P4] to

starter.

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1. Starter

All Models10. Place a pry bar between engine and frame (un-

der a crankcase bolt).

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1. Pry bar2. Crankcase bolt

11. Raise engine just enough to loosely install theremaining bolt [P2].

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PRYING ENGINE UP


INSTRUCTIONS

NOTICE Do not raise engine more thanneeded. Damage to others engine supportsmay occur.

12. Torque starter bolts to specification in the in-dicated order.

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TORQUING SEQUENCE — SOME PARTS REMOVED FORCLARITY

TIGHTENING TORQUE

28.5 N•m ± 1.5 N•m (21 lbf•ft ± 1 lbf•ft)

13. Reinstall engine stopper using 3 new bolts[P28]. Torque bolts to specification.

TIGHTENING TORQUE

10 N•m ± 2 N•m (89 lbf•in ± 18 lbf•in)

14. Secure engine support:14.1 Use the original washers.14.2 Use NEW bolts (see table).14.3 Apply LOCTITE 243 (BLUE) (P/N 293 800

060) on bolt threads.

ENGINE SUPPORT BOLT TO USE

Front [P26]

Rear [P25]

15. Torque bolts to specification.

TIGHTENING TORQUE

24.5 N•m ± 3.5 N•m (18 lbf•ft ± 3 lbf•ft)

Starter Cable Connection andRouting1. Connect starter cable [P6] to starter post. Use:

– Washer [P8]– Nut [P7]

2. Position starter cable terminal at an angle of 35°as shown.

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1. Starter post2. 35° angle

3. Torque post nut to specification.

TIGHTENING TORQUE

7.5 N•m ± 1 N•m (66 lbf•in ± 9 lbf•in)

4. From starter location (bold arrow), route startercable [P6] behind oil tank toward battery/sole-noid location.

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TYPICAL

5. Secure cable to engine bay floor using lockingtie [P24] as shown.

6. Secure cable to side member using 3 lockingties [P23], as shown.


INSTRUCTIONS

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TYPICAL1. Locking tie [P24]2. Locking tie[P23]

CAUTION Ensure all terminals are prop-erly crimped on wires/cables and that all con-nector housings are properly fastened. Keepwires/cables away from any rotating, moving,heating, vibrating and sharp edge parts. Useproper fastening devices as required.

Solenoid, Battery and Support

CAUTION Do not connect the BLACK neg-ative cable to the battery until instructed to.That will be done only when all the installationwill be completed.1. Locate the ground wire above the RH footrest.2. Remove and keep M6 screw and washer secur-

ing ground wire to frame.

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RH FOOTREST1. Ground wire2. M6 screw and washer

3. Install battery support [P9] on top of RHfootrest:3.1 Install BLACK battery cable [P17] to

footrest. Position the lock washer [P18]against footrest.

3.2 Install 2 new bolts [P11].NOTE: If there is no threaded inserts on vehi-cle, install nuts [P10] and washers [P12].

3.3 Secure ground wire to battery support[P9]. Use previously removed M6 boltand lock washer. Position the lock washeragainst battery support.

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1. Ground wire2. Previously removed lock washer. WASHER AGAINST BATTERY

SUPPORT3. Previously removed boltP18: LOCK WASHER AGAINST FOOTREST

4. Torque all bolts to specification.

TIGHTENING TORQUE

7 N•m ± 1.5 N•m (62 lbf•in ± 13 lbf•in)

5. Install battery [P13] in its support. Position thenegative post as shown.

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1. Negative post here

6. Secure starter solenoid [P15] onto battery strip[P14] as shown.– Bolt [P16]– Nut [P10]


INSTRUCTIONS

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7. Secure battery strip [P14] to battery support:– Bolt [P16]– Bolt [P27]

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SOME PARTS REMOVED FOR CLARITY PURPOSE

8. Torque bolts to specification.

TIGHTENING TORQUE

7.5 N•m ± 1 N•m (66 lbf•in ± 9 lbf•in)

9. Connect starter cable [P6], coming from starter,to solenoid post as shown. Secure cable termi-nal with nut [P7].

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10. Torque nut to specification.

TIGHTENING TORQUE

4 N•m ± .5 N•m (35 lbf•in ± 4 lbf•in)

Battery and SolenoidConnections600 E-TEC onlyBend terminal 30 degrees to avoid interferencewith temperature sensor.

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BEND TERMINAL 30 DEGREES

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INTERFERENCE TO BE AVOIDED

All E-TEC Models1. Slide protector caps [P22] onto RED battery ca-

ble ends [P19].2. Pass fuse wire [P20] eyelet through the protec-

tive cap of the angled battery cable end.


INSTRUCTIONS

3. Connect battery cable and fuse wire to batterypositive post. Torque bolt to specification.

TIGHTENING TORQUE

3.25 N•m ± .25 N•m (29 lbf•in ± 2 lbf•in)

4. Connect the other end to the solenoid post. Se-cure with nut [P7]. Torque nut to specification.

TIGHTENING TORQUE

4 N•m ± .5 N•m (35 lbf•in ± 4 lbf•in)

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P20 BEHIND P19 ON BATTERY POST

5. Cover solenoid terminal with the protector cap.6. Insert the fuse wire [P20] into the vehicle free

fuse holder.7. Recover the 30 A fuse from the unused sole-

noid wiring harness [P21].

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1. Recover the 30 A fuse

8. Install that fuse into fuse holder as shown.

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1. Insert fuse holder here2. Install the 30 A fuse here

9. Cut both locking ties securing solenoid controlwires to harness loom.

10. Coat battery posts and connectors with DI-ELECTRIC GREASE (P/N 293 550 004).

11. Cover battery positive terminal with the pro-tector cap.

2009 to 2012 E-TEC Models1. Cut the shrink tube [P31] to half length.

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2. Insert shrink tubes on the wires of the solenoidwiring harness [P30].

3. Connect its terminals to the 1-pin connectors ofthe vehicle solenoid control wires.

4. Slide shrink tubes over the 1-pin connectors.Ensure the terminals are completely covered.


INSTRUCTIONS

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1. Vehicle solenoid control wires2. 1-pin connectors

5. Heat shrink tubes.6. Connect the 2-pin connector of solenoid wiring

harness to solenoid.7. Secure vehicle connectors of the solenoid con-

trol wires with a locking tie [P23].

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1. 2-pin connector2. Vehicle connectors of the solenoid control wires

8. Connect the 2-pin connector to solenoid.9. Secure harness with a locking tie [P23].

NOTICE Make sure to secure the harness so itwill not touch solenoid screws and nuts.

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1. 2-pin connector

2013 and UP — E-TEC Models1. Connect the 2-pin connector to solenoid.2. Secure harness with a locking tie [P23].


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1. 2-pin connector

Power TEK Models1. Cut only the locking tie securing connector of

solenoid control wires to vehicle harness loom.


INSTRUCTIONS

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1. Cut this locking tie ONLY2. Connector

2. Connect solenoid wiring harness (long) [P21] tovehicle harness connector.

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1. Connect to vehicle harness connector

3. Fold back solenoid wiring harness end [P21]and secure to oil tank tie mount with a lockingtie [P23].

NOTICE Ensure to tie harness looms together,not the wires.

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1. Oil tank tie mount2. Tie harness looms together

4. Clip fuse holders from solenoid wiring harness[P21] to battery strip.

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1. Fuse holders2. Battery strip

5. Secure harness with a locking tie [P23]


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INSTRUCTIONS

6. Slide protector caps [P22] onto RED battery ca-ble ends [P19].

7. Pass eyelet of solenoid wiring harness [P21]through the protective cap of the straight bat-tery cable end.

8. Connect battery cable and eyelet to solenoidpost. Secure with nut [P7]. Torque nut to spec-ification.

TIGHTENING TORQUE

4 N•m ± .25 N•m (35 lbf•in ± 2 lbf•in)

9. Cover solenoid terminal with the protector cap.10. Connect the other end to the battery positive

post. Torque bolt to specification.

TIGHTENING TORQUE

3.25 N•m ± .25 N•m (29 lbf•in ± 2 lbf•in)

11. Coat battery posts and connectors with DI-ELECTRIC GREASE (P/N 293 550 004).

12. Cover battery positive terminal with the pro-tector cap.

13. Connect the 2-pin connector of solenoidwiring harness [P21] to solenoid.

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1. 2-pin connector

Starting Relay JumperRemovalE-TEC XP 2009 to 2013 Models1. Detach red jumper from oil tank using long nose

pliers.

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1. Red jumper

2. Disconnect jumper.3. Fold back wire and secure it to loom with lock-

ing tie [P23].

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Starting Relay InstallationE-TEC XP 2009 to 2013 Models1. Recover relay from the unused solenoid wiring

harness [P21].

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1. Recover the relay

2. Connect that relay to the unused connector onvehicle main wiring harness.


INSTRUCTIONS

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VIEW FROM LH SIDE1. Oil reservoir2. Relay connector

3. Secure relay to oil reservoir with a locking tie[P23].

Ignition SwitchThe “Start/RER” button on LH side of handlebarwill now serve its dual purpose of selecting re-verse and starting engine.

Finalizing Assembly1. Connect the BLACK battery cable [P17] to bat-

tery post. Torque bolt to specification.

TIGHTENING TORQUE

3.25 N•m ± .25 N•m (29 lbf•in ± 2 lbf•in)

CAUTION Always connect battery cablesexactly in the specified order. Connect REDpositive cable first, then BLACK negativeground cable.

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2. Reinstall tuned pipe and muffler.

E-TEC ModelsReconnect temperature sensor to muffler.Reinstall primary air intake silencer.– Guide the primary air intake silencer into the

adapter plate groove– Make sure that the primary air silencer is

pushed to the end of adapter plate and that thesecuring tab is fully engaged.

800R ModelsReinstall belt support using a locking tie [P23].

REV XM, REV XSReinstall:– Bottom pan cover– Upper body module– Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on

threads of stainless steel screws.

All Models3. Clean pulley sheaves and shaft with fine steel

wool and dry cloth. Do not use any other typeof abrasive.

4. Using a paper towel with PULLEY FLANGECLEANER (P/N 413 711 809), clean crankshafttapered end and the taper inside the fixedsheave of the drive pulley, crankshaft threadsand retaining screw threads. Avoid contactbetween cleaner and crankshaft seal be-cause damage may occur.

5. Remove all hardened oil deposits that havebaked on crankshaft and pulley tapered sur-faces with coarse or medium steel wool and/orsand paper no. 600.

6. Reclean mounting surfaces with paper toweland cleaning solvent.

7. Wipe off the mounting surfaces with a clean,dry paper towel.

NOTICE Mounting surfaces must be free ofany oil, cleaner or towel residue.Do not apply antiseize or any lubricant oncrankshaft and drive pulley tapers.

8. Install drive pulley on crankshaft extension.9. Install drive belt.10. Install a new conical spring washer [P29].11. Position its domed side against drive pulley

bolt


INSTRUCTIONS

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1. Drive pulley bolt2. Conical spring washer3. Domed side here

NOTICE Always use BRP genuine parts forconical spring washer and bolt.

12. Use the DRIVE PULLEY HOLDER (P/N 529 035674) to retain drive pulley.

13. Tighten drive belt bolt strictly as follows:13.1 Torque bolt to specification.

TIGHTENING TORQUE

120 N•m ± 5 N•m (89 lbf•ft ± 4 lbf•ft)

13.2 Install drive belt guard.13.3 Raise the rear of the vehicle and support

it with a mechanical stand.

WARNING

Ensure that the track is free of particleswhich could be thrown out while trackis rotating. Keep hands, tools, feet andclothing clear of track. Ensure nobodyis standing near the vehicle.

13.4 Accelerate the vehicle at low speed (ma-ximum 30 km/h (19 MPH) and apply thebrake. Repeat 5 times.

13.5 Re-torque drive pulley bolt to specifica-tion.

TIGHTENING TORQUE

120 N•m ± 5 N•m (89 lbf•ft ± 4 lbf•ft)

WARNING

After 10 hours of operation the trans-mission system of the vehicle must beinspected to ensure drive pulley bolt isproperly torqued.

14. Reinstall remaining removed parts. ApplyLOCTITE 243 (BLUE) (P/N 293 800 060) on allreused stainless steel screws.

15. Test electrical starting and ignition cut-outsystems as per normal starting procedure forelectric starter models.


parts to be installed - goodwin performance · electric starter (kit p/n 860 200 627) 600 ho e-tec,...

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