BRP SEA-DOO 420 881 151 Instructions Manual

Brand: BRP

Model: SEA-DOO 420 881 151

Category: Engine

Type: Instructions Manual

Supercharger Repair Kit

185 Engine (Kit P/N 420 881 151)

215/255/260 Engines (Kit P/N 420 881 102)

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

– For safety reasons, this kit must be installed by an authorized BRP dealer.

– This kit is designed for specific applicable models only (authorized BRP dealers will confirm model(s)). It is not rec-

ommended for units other than the one (those) for which it was sold.

– This instruction sheet MUST be given to the purchaser.

– Should removal of a locking device be required (e.g. lock tabs, self-locking fasteners, etc.), 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.

– Some components may be HOT. Always wait for engine to cool down before performing work.

TORQUE TO BE USED WHEN TORQUES ARE NOT SPECIFIED IN TEXT

FASTENER

SIZE 5.8 GRADE 8.8 GRADE 10.9 GRADE 12.9 GRADE

M4 1.8±0.2N•m

(16±2lbf•in)

2.8±0.2N•m

(25±2lbf•in)

3.8 ± 0.2 N•m

(34±2lbf•in)

4.5±0.5N•m

(40±4lbf•in)

M5 3.3±0.2N•m

(29±2lbf•in)

5.0±0.5N•m

(44±4lbf•in)

7.8 ± 0.7 N•m

(69±6lbf•in)

9.0±1.0N•m

(80±9lbf•in)

M6 7.5±1.0N•m

(66±9lbf•in)

10.0 ± 2.0 N•m

(89 ± 18 lbf•in)

12.8 ± 2.2 N•m

(113 ± 19 lbf•in)

16.0 ± 2.0 N•m

(142 ± 18 lbf•in)

M8 15.3 ± 1.7 N•m

(135 ± 15 lbf•in)

24.5 ± 3.5 N•m

(18±3lbf•ft)

31.5 ± 3.5 N•m

(23±3lbf•ft)

40.0 ± 5.0 N•m

(30±4lbf•ft)

M10 29 ± 3 N•m

(21±2lbf•ft)

48 ± 6 N•m

(35±4lbf•ft)

61 ± 9 N•m

(45±7lbf•ft)

73 ± 7 N•m

(54±5lbf•ft)

M12 52 ± 6 N•m

(38±4lbf•ft)

85 ± 10 N•m

(63±7lbf•ft)

105 ± 15 N•m

(77 ± 11 lbf•ft)

128 ± 17 N•m

(94 ± 13 lbf•ft)

M14 85 ± 10 N•m

(63±7lbf•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)

M16 126 ± 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)

M18 170 ± 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)

NOTE: 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.

NOTE: Installation time is approximately 1.1 hours.

Printed in Canada. (ssi2012-019 en TS)

®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

PARTS TO BE INSTALLED

P10

P11

P12

P18

P17 P19

P16

P13

P15

P14

P13

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ITEM P/N DESCRIPTION QTY

P1 420 842 833 Cap nut 1

P2 420 627 418 Washer 1

P3 420 950 950 O-ring 1

P4 420 851 703 Clamp 1

P5 420 947 012 Step collar 1

P6 420 950 940 Oil seal 1

P7 420 926 393 Retaining disc 1

P8 420 832 710 Bearing 2

P9 420 650 270 O-ring 2

P10 420 947 025 Spacer 10.2/16/53.8 1

P11 420 227 685 Thrust washer 1

P12 420 837 897 Compressor shaft assembly 1

P13 420 626 027 Friction shim 2

P14 420 632 435 Needle bearing 1

420 834 551 Drive gear 17T for kit (P/N 420 881 151) (185 engine)

P15 420 835 156 Drive gear 16T for kit (P/N 420 881 102)

(215/255/260 engines)

P16 420 926 377 Lock washer 1

P17 420 939 222 Spring washer 5

P18 420 926 363 L-ring 1

P19 420 942 950 Hex. nut 1

P20 420 827 968 Washer 6,4 (not shown) (kit (P/N 420 881 151)) 3

2 / 8 Instruction Sheet P/N 296 000 353

TOOLS REQUIRED

ITEM DESCRIPTION P/N

1Retaining key 529 036 027

2Support plate 529 035 947

3Gear holder 529 036 025

4Four pin socket 529 035 948

5Bearing support/pusher 529 035 950

6Torx†E8 adapter 529 035 938

7Needle bearing pusher 529 036 237

SERVICE PRODUCTS

DESCRIPTION P/N

Isoflex grease 293 550 021

Loctite 243†(blue – threadlocker) 293 800 060

XPS synthetic blend oil (summer

grade) 293 600 121

Super Lube Grease or equivalent 293 550 030

REPAIR PROCEDURE

General Notes

These new supercharger repair kits replace the

previous kits which are no longer available.

SUPERCHARGER REPAIR KIT

ENGINE NEW REPAIR

KIT

REPAIR KIT

185 (P/N 420 881

151)

(P/N 420 881

150)

215/255/260 (P/N 420 881

102)

(P/N 420 881

101)

Supercharger Removal

1. Remove the supercharger from the engine us-

ing the appropriate

SEA-DOO SHOP MANUAL

Supercharger Disassembly

1. Disassemble the supercharger using the appro-

priate

SEA-DOO SHOP MANUAL

Supercharger Kit Installation

CAUTION Use extreme care when work-

ing with supercharger parts. Supercharger

rotation reaches 45 000 RPM. Any modifica-

tion, improper repair/assembly or damage

on the parts, may result in damage of the

supercharger. Strictly follow the described

procedures.

CAUTION Refer to the appropriate Shop

Manual for reassembly of the Supercharger,

PLUS the added instructions required for

proper assembly of this kit in the below text.

Ensure to use all the new parts in this kit as

some of them are different from the parts that

were removed.

CAUTION It is the utmost importance that

all parts be absolutely clean. Any debris could

causeafailure.

Refer to

SEA-DOO SHOP MANUAL

and perform

the following steps :

1. Press one of the ball bearings on the shaft. To

hold the bearing use following tool.

† Loctite is a registed trademark of Henkel Corp.

† Torx is a trademark of Textron Inc.

Instruction Sheet P/N 296 000 353 3 / 8

REPAIR PROCEDURE

REQUIRED TOOL

SUPPORT PLATE (P/N 529

035 947)

2. Ensure to install the bearing [P8]so the closed

cage faces the impeller.

3. Install the second ball bearing [P8]in the super-

charger housing (engine side).

REQUIRED TOOL

BEARING SUPPORT/PUSHER

(P/N 529 035 950)

4. Ensure the closed bearing cage side is facing

the impeller.

5. Install and torque the retaining disc to specifica-

tion.

TIGHTENING TORQUE

Retainingdisc 40 N•m (30 lbf•ft)

6. Install the spacer sleeve [P10]and the thrust

washer [P11]on the shaft and then press it into

the housing.

7. Install the oil seal [P6]in the retaining disc [P7].

8. Finish assembling the impeller to the compres-

sor shaft assembly [P12].

ssi2005-008-002_a

Supercharger Reassembly

(Clutch Side)

CAUTION Manipulate the friction shims

with care, those parts are sensitive.

NOTE: The2frictionshims[P13]have the same

inner diameter.

ssi2008-003-005_a

1. Prepare parts for assembly by applying ISOFLEX

GREASE TOPAS NB 52 (P/N 293 550 021) as

shown in the next illustrations.

CAUTION No other grease can be used,

otherwise damage to needle bearing will oc-

cur.

Shaft (needle bearing

seat and collar)

Drive gear (inner

diameter)

Friction shims (inner

diameter and both sides)

Lock washer (inner

splines and friction shim

thrust surface)

2. Put the first friction shim [P13]on a workbench.

3. Put the drive gear [P15]on the friction shim.

4 / 8 Instruction Sheet P/N 296 000 353

REPAIR PROCEDURE

4. Install the NEW needle bearing [P14]in drive

gear.

4.1 Position the needle bearing on the drive

gear.

Smr2012-011-003_a

1. Needle bearing

2. Drive gear

3. Friction shim

4.2 Push the needle pins with inner plastic

cage into the drive gear.

REQUIRED TOOL

NEEDLE BEARING

PUSHER

(P/N 529 036 237)

Smr2012-011-005_a

1. Drive gear

2. Outer plastic cage

3. Needle bearing pusher

4.3 Remove needle bearing pusher and dis-

card outer plastic cage.

4.4 Check if all 40 needle pins are in place.

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1. Drive gear

2. 40 needle pins

3. Inner plastic cage

4. Needle bearing pusher

5. Outer plastic cage

5. Place the second friction shim [P13]on the

drive gear.

6. Install the package consisting of friction shim,

drive gear with needle bearing and friction shim

on the hub side of the compressor shaft

NOTE: The inner plastic cage is pushed out upon

installation on compressor shaft.

Smr2012-011-009_a

1. Package of friction shims, drive gear and needle bearing

2. Inner plastic cage

7. Discard the inner plastic cage and install the

lock washer [P16].

8. Apply engine oil to the spring washers [P17].

9. Position the spring washers as per illustration.

ssi2008-003-002_a

Instruction Sheet P/N 296 000 353 5 / 8

REPAIR PROCEDURE

CAUTION When installing the spring

washers [17], take care of the exact instal-

lation direction of the washers.

10. Install the L-ring [P18]on the compressor

shaft.

F00D3CA

11. Apply Loctite 243 (blue — threadlocker)

(P/N 293 800 060) on the hexagonal nut

[P19]threads.

12. Torque hexagonal nut to specification.

TIGHTENING TORQUE

Hexagonal nut 29 N•m (21 lbf•ft)

REQUIRED TOOL

SUPERCHARGER RETAINING

KEY (P/N 529 036 027)

F00D3FA

NOTE: The L-ring will preload the spring washers

after the hexagonal nut is torqued.

Slipping Movement Inspection

1. Hold the gear.

REQUIRED TOOL

SUPERCHARGER GEAR

HOLDER (P/N 529 036 025)

SUPPORT PLATE (P/N 529

035 947)

2. Rotate the clutch by turning the impeller cap nut

counterclockwise a minimum of 10 complete

revolutions.

These rotations will dissipate the grease on the

friction shims and gear enough to get a proper

reading when using a torque wrench to measure

the slip torque of the clutch.

ssi2005-008-005

3. Rotate again the impeller cap nut counterclock-

wise to measure the slip torque of the clutch.

4. The clutch should start to slip within the speci-

fied torque values.

SLIPPING MOVEMENT (NEW SUPERCHARGER)

9 N•m to 14 N•m (80 lbf•in to 124 lbf•in)

NOTE: After a few hours of run time, the slipping

torque will be reduced as the new parts break in.

SLIPPING MOVEMENT (BREAK-IN

SUPERCHARGER)

8 N•m to 12 N•m (71 lbf•in to 106 lbf•in)

NOTE: If a dial torque wrench is not available, a

click type torque wrench can be used. Refer to

the following procedure:

Click type torque wrench procedure

1. Set click type torque wrench at 9 N•m

(80 lbf•in).

– The wrench must click before the clutch

slips.

6 / 8 Instruction Sheet P/N 296 000 353

REPAIR PROCEDURE

2. Set the wrench at 14 N•m (124 lbf•in).

– The clutch must slip before the wrench

clicks.

Supercharger Installation

1. Replace the two O-rings of the supercharger

ground plate with new O-rings [P9]from the kit.

ssi2005-008-007_b

2. Install three washers [P20].

NOTE: Install washers only if the baseplate

part number 867 163 is found on MY 2003

or MY 2004 engines. The Baseplate 867 164

has the correct dimensions without using the

washers.

ssi2004-003-001_a

3. Ensure the three washers are in place (when

required) by visual and/or physical inspection.

NOTE: Some Loctite 495 (General Purpose Instant

Adhesive) (P/N 293 800 021) can be applied on the

spacers to hold them in place.

4. Sealing surface between supercharger and

PTO housing [1]has to be greased with Super

Lube Grease (P/N 293 550 030).

R1503motr247A

CAUTION Do not cover the oil hole of the

supercharger by applying too much grease

(Super Lube). Refer to the following illustra-

tions for details.

ssi2008-003-003_a

GOOD GREASE APPLICATION

1. Oil hole

Instruction Sheet P/N 296 000 353 7 / 8

REPAIR PROCEDURE

ssi2008-003-004_a

BAD GREASE APPLICATION

1. Oil hole

5. Install supercharger ass’y on PTO housing.

6. Apply Loctite 243 (blue — threadlocker) on the

retaining screws.

7. Torque screws to specification.

TIGHTENING TORQUE

Supercharger retaining

screws 9N•m (80lbf•in)

8. To tighten and torque the upper screw, use the

Torx adapter.

REQUIREDTOOL

TORX ADAPTER (P/N 529

035 938)

9. Ensure to install the tool perpendicularly (90°) to

torque wrench to apply the proper torque to the

screw.

F00B1UA 1

1. Tool perpendicular (90°) to torque wrench

A. 90º

CAUTION Not installing the tool as shown

will change the torque applied to the screw.

Proper torque and tightening sequence are

important.

10. When reinstalling exhaust system compo-

nents, validate LH muffler/exhaust pipe

alignment with exhaust manifold. Refer to

appropriate

SEA-DOO SHOP MANUAL

for

the procedure.

Recommended Engine Oil

Use XPS 4-STROKE SYNTH. BLEND OIL (SUMMER)

(P/N 293 600 121).

If the recommended XPSTM engine oil is not avail-

able, use a 10W40 mineral engine oil compatible

with wet clutches.

NOTE: The XPS engine oil has been thoroughly

tested to be free of any additives that could impair

the functionality of the supercharger clutch.

NOTICE NEVER use synthetic oil. This would

impair the proper operation of the super-

charger clutch. Do not add any additives to

the recommended oil. Mineral oils not recom-

mended by BRP may also contain additives

(friction modifiers) that may cause inappropri-

ate slippage of the supercharger and eventu-

ally lead to premature wear. For this reason,

XPS Synthetic Blend Summer Grade oil or a

BRP approved equivalent are the only recom-

mended oils. Use of any oil not recommended

by BRP may void BRP's limited warranty.

8 / 8 Instruction Sheet P/N 296 000 353

BRP SEA-DOO 420 881 151 Instructions Manual

Brand: BRP

Model: SEA-DOO 420 881 151

Category: Engine

Type: Instructions Manual

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