Air Intake Snorkel Kit

Transcription

1 SSV KIT - Air Intake Snorkel Kit Part number (SKU) : Product: Side-by-side Project no: Instruction Sheet P/N: Revision no: Revision date: Item covered: Air Intake Snorkel Kit 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 - This kit is designed for specific applicable models only (authorized BRP dealers will confirm model(s)). It is not recommended for units other than the one (those) for which it was sold. - If the installation of the kit requires a template, ensure template is to scale. - Should removal of a locking device (e.g. lock tabs, self-locking fasteners, etc.) be required when undergoing disassembly/ assembly, always replace with a new one. - Torque wrench tightening specifications must strictly be adhered to. - Always wear EYE PROTECTION AND APPROPRIATE GLOVES when using power tools. - Unless otherwise specified, engine must be OFF when performing any operation on the vehicle. - Always be aware of parts that can move, such as wheels, transmission components, etc. - Some components may be HOT. Always wait for engine to cool down before performing work. - This kit does not increase the maximum depth allowed to ride in. Refer to the operator's guide for safe riding depths. WARNING Some important safety information and/or operating instructions dedicated to the end user might be included in this instruction sheet. Make sure to give the kit part number as well as the instruction sheet included with this kit to the customer. Verify that the customer has access to all the information required for proper use of the accessory. NOTE: USE TIGHTENING TORQUES IN THE FOLLOWING TABLE IF NOT OTHERWISE SPECIFIED.

2 GRADE M4 1.8 ± 0.2 N m (16 ± 2 lbf in) 2.8 ± 0.2 N m (25 ± 2 lbf in) 3.8 ± 0.2 N m (34 ± 2 lbf in) 4.5 ± 0.5 N m (40 ± 4 lbf in) M5 3.3 ± 0.2 N m (29 ± 2 lbf in) 5 ± 0.5 N m (44 ± 4 lbf in) 7.8 ± 0.7 N m (69 ± 6 lbf in) 9 ± 1 N m (80 ± 9 lbf in) M6 7.5 ± 1 N m (66 ± 9 lbf in) 10 ± 2 N m (89 ± 18 lbf in) 12.8 ± 2.2 N m (113 ± 19 lbf in) 16 ± 2 N m (142 ± 18 lbf in) M ± 1.7 N m (135 ± 15 lbf in) 24.5 ± 3.5 N m (18 ± 3 lbf ft) 31.5 ± 3.5 N m (23 ± 3 lbf ft) 40 ± 5 N m (30 ± 4 lbf ft) M10 29 ± 3 N m (21 ± 2 lbf ft) 48 ± 6 N m (35 ± 4 lbf ft) 61 ± 9 N m (45 ± 7 lbf ft) 73 ± 7 N m (54 ± 5 lbf ft) M12 52 ± 6 N m (38 ± 4 lbf ft) 85 ± 10 N m (63 ± 7 lbf ft) 105 ± 15 N m (77 ± 11 lbf ft) 128 ± 17 N m (94 ± 13 lbf ft) M14 85 ± 10 N m (63 ± 7 lbf ft) 135 ± 15 N m (100 ± 11 lbf ft) 170 ± 20 N m (125 ± 15 lbf ft) 200 ± 25 N m (148 ± 18 lbf ft) M ± 14 N m (93 ± 10 lbf ft) 205 ± 25 N m (151 ± 18 lbf ft) 255 ± 30 N m (188 ± 22 lbf ft) 305 ± 35 N m (225 ± 26 lbf ft) M ± 20 N m (125 ± 15 lbf ft) 273 ± 32 N m (201 ± 24 lbf ft) 330 ± 25 N m (243 ± 18 lbf ft) 413 ± 47 N m (305 ± 35 lbf ft) The illustrations in this document show typical construction of the different assemblies and may not reproduce the full detail or exact shape of the parts; however, they represent parts that have the same or similar function. In the pictures below, parts may have been removed for clarity purposes. Installation time is approximately 2.0 hours. ICON LEGEND Icon indicates Parts Kept for Reinstallation Parts to be Discarded

3 REQUIRED TOOLS Required T ool Use T1 Drill bit 3.4 mm (9/64 in) To drill the holes in the firewall panel PARTS TO BE INSTALLED ITEM DESCRIPTION Part number QTY P1 Rear CVT Inlet Duct P2 Rear CVT Exhaust Duct P3 Front CVT Exhaust Duct P4 Front CVT Inlet Duct P5 Anti-Rotation Plate Not Available Separately 1 P6 Pop Rivet mm (1/8 in) P7 M3 Flat Washer P8 Pipe Support P9 M6 x 16 Torx Screw P10 Gasket P11 Gasket

4 P12 M5 x 0.8 Panel Nut P13 M5 x 20 Hex. Flange Screw P14 Engine Air Intake Pipe P15 Front CVT Inlet Pipe P16 Rear CVT Inlet Pipe P17 Pipe Holder P18 M6 x 14 Torx Screw P19 Rear CVT Exhaust Elbow P20 Rear CVT Exhaust Adapter P21 Rear CVT Exhaust Outlet Pipe P22 Plate P23 Open Clamp P24 Black Cap P25 M5 x 20 Torx Screw P26 M5 Elastic Flanged Nut P27 Flat Washer P28 K40 x 12 Torx Screw P29 P Trap P30 P Trap Exhaust Pipe P31 Grid P32 Pipe Cover P33 Norma Clamp P34 Norma Clamp P35 Norma Clamp P36 Norma Clamp P37 Turn Key Clamp P38 Airbox Drain Plug P39 Bulkhead Cover P40 Insert P41 M6 x 20 Torx Screw P42 M6 x 50 Torx Screw

5 P43 M6 Elastic Flanged Nut P44 Transmission Hose Not Available Separately 1 P45 Elbow Fitting P mm Locking Tie P47 Pop Rivet 4.76 mm (3/16 in) INSTRUCTIONS Vehicle Preparation 1. Remove the passenger seat. 2. Remove the rear service cover. 3. Remove the driver seat.

6 4. Refer to BODY section of the appropriate shop manual for rear body module removal. 5. Remove the CVT filter. 6. Remove and keep the screws from the intercooler and its support. 7. Remove and discard the screws and remove the intercooler support.

7 NOTE: Do NOT disconnect the intercooler. 8. Loosen up the hose clamps shown below. 9. Remove the air inlet Y pipe and the adapter. 10. Loosen up the hose clamp and remove the rear CVT exhaust.

8 11. Loosen up the hose clamp and remove the CVT inlet hose. 12. Loosen up the hose clamp and remove the front CVT air inlet hose. 13. Loosen up the hose clamp, remove the plastic rivet and remove the CVT front exhaust pipe.

9 14. Inspect the airbox for cracks or failures. Maverick X3 are equipped with three different airboxes. A sealed airbox is required for this kit (P/N ). The sealed airbox is installed on vehicles manufactured after January 1st NOTE: Ensure you have the proper airbox. The sealed airbox has these clamps and one seal onto its cover. It is required for all XMR models. 1. Clamps

10 1. Seal The airbox also needs to be glued in place. if movement can be felt, replace the airbox. Part Installation 1. Locate the anti-rotation plate on the firewall panel. Maverick X3 are equipped with two different firewall panels. The firewall with anti-rotation plate is required for this kit. The plates are factory installed on vehicles manufactured after January 1st Anti-Rotation Plate NOTE: If you are not equipped with the anti-rotation plate, proceed to the following four steps, skip them otherwise. 2. Drill the holes 3.4 mm (9/64 in) for the rivets using the template. 3. Install the anti-rotation plate [P5] using two pop rivets 1/8'' [P6] and two M3 flat washers [P7].

11 1. Pop RIvets 1/8'' [P6] and M3 Flat Washers [P7] 4. Cut the firewall panel in order to reach the new airbox clamps. Use the template and cut the hole as shown below. A reciprocating saw is recommended for the cut. NOTICE Make sure NO other components are near the cut on the firewall panel. 5. Install the bulkhead cover [P39] on the hole.

12 1. Bulkhead Cover [P39] 6. Install the airbox drain plug [P38] with turn key clamp [P37]. 1. Airbox Drain Plug [38] and Turn Key Clamp [37] 7. Remove the valve bracket.

13 1. Valve Bracket 8. Install the front CVT exhaust duct [P3] with norma clamp [P36]. tightening torque Norma Clamp [P36] 2 ± 0.3 N m (18 ± 3 lbf in) 9. Install the P trap exhaust pipe [P30] with norma clamp [P36].

14 1. P Trap Exhaust Pipe [P30] 2. Norma Clamp [P36] tightening torque Norma Clamp [P36] 2 ± 0.3 N m (18 ± 3 lbf in) 10. Install the P trap [P29] between the two seats with norma clamp [P36]. 1. P Trap [P29]