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)
©2012 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved. Instruction Sheet P/N 296 000 353 1/ 8
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.
PARTS TO BE INSTALLED
PARTS TO BE INSTALLED
P1
P3
P2
P5
P6
P7
P8
P4
P8
P9
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)
1
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
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
PREVIOUS
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].
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Supercharger Reassembly
(Clutch Side)
CAUTION Manipulate the friction shims
with care, those parts are sensitive.
NOTE: The2frictionshims[P13]have the same
inner diameter.
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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.
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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)
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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.
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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).
1
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.
A
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
/
