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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
Oil seal installer529 036 069 Recommended
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
529 014 500 RecommendedAll models
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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
Propulsion / Transmission
Oil seal installer529 035 693 Recommended
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
Propulsion / Transmission
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
Propulsion / Transmission
Oil seal installer529 036 070 Recommended
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
Outlander, RenegadeP/N
Swing arm retaining nut socket529 035 925 Mandatory
Outlander, RenegadeP/N
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
295 000 069 RecommendedAll models
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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
414 837 300 RecommendedAll models
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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