march 27 2008 service tools 2008-12 - brp...

Subject : Service ToolsDate : March 27 2008 No 2008-12Year

2006-2007-2008Model

All

Mandatory Tools: These tools are absolutely needed to perform certain service procedures.They will be automatically shipped to dealerships. They do not need to be ordered separately.

Recommended Tools: These tools will facilitate the Technicians work. They will not be automatically shipped to dealerships. They need to be ordered separately.

BRP is proud to introduce its latest Service Tools Bulletin. These special tools were designed to help you efficiently service BRP vehicles. Please always make sure to use special tools along with the appropriate Shop Manual(s) and respect all safety measures.

Table of contents Tools by System:

Engine .......................................................................................................................... 2PFuel .............................................................................................................................. 7PCooling ......................................................................................................................... 7PElectrical ....................................................................................................................... 8PLubrication .................................................................................................................... 10PPropulsion / Transmission ............................................................................................ 10PSteering ........................................................................................................................ 13PSuspension .................................................................................................................. 14PVarious ......................................................................................................................... 16P

Index of tools by Part Number: 18P..............................................................................

1/18©2008 Bombardier Recreational Products inc. and BRP US inc. All rights reserved.®™ and the BRP logo are trademarks of Bombardier Recreational Products inc. or its affiliates.

Printed in Canada (vbs2008-013)

Engine

TDC dial indicator 25 mm414 104 700 Recommended

For ignition timing static measurement

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P/NVacuum pressure pump

529 021 800 RecommendedAll models

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P/NLeak test kit (fuel/oil)

529 033 100 MandatoryAll models

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P/N

Spring installer remover529 035 559 Recommended

Replaced by 529035983 or 529035989

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P/NEngine lifting bar

529 035 610 RecommendedTraxter 500

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P/NCrankshaft locking screw

529 035 617 MandatoryQuest 500/610, DS650/Outlander/Renegade

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P/N

Crankshaft locking bolt529 035 645 Recommended

Traxter 500

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P/NSocket 46 mm

529 035 648 RecommendedTraxterCrankshaft nut

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P/NEngine leak down test kit

529 035 661 RecommendedAll 4-stroke enginesTo perform a leak down test on engine.

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P/N

Valve stem seal installer529 035 687 Recommended

610 engine

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P/NValve spring compressor

529 035 724 Recommended4-TEC enginesTo be used with valve spring compressor cup 529 035 764 and 529 036 073

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P/NCrankshaft bearing puller

529 035 752 Recommended610/500 engines

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P/N

2/18Service 2008-12

Engine

Crankshaft bearing puller529 035 753 Recommended

610/500 engines

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P/NCrankcase support

529 035 754 RecommendedOutlander 330/400, Quest 500/610

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P/NValve spring compressor cup

529 035 764 RecommendedV-1000/ V-1300/330/400/490/660/810To be used with valve spring compressor 519 035 724.

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P/N

Piston circlip installer529 035 765 Mandatory

610/500/1503/V-1000 engines

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P/NCeramic seal installer

529 035 766 RecommendedAll V-twin, 330/400, 610/500, 500 eng.Use with 529 036 130

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P/NEngine lifting ring

529 035 770 RecommendedQuest 610/500P/N

Oil pump rotor remover529 035 795 Recommended

DS 50, DS 90 2002/07P/N

Suction pump529 035 880 Recommended

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P/NEngine lifting bar

529 035 898 RecommendedOutlander 330 & 400P/N

Crankcase support (MAG side)529 035 916 Recommended

330/400 engineP/N

Plain bearing remover/installer PTO/MAG529 035 917 Recommended

610, 500, 650, 800 enginesP/N

Piston ring compressor529 035 919 Recommended

V-800 engineP/N

3/18Service 2008-12

Engine

Piston circlip installer529 035 921 Mandatory

330, 400, 500, 650, 800 enginesP/N

Valve guide remover 5 mm529 035 924 Recommended

400, 500, 650, 800 enginesP/N

Camshaft locking tool529 035 926 Mandatory

400, 500, 650, 800 enginesP/N

Oil seal installer529 035 933 Recommended

449/991 engines, Outlander 330/400Use with handle 420 877 650 Same usage as 529 036 069.

P/NStarter drive needle installer

529 035 934 Recommended330/400 engineUse with handle 420 877 650

P/NOil seal protector

529 035 935 Mandatory330/400 engineUse on crankshaft MAG side

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P/N

Piston ring compressor529 035 977 Recommended

330 engineP/N

Engine lifting tool529 036 022 Recommended

V-490, V-660 & V-810 enginesP/N

Drive shaft oil seal installer529 036 028 Recommended

V-490, V-660 & V-810 enginesP/N

Drive shaft oil seal protector529 036 029 Recommended

V-490, V-660 & V-810 enginesP/N

Crankcase support MAG/PTO529 036 031 Recommended

V-490, V-660 & V-810 enginesP/N

PTO cover plain bearing remover529 036 032 Recommended

V-490, V-660 & V-810 enginesP/N

4/18Service 2008-12

Engine

PTO cover oil seal installer529 036 033 Recommended

V-490, V-660 & V-810 enginesP/N

Crankshaft protector529 036 034 Recommended

V-490, V-660 & V-810 enginesP/N

Piston circlip installer529 036 048 Recommended

DS 250P/N

Magneto puller529 036 049 Mandatory

DS 250P/N

Crankshaft protector529 036 051 Recommended

DS 250P/N

Camshaft locking tool529 036 055 Mandatory

DS 250P/N

Piston circlip installer529 036 058 Recommended

V-490 engineP/N


449/991 engines, Outlander 330/400Use with handle 420 877 650Same usage as 529 035 933.

P/NValve spring compressor cup

529 036 073 Recommended449, 991, 610/500 engines, Traxter 500To be used with 529 035 724

P/N

Valve guide remover (6 mm)529 036 074 Recommended

449, 991 enginesvalve guide pusher

P/NValve guide installer (6 mm)

529 036 075 Recommended449, 991 enginesValve guide insertion jig

P/NWrench 11 mm

529 036 076 Mandatory449 engineClutch

P/N

5/18Service 2008-12

Engine

Bearing installer529 036 078 Recommended

449 engineUse with handle 420 877 650

P/NPiston circlip installer

529 036 083 Mandatory449 engineP/N

Camshaft ajustment tool529 036 084 Recommended

449 engineP/N

Valve Guide Installer 6 mm529 036 087 Recommended

1503,Traxter 500, Quest 610/500P/N

Crank lock, driven open tool529 036 098 Mandatory

610/500, 991, V-490, V-660, V-810P/N

Crankshaft locking screw529 036 107 Mandatory

449 engineP/N

Ceramic seal pusher plate529 036 130 Recommended

V-490, V-660 & V-810 enginesUse with ceramic seal installer 529035766

P/NPiston ring compressor

Snap-on RC 980 Recommended4-TECNot sold by BRP

P/NTorque angle gauge

Snap-on TA362 RecommendedUsed on most 4-stroke engines.Not sold by BRP

P/N

Valve stem seal removal pliersSnap-on YA 8230 Recommended

1503, 991 engines, DS650Not sold by BRP

P/N

6/18Service 2008-12

Fuel

Float lever measurement529 035 520 Recommended

Carburetor-equipped vehicles

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P/NFuel pressure gauge

529 035 591 Recommended787 RFI, 793 SDI & 4-TEC enginesReplaced by 529 035 709. Spare plastic clip P/N 275500429

P/NOil/fuel pressure gauge

529 035 709 MandatoryInjection type enginesUse with 529035652, 529035714 & 529036023

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P/N

Fuel line remover529 035 714 Mandatory

Injection modelsUsed also with gauge P/N 529 035 709, 529 035 652 & 529 036 023

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P/NAdjustment tool pilot screw

529 035 732 Recommended

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P/NFuel hose adapter

529 036 023 MandatoryInjection type vehiclesTo be used with 529 035 709. Replacement clip 513 033 135

P/N

Cooling

Test cap529 035 991 Recommended

All modelsTo be used with Vacuum/Pressure Pump 529 021 800.

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P/NCoolant pump oil seal installer

529 036 052 RecommendedDS 250P/N

Water pump seal installer529 036 139 Recommended

449 engineP/N

7/18Service 2008-12

Electrical

ECM adapter tool420 277 010 Mandatory

All modelsAll injected 2-TEC & 4-TEC with VDO ECM

P/NDigital induction tachometer


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P/NWire jumper

529 035 605 RecommendedTraxter

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P/N

T harness529 035 653 Recommended

TraxterTo check shifting.

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P/NCrimping plier for heavy gage wire

529 035 730 RecommendedAll modelsEx.: To crimp battery cable terminals.

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P/NFlywheel puller

529 035 748 MandatoryAll V-twin

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P/N

Digital multimeter (basic model)529 035 774 RecommendedP/N

Flywheel puller529 035 792 Recommended

DS 50/90, MY 2002-7P/N

Magneto puller529 035 798 Recommended

DS 50, DS 90 2002/07P/N

Fluke 115 digital multimeter529 035 868 Recommended

All models

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P/NAMP die

529 035 908 RecommendedAll models with AMP connectorsTo use with crimping tool 529 035 909 to crimp Deutsch connectors.

P/NCrimping tool

529 035 909 RecommendedTo use with compatible die to crimp different connectors

P/N

8/18Service 2008-12

Electrical

Magneto harness adapter529 036 016 Recommended

1503, 449To test the magneto.

P/NMPI-2 interface card

529 036 018 MandatoryReplaces the MPI.P/N

4-pin magneto diagnostic harness529 036 021 Recommended

V-490, V-660 & V-810 enginesP/N

Test probes529 036 063 Recommended

All modelsTo back probe various connectors.

P/NECM adapter tool

529 036 085 Mandatory449, 400 EFI enginesP/N

MPI-2 diagnostic cable710 000 851 Mandatory

All DESS-equipped vehiclesP/N

Multilock terminal housing connector extAMP 755430-2 Recommended

Not sold by BRP

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P/N

9/18Service 2008-12

Lubrication

Hose oil pressure529 035 652 Mandatory

4-TEC enginesUsed with 529 035 709.

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P/NOil pressure adapter

529 036 079 Mandatory449 engineTo be used with 529 035 652.

P/N

Propulsion / Transmission

Drive pulley holder (CVT)529 006 400 RecommendedP/N

Transmission wrench529 035 599 Recommended

TraxterP/N

Clutch assembly holder529 035 618 Recommended

Traxter

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P/N

Clutch spanner529 035 647 Mandatory

Traxter, 449 engine

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P/NSocket spanner

529 035 649 RecommendedOutlander, Traxter & QuestTo remove the pinion screw in the differential.

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P/NBacklash measurement tool

529 035 665 RecommendedOutlander, RenegadeP/N

10/18Service 2008-12



449 engineP/N

Install ring wear529 035 694 Recommended

DS 650Rear axle

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P/NClutch holder

529 035 745 Recommended610/500 engines

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P/N

Clutch puller529 035 746 Mandatory

610/500, V-490, V-660, V-810 engines

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P/NGear lock pin

529 035 747 Recommended610/500, V-490, V-660, V-810 enginesReplaced by 529036098

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P/NOil seal installer (gearbox)

529 035 758 RecommendedV-490, V-660, V-810 enginesUse with handle 420 877 650

P/N

Bearing installer (gearbox)529 035 762 Recommended

V-490, V-660, V-810 enginesUse with handle 420 877 650

P/NBearing installer (gearbox)

529 035 763 RecommendedV-490, V-660, V-810 enginesUse with handle 420 877 650

P/NDriven clutch holder

529 035 771 Recommended330/400, 610/500, V-490, V-660, V-810

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P/N

Bearing alignment tool529 035 806 Recommended

Quest 500 & 650

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P/NOil seal installer

529 035 854 Recommended449 engineP/N

Needle bearing installer (output shaft)529 035 858 Recommended

DS 70, DS 90Use with handle 420 877 650

P/N

11/18Service 2008-12


Clutch holding tool529 035 862 Recommended

Rally 200

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P/NClutch support

529 035 863 RecommendedRally 200

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P/NClutch holding tool

529 035 864 RecommendedRally 200 & DS 250

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P/N

Rear axle key529 035 951 Recommended

DS 650

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P/NClutch puller

529 035 992 RecommendedSarasotaP/N

CV joint extractor529 036 005 Recommended

Outlander/Renegade V-660 & V-810P/N

Clutch/driven spring compressor tool529 036 012 Recommended

Most drive & driven pulleysP/N

Backlash measurement tool529 036 030 Recommended

Outlander/RenegadeP/N

Driven pulley support tabs529 036 047 Recommended

DS 250P/N

Countershaft bearing installer529 036 053 Recommended

DS 250Use with handle 420 877 650

P/NPulley Holder

529 036 054 RecommendedRally, DS 250, DS 70/90P/N

Protection sleeve529 036 068 Recommended

449 engineP/N

12/18Service 2008-12



449 engineinsertion jig for gearshift shaft

P/NProtection sleeve

529 036 071 Recommended449 engineGearshift shaft

P/NAxle key

529 036 082 RecommendedDS 450P/N

Oetiker clamp pincer (CV joint)529 036 120 Recommended

All modelsFor Stepless Low Profile Clamps 192 Clamp pincer with special jaw form

P/N

Steering

Heated grip installer529 035 897 Recommended

Straight grips

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P/NDirection alignment tool

529 036 059 RecommendedAll except DS 450P/N

13/18Service 2008-12

Suspension

Gas shock filling tool503 190 102 Recommended

T/A shocksTo be used with P/N 529035570. Spare needle P/N 529035930.

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P/NBall joint installer

529 000 012 RecommendedREV, RT, DS 650, DS 450P/N

Shock preload adjustment wrench529 032 900 RecommendedP/N

Spring compressor529 035 504 Recommended

No longer sold, replaced by P/N 529 036 007.

P/NShock filling valve

529 035 570 RecommendedT/A shocksP/N

Hub puller529 035 612 RecommendedP/N

Shock wrench529 035 727 Recommended

All T/A shocksP/N

Wrench529 035 729 Recommended

DS 650P/N

Open wrench 50 mm529 035 866 Recommended

RallyRally axle nut

P/N

Ball joint remover support529 035 873 Recommended

REV, RTReplaced by 529036121

P/NBall joint installer support

529 035 875 RecommendedREV, RT, OutlanderP/N

Crow foot529 035 884 Recommended

Rally 200Rear axle nut

P/N

14/18Service 2008-12

Suspension

Bearing remover/installer529 035 918 Mandatory

Outlander, Renegade, DS 450P/N

Trailing arm bearing install./remover529 035 920 Mandatory

Outlander, RenegadeP/N

Bearing remover trailing arm support529 035 922 Mandatory


Swing arm retaining nut socket529 035 925 Mandatory


Spring Remover529 036 007 Recommended

All modelsTo remove coil spring from shock.

P/NBall joint installer

529 036 020 MandatoryOutlander/RenegadeP/N

Rear axle key529 036 046 Recommended

DS 250P/N

Needle bearing installer529 036 109 Recommended

DS 450P/N

Ball joint remover support529 036 121 Recommended

REV, RT, Outlander, roadstersP/N

15/18Service 2008-12

Various

Caillau pliers295 000 054 Recommended

All models

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P/NOetiker Pliers


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P/NOetiker pliers

295 000 070 RecommendedAll modelsP/N

Small hose pincher295 000 076 Recommended

All models

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P/NFlexible spout for oil


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P/NPusher handle

420 877 650 RecommendedAll modelsTo be used with many pushers.

P/N

Supertitanium drill bit 3/16"529 031 800 Recommended

To drill/remove many kinds of rivet.P/N

Large hose pincher529 032 500 Recommended

All models

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P/NCover remover

529 035 622 RecommendedDS 650

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P/N

Cable luber529 035 738 Mandatory

All cablesP/N

Allen key 3 mm529 035 781 Recommended

DS 50, DS 90 2002/07P/N

Output shaft seal installer529 035 941 Mandatory

400 enginesUse with handle 420 877 650

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P/N

16/18Service 2008-12

Various

Spring removal tool529 035 983 Recommended

All models

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P/NBlind hole bearing puller set

529 036 117 RecommendedAll modelsReplaced by 529036056

P/N

17/18Service 2008-12

Index Tool Part Numbers ... Page These tools are mandatory295000054 .............. 529035747 .............. 529035983 .............. 529036120 ..............16 11 17 13295000069 .............. 529035748 .............. 529035991 .............. 529036121 ..............16 8 7 15295000070 .............. 529035752 .............. 529035992 .............. 529036130 ..............16 2 12 6295000076 .............. 529035753 .............. 529036005 .............. 529036139 ..............16 3 12 7414104700 .............. 529035754 .............. 529036007 .............. 710000851 ..............2 3 15 9414837300 .............. 529035758 .............. 529036012 .............. AMP 755430-2 ........16 11 12 9420277010 .............. 529035762 .............. 529036016 .............. Snap-on RC 980 .....8 11 9 6420877650 .............. 529035763 .............. 529036018 .............. Snap-on TA362 .......16 11 9 6503190102 .............. 529035764 .............. 529036020 .............. Snap-on YA 8230 ....14 3 15 6529000012 .............. 529035765 .............. 529036021 ..............14 3 9529006400 .............. 529035766 .............. 529036022 ..............10 3 4529014500 .............. 529035770 .............. 529036023 ..............8 3 7529021800 .............. 529035771 .............. 529036028 ..............2 11 4529031800 .............. 529035774 .............. 529036029 ..............16 8 4529032500 .............. 529035781 .............. 529036030 ..............16 16 12529032900 .............. 529035792 .............. 529036031 ..............14 8 4529033100 .............. 529035795 .............. 529036032 ..............2 3 4529035504 .............. 529035798 .............. 529036033 ..............14 8 5529035520 .............. 529035806 .............. 529036034 ..............7 11 5529035559 .............. 529035854 .............. 529036046 ..............2 11 15529035570 .............. 529035858 .............. 529036047 ..............14 11 12529035591 .............. 529035862 .............. 529036048 ..............7 12 5529035599 .............. 529035863 .............. 529036049 ..............10 12 5529035605 .............. 529035864 .............. 529036051 ..............8 12 5529035610 .............. 529035866 .............. 529036052 ..............2 14 7529035612 .............. 529035868 .............. 529036053 ..............14 8 12529035617 .............. 529035873 .............. 529036054 ..............2 14 12529035618 .............. 529035875 .............. 529036055 ..............10 14 5529035622 .............. 529035880 .............. 529036058 ..............16 3 5529035645 .............. 529035884 .............. 529036059 ..............2 14 13529035647 .............. 529035897 .............. 529036063 ..............10 13 9529035648 .............. 529035898 .............. 529036068 ..............2 3 12529035649 .............. 529035908 .............. 529036069 ..............10 8 5529035652 .............. 529035909 .............. 529036070 ..............10 8 13529035653 .............. 529035916 .............. 529036071 ..............8 3 13529035661 .............. 529035917 .............. 529036073 ..............2 3 5529035665 .............. 529035918 .............. 529036074 ..............10 15 5529035687 .............. 529035919 .............. 529036075 ..............2 3 5529035693 .............. 529035920 .............. 529036076 ..............11 15 5529035694 .............. 529035921 .............. 529036078 ..............11 4 6529035709 .............. 529035922 .............. 529036079 ..............7 15 10529035714 .............. 529035924 .............. 529036082 ..............7 4 13529035724 .............. 529035925 .............. 529036083 ..............2 15 6529035727 .............. 529035926 .............. 529036084 ..............14 4 6529035729 .............. 529035933 .............. 529036085 ..............14 4 9529035730 .............. 529035934 .............. 529036087 ..............8 4 6529035732 .............. 529035935 .............. 529036098 ..............7 4 6529035738 .............. 529035941 .............. 529036107 ..............16 16 6529035745 .............. 529035951 .............. 529036109 ..............11 12 15529035746 .............. 529035977 .............. 529036117 ..............11 4 17

18/18Service 2008-12

march 27 2008 service tools 2008-12 - brp...

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