Section 01 MAINTENANCE

Subsection 02 (PERIODIC MAINTENANCE SCHEDULE )

PERIODIC MAINTENANCE SCHEDULE

Procedures are detailed in PERIODIC MAINTENANCE PROCEDURES subsection.
EVERY 1 500 KM (1,000 MI)
T/A shocks oil change / service.. First at 1500 km, then every 3000 km or once a year
Models with chaincase: Adjust drive chain
Models with gearbox: Check oil level

EVERY 3 000 KM (2,000 MI) OR 1 YEAR

(WHICHEVER COMES FIRST)
Replace drive pulley O-rings (1200 4-TEC only)
Clean drive pulley
Tighten drive pulley retaining screw to specified torque
Clean driven pulley
Adjust and align track
Inspect brake hose, pads and disk
Inspect steering mechanism
Inspect front suspension
Inspect rear suspension and stopper strap. PPS Suspension: Replace stopper strap.
Lubricate front and rear suspension whenever the vehicle is used in wet conditions (wet snow, rain, puddles)
Lubricate QRS axle gearbox end. (XU models)

EVERY 6 000 KM (4,000 MI) OR AT PRE-SEASON

(WHICHEVER COMES FIRST)
Change engine oil and filter

EVERY 6 000 KM (4,000 MI) OR 2 YEARS

(WHICHEVER COMES FIRST)
Replace fuel filter
Inspect drive pulley sliders and replace if necessary (1200 4-TEC only)
Replace brake fluid
Inspect throttle cable

EVERY 10 000 KM (6,000 MI) OR 3 YEARS

(WHICHEVER COMES FIRST)
Replace spark plugs

mmr2011-159 9
Section 01 MAINTENANCE
Subsection 02 (PERIODIC MAINTENANCE SCHEDULE )

EVERY 20 000 KM (12,500 MI)

Check valve clearance and adjust if necessary (1200 4-TEC)

EVERY 5 YEARS
Replace engine coolant

10 mmr2011-159
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

PERIODIC MAINTENANCE
PROCEDURES
SERVICE TOOLS
Description Part Number Page
TENSIOMETER.............................................................................. 414 348 200 ........................................... 26

SERVICE PRODUCTS
Description Part Number Page
BRAKE FLUID................................................................................ 293 600 131 ........................................... 23
BRP PREMIXED COOLANT .......................................................... 219 700 362 ........................................... 11
PULLEY FLANGE CLEANER ......................................................... 619 600 022 ..................................... 21, 26
SUSPENSION GREASE ................................................................. 293 550 033 ..................................... 28–29
XPS SYNTHETIC CHAINCASE OIL ............................................... 413 803 300 ........................................... 24
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 24
XPS SYNTHETIC OIL (ALL CLIMATE) ........................................... 293 600 112 ........................................... 13

GENERAL NOTICE To prevent rust formation or freez-

ing condition, always replenish the system
This subsection provides general maintenance in- with the BRP premixed coolant or with 50%
structions. Where detailed instructions for disas- antifreeze and 50% water. Do not use tap wa-
sembly or reassembly is required, refer to the ap- ter, straight antifreeze or straight water in the
plicable subsection. system. Tap water contains minerals and im-
purities which build up in the system. During
PROCEDURES cold weather, straight water causes the system
to freeze while straight antifreeze thickens (like
ENGINE slush ice) and does not have the same effi-
ciency. Always use ethylene glycol antifreeze
Heat Shields Inspection containing corrosion inhibitors specifically
Scheduled recommended for aluminum engines.
Break-In Storage Preseason
Maintenance
✔ Engine Coolant Level Verification
Scheduled
Visually inspect heat shields on exhaust system, Break-In Storage Preseason
Maintenance
coolant hoses, electrical harness and body panels. ✔
Replace any damaged shield.
Check coolant level at room temperature with the
Recommended Engine Coolant cap removed. Liquid should be at cold level line
Use BRP PREMIXED COOLANT (P/N 219 700 362) or (engine cold) of coolant tank.
a blend of 50% antifreeze with 50% distilled wa- NOTE: When checking level at low temperature it
ter. may be slightly lower then the mark.
To prevent antifreeze deterioration, always use
the same brand. Never mix different brands un-
less cooling system is completely flushed and
refilled.

mmr2011-160 11
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

mmr2011-071-005_c
fmo2007-009-010_a 600 ACE
TYPICAL 1. Drain screw
1. Coolant tank
2. COLD LEVEL line

Engine Coolant Strength Verification

Scheduled
Break-In Storage Preseason
Maintenance
✔

Remove pressure cap.

Use an antifreeze tester to test coolant strength.
MINIMUM RECOMMENDED COOLANT
STRENGTH
-30°C (-22°F) mmr2009-112-046_a

1200 4-TEC
1. Drain screw
Engine Coolant Replacement 2. Water pump (under exhaust manifold)

Break-In
Scheduled
Storage Preseason
4. Remove coolant reservoir cap.
Maintenance
5. When coolant level is low enough, lift the rear
✔ of vehicle to drain the heat exchangers.
Cooling System Draining (600 ACE and
1200 4-TEC)

WARNING
Never drain or refill the cooling system when
engine is hot.

1. Remove body parts as required to access to the

water pump.
2. Place a large drain pan under the vehicle bottom
pan.
3. Remove drain screw at water pump to drain fmr2011-001-004

coolant.
6. Install new sealing washer on drain screw.
7. Tighten drain screw to specification.
DRAIN SCREW TORQUE
11 N•m ± 1 N•m (97 lbf•in ± 9 lbf•in)

12 mmr2011-160

Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)
Cooling System Refilling and Bleeding
1. Apply parking brake.
2. From underneath the back end of the chassis,
remove the heat exchanger drain plug.
mmr2009-156-004_a
1. Drain plug
3. Fill coolant reservoir until coolant comes out of
heat exchanger.
4. Install drain plug and tighten it to specification.
DRAIN PLUG TORQUE
10 N•m (89 lbf•in)
5. Lift front of vehicle by 25 cm ± 5 cm
(10 in ± 2 in) and support safely.
6. Fill coolant tank up to COLD LEVEL line.
7. Start engine.
8. Add coolant up to line while engine is idling un-
til rear heat exchangers are warm to the touch
(about 4 to 5 minutes).
NOTE: Always monitor coolant level while filling
coolant tank to avoid an empty coolant reservoir,
and thus allow air to enter the system.
9. Install pressure cap.
Lower vehicle back on the ground.
10. Lift rear of vehicle and support it safely.
mmr2011-160
Section 01 MAINTENANCE
WARNING
Before revving engine, ensure that the track
is free of 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 panel. Ensure no one is stand-
ing in close proximity to the snowmobile,
especially at the rear of the track. Centrifugal
force could cause debris, damaged or loose
studs, pieces of torn track, or an entire track
to be violently thrown backwards out of the
frame with tremendous force, possibly re-
sulting in the loss of a leg or other serious
injury.
11. Remove parking brake.
12. Activate throttle lever 3 - 4 times to bring en-
gine speed to 7000 RPM.
13. Apply the brake.
14. Lower vehicle back on ground.
15. Stop engine.
16. Add coolant up to 15 mm (1/2 in) above the
COLD LEVEL line.
17. When engine has completely cooled down,
recheck coolant level in coolant tank and refill
up to line if needed.
18. Perform ENGINE COOLANT STRENGTH VER-
IFICATION. See procedure in this subsection.
19. Adjust mixture if necessary.
20. Reinstall removed parts.
21. Run vehicle a few minutes then recheck
coolant level.
Recommended Engine Oil (600 ACE
and 1200 4-TEC)
ENGINE RECOMMENDED ENGINE OIL
600 ACE XPS SYNTHETIC OIL (ALL
1200 4-TEC CLIMATE) (P/N 293 600 112)
NOTICE The engine of this snowmobile has
been developed and validated using the BRP
XPS™ Synthetic 4-stroke oil. BRP strongly rec-
ommends the use of its XPS Synthetic 4-stroke
oil at all times. Damages caused by oil which is
not suitable for the engine will not be covered
by the BRP limited warranty.
13
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

If the recommended oil is not available, use SAE 5. Unscrew and remove dipstick and wipe clean.
0W-40 synthetic-based oil that meets or exceeds 6. Insert dipstick in the filler tube and again tighten
the requirements for API service classification it.
SM.

Engine Oil Level Verification (600 ACE

and 1200 4-TEC)
NOTICE Operating the engine with an im-
proper oil level may cause severe engine
damage. Follow this procedure to obtain a
precise reading of the engine oil level.

mmr2011-070-003_b

TYPICAL
Step 1: Insert dipstick
Step 2: Tighten dipstick.

7. Remove dipstick again and check oil level. It

should be near or equal to the upper mark.

mmr2011-070-003_a

TYPICAL 600 ACE - LH SIDE

1. Oil tank dipstick
MAX.

MIN.

mmo2009-005-027_a

1. Operating range

8. To add oil, place a funnel into the filler tube to

mmr2009-111-010_a avoid spillage.
TYPICAL 1200 4-TEC- LH SIDE 8.1 Add a small amount of oil and recheck oil
1. Oil tank dipstick
level.
With the engine at normal operating temperature, 8.2 Repeat the operation until oil level reaches
place vehicle on a level surface and proceed as the dipstick’s upper mark. Do not overfill.
follows to check oil level:
NOTE: The oil quantity between MIN. and MAX.
1. Start engine and let it idle for at least 20 sec- mark is approximately 500 ml (16.9 U.S. oz).
onds.
9. Reinstall dipstick and properly tighten it.
2. Stop engine.
10. Wipe off any oil spillage.
3. Open the LH side panel.
11. Install drive belt guard.
4. If applicable, remove the drive belt guard. refer
to DRIVE BELT subsection. 12. Close the LH side panel.

14 mmr2011-160
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

Engine Oil Replacement (600 ACE)

Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔

WARNING
The engine oil can be very hot. Wait until en-
gine oil is warm.

NOTICE Engine oil and oil filter must be re-

placed at the same time.
1. Place vehicle on a level surface.
mmr2011-070-060_a

2. Remove the LH side panel. 1. Drain plugs access cover

3. Remove dipstick.

mmr2011-070-060_b
mmr2011-070-003_a
PIVOT THE ACCESS COVER
LH SIDE OF VEHICLE 1. Retaining screws
1. Oil tank dipstick

4. From underneath the vehicle, access the drain 5. Clean drain plug area.
plug: 6. Place a drain pan under the bottom pan open-
4.1 Remove one access cover retaining screw ing.
and loosen the other. 7. Remove engine drain plugs in the following or-
4.2 Pivot the access cover to clear the bottom der.
pan opening. 7.1 Main drain plug.
7.2 Secondary drain plug.

mmr2011-160 15
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

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

15. Ensure there are no leaks.
16. Stop engine and check oil level as explained in
this subsection. Refill if necessary.
17. Dispose oil and filter as per your local environ-
mental regulations.

Engine Oil Replacement (1200 4-TEC)

Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔

mmr2011-070-053_a WARNING
UNDERNEATH THE ENGINE The engine oil can be very hot. Wait until en-
1. Main drain plug
2. Secondary drain plug gine oil is warm.
8. Allow oil to drain completely.
9. Install NEW sealing washers on oil drain plugs. NOTICE Engine oil and oil filter must be re-
placed at the same time.
NOTICE Never use a sealing washer a sec-
ond time. Always replace with a new one. 1. Place vehicle on a level surface.
2. Remove the LH side panel.
3. Remove the drive belt guard. Refer to DRIVE
BELT subsection.
4. Remove dipstick.

mmr2011-070-004_a

1. Sealing washer
2. Oil drain plug

10. Install drain plugs and tighten to the specified

torque. mmr2009-111-100_b

DRAIN PLUGS TIGHTENING TORQUE LH SIDE OF VEHICLE

1. Oil tank dipstick
20 N•m ± 2 N•m (15 lbf•ft ± 1.5 lbf•ft)
5. From underneath of vehicle, clean drain plug
11. Replace OIL FILTER, see procedure in this area.
subsection.
12. Refill oil tank at the proper level with the rec-
ommended oil.
APPROXIMATE ENGINE OIL CAPACITY
(WITH FILTER)
600 ACE 2.1 L (2.2 qt (U.S. liq.))

13. Reinstall dipstick in oil tank and properly

tighten it.

16 mmr2011-160
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

13. Reinstall dipstick in oil tank.

14. Start engine and let it idle for a few minutes.
15. Ensure there are no leaks.
16. Stop engine and check oil level as explained in
this subsection. Refill as necessary.
17. Dispose oil and filter as per your local environ-
mental regulations.

Engine Oil Filter Replacement

(600 ACE)
mmr2009-111-101_a

1. Frame opening to reach drain plug Oil Filter Removal

1. Remove the RH side panel.
6. Place a drain pan under frame opening.
2. Clean oil filter area.
7. Remove engine oil drain plug and discard seal-
ing washer. 3. Remove:
– Oil filter cover screws
8. Allow oil to drain completely.
– Oil filter cover with O-ring
9. Install NEW sealing washer and O-ring on oil
– Oil filter.
drain plug.
NOTICE Never use a sealing washer a sec-
ond time. Always replace with a new one.

mmr2011-070-007_a

1. Oil filter cover screws

2. Oil filter cover
3. O-ring
4. Oil filter
mmr2009-111-005_a

1. Sealing washer 4. Dispose filter as per your local environmental

2. O-ring
3. Oil drain plug regulations.
10. Install drain plug and tighten to the specified Oil Filter Installation
torque. 1. Check the oil filter inlet and outlet orifices inside
DRAIN PLUG TIGHTENING TORQUE oil filter receptacle (integrated part of magneto
cover) for dirt and contaminations.
30 N•m (22 lbf•ft)

11. Replace OIL FILTER, see procedure in this

subsection.
12. Refill oil tank at the proper level with the rec-
ommended oil.
APPROXIMATE ENGINE OIL CAPACITY
(WITH FILTER)
1200 4-TEC 3.5 L (3.7 qt (U.S. liq.))

mmr2011-160 17
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

mmr2009-111-006_a
mmr2011-070-008_a
1. Oil filter cover screws
1. Oil inlet orifice from the oil pressure pump 2. Oil filter cover
2. Oil outlet orifice to the engine lubrication system 3. O-ring
3. Oil filter receptacle 4. Oil filter

2. Install a O-ring on oil filter cover.
3. Lubricate filter seal and cover O-ring with en-
gine oil.
5. Dispose filter as per your local environmental
regulations.
Oil Filter Installation
1. Check the oil filter inlet and outlet orifices inside
oil filter receptacle (integrated part of magneto
cover) for dirt and contaminations.

mmr2011-070-009_a

1. Lubricate with engine oil

4. Install the oil filter cover.

5. Tighten oil filter cover screws to the specified
torque.
mmr2009-111-007_a
OIL FILTER COVER TIGHTENING TORQUE
1. Oil inlet orifice from the oil pressure pump
10 N•m ± 1 N•m (89 lbf•in ± 9 lbf•in) 2. Oil outlet orifice to the engine lubrication system
3. Oil filter receptacle

Oil Filter Replacement (1200 4-TEC) 2. Install a NEW O-ring on oil filter cover.
3. Lubricate filter seal and cover O-ring with en-
Oil Filter Removal gine oil.
1. Remove the RH side panel.
2. Remove muffler, refer to EXHAUST SYSTEM
subsection.
3. Clean oil filter area.
4. Remove:
– Oil filter cover screws
– Oil filter cover with O-ring
– Oil filter.

18 mmr2011-160
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

Valve Clearance Inspection

1. Remove the VALVE COVER, see procedure in
this subsection.
2. Remove spark plugs.
3. Using the drive pulley, turn engine counter-
clockwise until camshaft lobes are opposite to
cam followers.
4. Use a feeler gauge and check the valve clear-
ance between camshaft and cam follower.

mmr2009-111-008_a

1. Lubricate with engine oil

4. Install the oil filter cover.

5. Tighten oil filter cover screws to the specified
torque.
OIL FILTER COVER TIGHTENING TORQUE
10 N•m ± 1 N•m (89 lbf•in ± 9 lbf•in)

Engine Seals and Gaskets Inspection mmr2009-115-004_a

(600 ACE and 1200 4-TEC) 1. Camshaft lobe opposite to cam follower
2. Feeler gauge
Scheduled 3. Cam follower
Break-In Storage Preseason
Maintenance
5. Repeat steps 3 and 4 for all intake and exhaust
✔ ✔
valves.
Visually inspect the seals and gaskets area for 6. Adjust the valve clearance if out of specifica-
leaks. tion, see VALVE CLEARANCE ADJUSTMENT.
VALVE CLEARANCE
Exhaust System Inspection
0.30 mm to 0.40 mm
Scheduled EXHAUST
Break-In Storage Preseason (.0118 in to .0157 in)
Maintenance
✔ ✔ 0.10 mm to 0.20 mm
INTAKE
(.0039 in to .0079 in)
Check the following components for cracks, ex-
haust leakage or other damage: Valve Clearance Adjustment
– Muffler If the valve clearance is out of specification, adjust
– Tuned pipe and shields valve clearance by replacing the adjustment shim
– Manifold. of the respective valve. Proceed as follows.
1. Turn drive pulley counterclockwise and position
Valve Clearance Inspection and appropriate camshaft lobe opposite to cam fol-
Adjustment (1200 4-TEC) lower.
Scheduled 2. Remove cam follower spacer.
Break-In Storage Preseason
Maintenance
✔

Check and adjust the valve clearance only on a

cold engine, at room temperature.
When the valve clearance has to be measured or
adjusted, the piston must be at TDC of compres-
sion stroke.

mmr2011-160 19
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

6. After reassembly of parts, measure the valve

clearance again.
If valve clearance is still out of specification, re-
peat all steps until the specified clearance is ob-
tained.

FUEL SYSTEM
Fuel Lines and Connection Inspection
Scheduled
Break-In Storage Preseason
Maintenance
mmr2009-115-005_a ✔ ✔
1. Spacer
2. Cam followers Visually inspect fuel lines and connections for
3. Slide cam follower aside to gain access to the cracks or leaks.
adjustment shim.
Fuel Pump Outlet Filter Replacement
(600 ACE and 1200 4-TEC)
Scheduled
Break-In Storage Preseason
Maintenance
✔

NOTE: The fuel pump outlet filter is housed

within the mounting flange of the fuel pump
module. It can be replaced without removing the
fuel pump module from the fuel tank.
1. Disconnect fuel pump electrical connector to
deactivate fuel pump.
2. Place several shop rags under the fuel pump
pressure hose fitting to prevent fuel from leak-
mmr2009-115-006_a
ing onto the connectors of the voltage regula-
1. Cam followers
2. Adjustment shim tor/rectifier unit.
3. Remove following parts from fuel pump mod-
4. Remove adjustment shim and measure its ule.
thickness with a micrometer.
NOTE: Do not remove fuel pump module from
fuel tank.

mmr2011-089-009_a

1. Filter cover retainer with screws (2)

2. Filter cover
3. Wave spring
mmr2009-115-007_a 4. Filter element.
1. Adjustment shim
4. Install NEW O-ring seals on filter cover and in
5. Choose the proper adjustment shim thickness filter housing.
to reach the specified valve clearance.

20 mmr2011-160
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

7. Install and reconnect the fuel pump module

(pressure hose and electrical connector), refer
to FUEL PUMP INSTALLATION (600 ACE AND
1200 4-TEC) in the FUEL TANK AND FUEL
PUMP subsection.
8. Carry out a FUEL SYSTEM PRESSURIZATION
AND LEAK TEST as detailed in the FUEL TANK
AND FUEL PUMP subsection.
9. Install remaining parts in the reverse order of
removal, refer to FUEL TANK INSTALLATION in
this subsection.

Throttle Body Inspection and Cleaning

Scheduled
mmr2011-089-010_a Break-In Storage Preseason
1. New O-ring seals
Maintenance
✔
5. Insert filter element as per following illustration.
Clean throttle plates and throttle body bores using
PULLEY FLANGE CLEANER (P/N 619 600 022).

Throttle Cable Inspection

Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔ ✔

Visually inspect cable sheath for kinks, wear other

damage.
Visually inspect cable at throttle plate and throttle
lever for fraying or other damage.
mmr2011-089-011_a
Make sure the throttle cable operates smoothly.
1. This end in first
Oil injection Pump Strainer Inspection
6. Install remaining filter parts. and Cleaning (E-TEC)
Scheduled
Break-In Storage Preseason
Maintenance
✔

Refer to OIL INJECTION PUMP in LUBRICATION

SYSTEM subsection.

ELECTRICAL SYSTEM
Battery Charging
Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔

mmr2011-089-012_a To charge battery, refer to CHARGING SYSTEM

1. Wave spring subsection.
2. Filter cover
3. Cover retainer with screws (2)

FILTER COVER SCREW TORQUE

3 N•m (27 lbf•in)

mmr2011-160 21
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

Headlights beam aiming adjustment SPARK GAP

ENGINE TORQUE
Scheduled PLUG mm (in)
Break-In Storage Preseason
Maintenance NGK 11 N•m 0.7 mm
600 ACE
✔ CR7EB (97 lbf•in) (.028 in)

Refer to LIGHTS, GAUGE AND ACCESSORIES 1200 NGK 11 N•m 0.7 mm

4-TEC CR8EKB (97 lbf•in) (.028 in)
subsection.

Spark Plugs Replacement (600 ACE 2. Hand screw spark plug into cylinder head.
Then, tighten the spark plug clockwise to
and 1200 4-TEC) specified torque with an approved spark plug
Scheduled socket.
Break-In Storage Preseason
Maintenance
3. Install ignition coil. Refer to IGNITION SYSTEM
✔ ✔
subsection.
Spark Plug Removal 4. Complete the installation in the reverse order of
the removal.
1. Remove ignition coil. Refer to IGNITION SYS-
TEM subsection. Spark Plug Inspection
2. Using an approved spark plug socket, release
the torque applied to the spark plug and un- Spark Plug Analysis
screw a few turns.

1 2
A00E0AA 1 2 3
TYPICAL
1. Overheated (light gray, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, gray, melted coating)

A00E0BA
1. Aproved socket
2. Improper socket
3. Clean the spark plug and cylinder head with
pressurize air.
4. Remove spark plug.
Spark Plug Installation
Prior to installation, ensure the contact surfaces of
the cylinder head and spark plug are free of grime.
1. Using a wire feeler gauge, check electrode gap
as specified in the following chart.
NOTICE Do not adjust gap on this type of
spark plug. The adjustment could weaken neg-
ative electrodes which may lead to electrode
breakage and severe engine damage.
The plug face reveals the condition of the engine,
operating condition, method of driving and fuel
mixture. For this reason it is advisable to inspect
the spark plug at prescribed intervals, examining
the plug face (i.e. the part of the plug projecting
into the combustion chamber).
Troubleshooting a Fouled Spark Plug
Fouling of the spark plug is indicated by irregular
running or misfiring of the engine, decreased
engine speed due to misfiring, reduced perfor-
mance, and increased fuel consumption.
Other possible causes are: a incorrect or bad
fuel, defective ignition system, incorrect spark
plug gap, loss of compression, or lubricating oil
entering the combustion chamber.
The plug face of a fouled spark plug has either a
wet or dry black carbon deposit. Such coatings
form a conductive connection between the center
electrode and the ground electrode.

22 mmr2011-160
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

DRIVE SYSTEM AND BRAKE

Recommended Brake Fluid
Always use brake fluid meeting the specification
DOT 4 such as BRAKE FLUID (P/N 293 600 131).

Brake Fluid Level Verification

Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔

With the vehicle on a level surface, position steer- mmr2008-043-102_a

ing in straight-ahead position to ensure reservoir 1. Reservoir cover

is level. 2. Diaphragm

Brake fluid must always be above the MIN. line 3. Connect a clear hose to caliper bleeder.
when brake lever is squeezed. 4. Place the other end of hose in a container.
5. Loosen bleeder and pump brake lever until no
more fluid flows out of bleeder.

mmr2008-043-101_a

1. MINIMUM line

Add fluid as required. Do not overfill.

mmr2008-043-103_a
NOTE: A low level may indicate leaks or worn TYPICAL
brake pads. 1. Bleeder
2. Clear hose to catch used brake fluid
Brake Fluid Replacement To fill brake system when it is empty, proceed as
Scheduled
Break-In Storage Preseason follows:
Maintenance
✔ 1. Ensure reservoir cover is removed.
2. Using a large syringe and a suitable tube, inject
To drain brake fluid, proceed as follows: brake fluid slowly into the caliper.
1. Place vehicle on a level surface.
2. Remove reservoir cover with its diaphragm.

mmr2008-043-104

TYPICAL

mmr2011-160 23
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

3. Continue to inject brake fluid until master cylin- Break-In Inspection

der reservoir is half full. Visually inspect the brake hose for leaks or any
4. Close bleeder. damage.
5. Fill up reservoir and install cover. Visually inspect pads and disc for abnormal wear
6. Squeeze brake lever. or any damage.
6.1 If brake lever is firm, bleeding of the brake Scheduled Maintenance and Preseason
system is not required. Torque bleeder as Visually inspect the brake hose for leaks or any
specified. damage.
BRAKE CALIPER BLEEDER TORQUE Refer to BRAKE subsection and carry out:
9 N•m (80 lbf•in) – BRAKE PAD INSPECTION
– BRAKE DISC INSPECTION.
6.2 If brake lever is spongy, refer to BRAKE
SYSTEM BLEEDING in this subsection. Brake Lever Pivot Lubrication
Scheduled
Brake System Bleeding Break-In
Maintenance
Storage Preseason
1. Install a clear hose on bleeder. ✔
2. Place the other end in a container partially filled
with clean brake fluid. 1. Remove brake lever pivot bolt.
3. Pump up brake system pressure using the 2. Lubricate brake lever pivot bolt using XPS SYN-
brake lever until lever resistance is felt. THETIC GREASE (P/N 293 550 010).

4. Squeeze and hold brake lever and open bleeder.

When the lever touches the handlebar, do not
release it and close the bleeder. 1
5. Release brake lever slowly.
6. Repeat the procedure until no more air bubbles
appear in hose.
NOTE: Check fluid level often to prevent air from
being pumped into the circuit.
7. Install cover on reservoir.
8. Squeeze brake lever.
mmr2009-130-001_a
NOTE: If brake lever feels firm; bleeding proce-
1. Lubricate this surface
dure is complete. Torque bleeder as specified. If
brake lever is still spongy; go to step 9 3. Install brake lever pivot bolt.
BRAKE CALIPER BLEEDER TORQUE 4. Torque nut on brake lever pivot bolt as speci-
9 N•m (80 lbf•in)
fied.
PIVOT BOLT TORQUE, BRAKE LEVER
9. Push back brake pads with caliper still installed
6 N•m (53 lbf•in)
and squeeze brake lever.
10. Repeat step 2 to step 5.
Recommended Gearbox Oil
11. Torque bleeder as specified.
RECOMMENDED GEARBOX OIL
12. Adjust brake fluid reservoir level.
XPS SYNTHETIC CHAINCASE OIL (P/N 413 803 300)
13. Install diaphragm and cover on reservoir.

Brake Hose, Pads and Disc Inspection

Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔ ✔

24 mmr2011-160
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

NOTICE The gearbox of this snowmobile has

been developed and validated using the XPS™
Synthetic chaincase oil. BRP strongly recom-
mends the use of its XPS Synthetic chaincase
oil at all times. Damages caused by oil which
is not suitable for the gearbox will not be cov-
ered by the BRP limited warranty.

Gearbox Oil Level Verification

With the vehicle on a level surface, check the oil
level by removing the check plug on the left side
of gearbox.
mmr2009-176-001_a

Oil level must reach the threaded hole's lower 1. Drain plug access hole
edge.
5. Wait a while to allow oil to flow out of gearbox.
6. Install drain plug and torque it to 8 N•m
(71 lbf•in).
Gearbox Oil Filling
1. Remove the filler cap.

mmo2009-004-033_a

1. Check plug

1. Reinstall check plug and torque to

10 N•m ± 1 N•m (89 lbf•in ± 9 lbf•in). mmr2011-160-001_a

TYPICAL
Gearbox Oil Replacement 1. Filler cap

Gearbox Oil Draining 2. Pour recommended oil in gearbox by the filler

1. Place the vehicle on a level surface. hole until oil comes out by the check plug hole.
2. Place a drain pan under gearbox drain plug area. 3. Reinstall check plug and torque to 10 N•m
(89 lbf•in).
3. Remove filler cap.
4. Remove the drain plug located at the bottom Drive Belt Inspection
of gearbox. Reach the drain plug by the access Scheduled
hole. Break-In Storage Preseason
Maintenance
✔ ✔

Refer to DRIVE BELT subsection.

Drive Pulley Inspection and Cleaning

Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔ ✔

Refer to DRIVE PULLEY subsection.

mmr2011-160 25
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

Drive Pulley Retaining Screw 3. Preset the TENSIOMETER (P/N 414 348 200) as
Tightening specified in the following table.
Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔
414348200
Refer to DRIVE PULLEY subsection.
TRACK TENSIOMETER PRESETTING
Drive Pulley Wear Parts Inspection and DEFLECTION O-RING
Replacement (BOTTOM)
LOAD O-RING (TOP)
Scheduled
Break-In Storage Preseason 4.5 cm (1.772 in) 0 kgf (0 lbf)
Maintenance
✔

Replace drive pulley wear parts as per PERIODIC

MAINTENANCE SCHEDULE. Refer to DRIVE
PULLEY subsection.
Driven Pulley Inspection and Cleaning mmr2009-133-003_b

Scheduled DEFLECTION SETTING

Break-In Storage Preseason 1. Bottom O-ring
Maintenance
✔ ✔ ✔ 4. Position the tensiometer on track, halfway be-
tween front and rear idler wheels.
Inspect pulley sheaves for dirt, marks or
scratches. 5. Push the tensiometer downwards until bottom
O-ring (deflection) be aligned with the bottom
Test sliding sheave operation. of slider shoe.
Use PULLEY FLANGE CLEANER (P/N 619 600 022)
and a clean rag to clean pulley sheaves as neces-
sary.
NOTE: When removing dust on the cam, avoid al-
tering the teflon coating. Use a dry cloth only.

Driven Pulley Spring Preload

Scheduled
Break-In Storage Preseason
Maintenance
✔

Refer to DRIVEN PULLEY AND COUNTERSHAFT

mmr2009-133-001_a
(600 ACE) or DRIVEN PULLEY AND COUNTER-
SHAFT (1200 4-TEC) subsections.
Track Adjustment and Alignment
Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔ ✔

Track tension and alignment are interrelated. Do

not adjust one without checking the other. Track
tension procedure must be carried out prior to
track alignment.
Track Tension Verification
1. Lift rear of vehicle and support it off the ground.
2. Allow rear suspension to fully extend.
26 mmr2011-160
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

mmr2008-048-007_a

mmr2009-133-002_a 1. RH rear idler wheel cap

1. Deflection O-ring aligned with slider shoe
3. Loosen rear axle screws (one each side).
6. Read load recorded by the upper O-ring on the
tensiometer.

mmr2009-133-003_a

LOAD READING
1. Upper O-ring

Load reading must be as per the following table.

TRACK ADJUSTMENT SPECIFICATION
mmr2008-048-008_a

TRACK DEFLECTION 1. RH rear axle screw

4.5 cm (1-9/16 in)
SETTING
4. Tighten or loosen both adjustment screws to
TRACK LOAD 6.0 kgf to 8.5 kgf increase or decrease track tension.
READING (13 lbf to 19 lbf)

7. If load reading is not in accordance with the

specification, adjust track tension. Refer to
TRACK TENSION ADJUSTMENT.
NOTICE Too much tension will result in
power loss and excessive stresses on suspen-
sion components.
Track Tension Adjustment
NOTE: After track tension adjustment, ride the
snowmobile in snow for 15 to 20 minutes and
recheck track tension. mmr2008-048-009_a

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

2. Remove rear idler wheel caps.

mmr2011-160 27
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

1200 4-TEC, 59 Yeti 3.3 Tighten adjustment screw on side where

the slider shoe is the farthest from the
track inset guides.

1 2 1

3
A01F0BA

fmr2011-048-010_a
1. RH adjustment screw
5. Verify track tension, refer to TRACK TENSION
VERIFICATION in this subsection.
Track Alignment
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.
Ensure no one is standing in close proximity
to the vehicle. Never rotate at high speed.
1. Start engine and accelerate slightly until the
track barely turns. This must be done in a short
period of time (1 to 2 minutes).
2. Ensure the track is well centered; equal dis-
tance on both sides between edges of track
guides and slider shoes.
1 with other parts.
2
1. Track guides
2. Slider shoes
3. Tighten on this side
4. Restart engine.
5. Rotate track slowly and recheck alignment.
6. If satisfactory alignment is achieved:
6.1 Tighten idler wheel retaining screws.
IDLER WHEEL SCREW TIGHTENING
TORQUE
48 N•m (35 lbf•ft)
6.2 Reinstall wheel caps.
CHASSIS
Front Suspension Lubrication
Lubricate front suspension at grease fittings using
SUSPENSION GREASE (P/N 293 550 033).
Generally, 4 to 5 grease gun strokes is sufficient.
NOTE: If too much grease is injected, the over-
flow will come out at steering levers and ski legs.
Wipe off any excess of grease to avoid contact

3
A01F05A

1. Guides
2. Slider shoes
3. Equal distance

3. To correct track alignment: mmo2010-007-014_a

3.1 Stop engine. LH SIDE SHOWN

1. Grease fitting
3.2 Loosen rear wheel screws. 2. Steering arm

28 mmr2011-160
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

Front Suspension Inspection

Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔ ✔

Visually inspect front suspension for tightness of

components:
– Arms
– Stabilizer bar
– Shock absorbers
– Ball joints.

Rear Suspension Lubrication mmr2011-221-008_a

REAR ARM
Scheduled 1. Grease fitting
Break-In Storage Preseason
Maintenance
✔ ✔

Lubricate the following suspension pivots at

grease fittings using SUSPENSION GREASE
(P/N 293 550 033).
Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔

mmr2010-035-011_b

PIVOT ARM
1. Grease fitting

Lubrication (PPS-154)

mmr2010-035-010_a

FRONT ARM - LOWER SHAFT

1. Grease fitting

fmr2011-001-006_b

GREASE FITTINGS

Rear Suspension, Stopper Straps and

slider shoes inspection
Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔ ✔

mmr2011-221-009_a

FRONT ARM - UPPER SHAFT

1. Grease fitting

mmr2011-160 29
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

Rear Suspension Mechanism and Stopper Visually inspect steering mechanism for tightness
Straps Inspection of components (steering arms, tie rods, ski bolts,
1. Inspect rear suspension components for wear, ski legs, etc.).
deterioration or damage, replace defective
parts if necessary.
2. Inspect stopper straps for wear or cracks.
3. Check bolt and nut securing straps for tight-
ness. If loose, inspect strap holes for deforma-
tion. Replace strap if necessary.
Slider Shoe Inspection
Slider shoes are worn out and must be replaced
when there is just 1 mm to 2 mm (.04 in to .08 in)
of remaining material exceeding the molding line.

mmr2011-117-004_a

1. Slider shoe
2. Molding line
A. Minimum thickness: 1 mm to 2 mm (.04 in to .08 in)

NOTICE Slider shoes must always be re-

placed in pairs.

Ski and Runner inspection

Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔

Lift the front of vehicle and check ski runners for

wear or damage (missing or broken carbide). Re-
place if necessary.
Inspect ski for excessive wear or other damage.
Replace if necessary.

Steering Mechanism Inspection

Scheduled
Break-In Storage Preseason
Maintenance
✔ ✔ ✔

30 mmr2011-160