2012 Ski-Doo REV XP 600, 600 HO E-TEC, 800R Power TEK & 800R E-TEC Series
2012 Ski-Doo REV XR 600 HO E-TEC & 800R E-TEC Series
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SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to cor-
rectly service and repair 2012 Ski-Doo
®
snowmo-
biles described in the list in the INTRODUCTION.
This edition was primarily published to be used by
technicians who are already familiar with service
procedures relating to Bombardier Recreational
Products Inc. (BRP) products. Mechanical tech-
nicians should attend continuous training courses
given by BRPTI.
Please note that the instructions will apply only
if proper hand tools and special service tools are
used.
The content of this manual depicts parts and/or
procedures applicable to a particular product at
time of writing. Service and Warranty Bulletins
may be published to update the content of this
manual. Dealer modifications that were carried
out after manufacturing of the product, wether or
not authorized by BRP, are not included.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or ex-
act replicas of the parts.
The use of BRP parts is most strongly recom-
mended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.
The engines and the corresponding components
identified in this document should not be utilized
on product(s) other than those mentioned in this
document.
It is understood that certain modifications may
render use of the vehicle illegal under existing
federal, provincial and state regulations.
This manual emphasizes particular information de-
noted by the wording and symbols:
WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.
CAUTION Indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
NOTICE
Denotes an instruction which, if not
followed, could severely damage vehicle com-
ponents.
NOTE: Indicates supplementary information
needed to fully complete an instruction.
Although the mere reading of such information
does not eliminate the hazard, your understand-
ing of the information provided will promote its
correct use. Always use common shop safety
practice.
It is understood that this manual may be trans-
lated into another language. In the event of any
discrepancy, the English version shall prevail.
BRP disclaims liability for all damages and/or in-
juries resulting from the improper use of the con-
tents.
Unless otherwise indicated, engine must be OFF
and tether cord removed prior to perform any ser-
vices.
We strongly recommend that any services be car-
ried out and/or verified by a highly skilled profes-
sional mechanic.
INTRODUCTION
INTRODUCTION
This Shop Manual covers the following BRP made
2012 snowmobiles:
CHASSIS ENGINE
600
600 HO E-TEC
®
800R Power TEK™
REV-XP™
800R E-TEC
600 HO E-TEC
REV-XR™
800R E-TEC
The information and component/system descrip-
tions contained in this manual are correct at time
of writing. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
Due to late changes, there may be some differ-
ences between the manufactured product and the
description and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
VEHICLE INFORMATION
VEHICLE IDENTIFICATION
NUMBER (VIN)
mmo2008-003-008_a
TYPICAL
1. Vehicle identification number
Identification Number Description
2BPS LSAB 9 A 1 000001
Model number
Serial number
Model year: A = 2010
B = 2011
C = 2012
etc.
ENGINE SERIAL NUMBER
mmo2007-002-007_a
TYPICAL — 600 AND 600 HO E-TEC ENGINES
1. Engine serial number
mmo2007-002-006_a
TYPICAL — 800R POWER TEK AND 800R E-TEC ENGINES
1. Engine serial number
SNOWMOBILE LIFTING
To lift the snowmobile securely, it is important to
use the reinforced footrest holes.
INTRODUCTION
mmr2008-002-100_a
1. Reinforced holes in footrest
Install lifting tool hooks in holes as shown.
mmr2008-002-101_a
1. Hook of lifting tool
NOTICE Do not use footrest opening or steer-
ing column to lift the snowmobile. Frame or
steering system could be seriously damaged.
ENGINE EMISSIONS
INFORMATION
Manufacturer's Responsibility
Manufacturers of engines must determine the
exhaust emission levels for each engine horse-
power family and certify these engines with the
United States of America ENVIRONMENTAL
PROTECTION AGENCY (EPA). An emissions con-
trol information label, showing emission levels
and engine specifications, must be placed on
each vehicle at the time of manufacture.
Dealer Responsibility
When servicing any snowmobile that carries an
emissions control information label, adjustments
must be kept within published factory specifica-
tions.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the engine in any man-
ner that would alter the engine power or allow
emission levels to exceed their predetermined
factory specifications.
Exceptions include manufacturer's prescribed
changes, such as altitude adjustments for exam-
ple.
Owner Responsibility
The owner/operator is required to have engine
maintenance performed to maintain emission
levels within prescribed certification standards.
The owner/operator is not to, and should not allow
anyone else to modify the engine in any manner
that would alter the engine power or allow emis-
sions levels to exceed their predetermined factory
specifications.
EPA Emission Regulations
Snowmobiles manufactured by BRP are certified
to the EPA standards as conforming to the require-
ments of the regulations for the control of air pol-
lution emitted from new snowmobiles engines.
This certification is contingent on certain adjust-
ments being set to factory standards. For this rea-
son, the factory procedure for servicing the prod-
uct must be strictly followed and, whenever prac-
ticable, returned to the original intent of the de-
sign.
The responsibilities listed above are general and
in no way a complete listing of the rules and
regulations pertaining to the EPA requirements
on exhaust emissions for snowmobiles products.
For more detailed information on this subject, you
may contact the following locations:
FOR ALL COURIER SERVICES:
U.S. Environmental Protection Agency
Office of Transportation and Air Quality
1310 L Street NW
Washington D.C. 20005
REGULAR US POSTAL MAIL:
1200 Pennsylvania Ave. NW
Mail Code 6403J
Washington D.C. 20460
INTERNET: http://www.epa.gov/otaq/
E-MAIL: otaqpublicweb@epa.gov
INTRODUCTION
MANUAL INFORMATION
MANUAL PROCEDURES
Many of the procedures in this manual are inter-
related. Before undertaking any task, you should
read and thoroughly understand the entire section
or subsection in which the procedure is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before starting any
procedure, be sure that you have on hand all re-
quired tools, or their approved equivalents.
The use of RIGHT and LEFT indications in the text
are always referenced to the driving position (sit-
ting on the vehicle).
TYPICAL
1. Left
2. Right
This manual uses technical terms which may be
different from the ones of the PARTS CATALOGS.
When ordering parts always refer to the specific
model PARTS CATALOGS.
MANUAL LAYOUT
This manual is divided into many major sections as
can be seen in the main table of contents at the
beginning of the manual.
Each section is divided into various subsections,
and again, each subsection has one or more divi-
sions.
Illustrations and photos show the typical construc-
tion of various assemblies and, in all cases, may
not reproduce the full detail or exact shape of the
parts used in a particular model vehicle. However,
they represent parts which have the same or a
similar function.
INTRODUCTION
Typical_iso_2008_en
INTRODUCTION
typical_txt_2008_en
INTRODUCTION
TIGHTENING TORQUE
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, refer to the following table.
WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices when removed (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter
pins, etc.) must be replaced.
In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce-
dure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.
NOTICE
Be sure to use the recommended tightening torque for the specified fastener used.
NOTE: When possible, always apply torque on the nut.
NOTE: Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are
used to secure a part (eg. a cylinder head). Some parts must be torqued according to a specific sequence
and torque pattern as detailed in the installation procedure.
FASTENER GRADE/TORQUE
FASTENER
SIZE
5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
M4
1.5 – 2 N•m
(13 – 18 lbf•in)
2.5 – 3 N•m
(22 – 27 lbf•in)
3.5 – 4 N•m
(31 – 35 lbf•ft)
4 – 5 N•m
(35 – 44 lbf•ft)
M5
3 – 3.5 N•m
(27 – 31 lbf•ft)
4.5 – 5.5 N•m
(40 – 47 lbf•ft)
7 – 8.5 N•m
(62 – 75 lbf•ft)
8 – 10 N•m
(71 – 89 lbf•ft)
M6
6.5 – 8.5 N•m
(58 – 75 lbf•ft)
8 – 12 N•m
(71 – 106 lbf•ft)
10.5 – 15 N•m
(93 – 133 lbf•in)
16 N•m (142 lbf•in)
M8 15 N•m (133 lbf•in) 25 N•m (18 lbf•ft) 32 N•m (24 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 73 N•m (54 lbf•ft)
M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 128 N•m (94 lbf•ft)
M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)
INTRODUCTION
FASTENER INFORMATION
NOTICE
Most components in the vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners
could cause damage to the vehicle or possible
personal injury.
SELF-LOCKING FASTENERS
PROCEDURE
A00A6LA
TYPICAL — SELF-LOCKING FASTENER
The following describes common procedures
used when working with self-locking fasteners.
Use a metal brush or a tap to properly clean a
threaded hole, then use a solvent. Allow the sol-
vent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper
adhesion of the product used for locking the fas-
tener.
LOCTITE
®
APPLICATION
PROCEDURE
The following describes common procedures
used when working with Loctite products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.
Threadlocker Application for
Uncovered Holes (Bolts and Nuts)
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
threads and allow to dry.
3. Choose proper strength Loctite threadlocker.
4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
Threadlocker Application for Blind
Holes
lmr2007-040-004_a
1. On fastener threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
INTRODUCTION
4. Apply several drops along the threaded hole
and at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
Threadlocker Application for Stud
Installation in Blind Holes
lmr2007-040-005_a
1. On stud threads
2. On threads and in the hole
3. On retaining nut threads
1. Clean threads (stud and hole) with solvent.
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
threads and allow to dry.
3. Put 2 or 3 drops of proper strength Loctite
threadlocker on female threads and in hole.
NOTE: To avoid a hydro lock situation, do not ap-
ply too much Loctite.
4. Apply several drops of proper strength Loctite
on stud threads.
5. Install stud.
6. Install cover, part, etc.
7. Apply a few drops of proper strength Loctite on
uncovered stud threads.
8. Install and tighten retaining nut(s) as required.
Threadlocker Application for
Pre-Assembled Parts
A00A3OA
1
2
1. Apply here
2. Do not apply
1. Clean bolts and nuts with solvent.
2. Assemble components.
3. Tighten nuts.
4. Apply a few drops of proper strength Loctite on
bolt/nut contact surfaces.
5. Avoid touching metal with tip of flask.
NOTE: For preventive maintenance on exist-
ing equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.
Threadlocker Application for an
Adjustment Screw
1. Apply here
2. Plunger
1. Adjust screw to proper setting.
2. Apply a few drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
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2012 Ski-Doo MX Z TNT E-TEC 800R Factory Service & Work Shop Manual
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Description
Upon purchasing this manual, you will receive a .PDF file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your 2012 Ski-Doo MX Z TNT E-TEC 800R.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every nut and bolt. With hundreds of pages, it offers solutions for various issues, from simple tasks like an oil change to more complex procedures like a transmission swap. The manual includes numerous illustrations to assist you and features easy-to-understand text.
Utilize the search function to navigate the manual efficiently and print the necessary pages. This Factory Service Repair Manual is designed to walk you through the fundamentals of maintenance and repair, providing step-by-step instructions to equip you with the knowledge mastered by factory-trained technicians.
By utilizing the insights from this service repair manual, any owner can confidently make informed decisions regarding the maintenance and repair of their machine.
Our commitment extends beyond providing a high-quality service manual; we also ensure excellent customer service, guaranteeing your satisfaction.
