REAR TRUNK BOX QUICK ATTACH(Kit P/N 703 500 540)

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

– This instruction sheet MUST be given to the purchaser.

� WARNING

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

The following symbols may be used in this document:

Symbol Description

�WARNINGIndicates a potentially hazardous situation which, if not avoided, could result inserious injury or death.

CAUTION: Denotes an instruction which, if not followed, could severely damage vehiclecomponents.

NOTE: Indicates supplementary information needed to fully complete an instruction.

FASTENER GRADE/TORQUE TO BE USED WHEN TORQUES ARE NOT SPECIFIED IN TEXT.FASTENERSIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade

M4 1.5 — 2 N•m(13 — 18 lbf•in)

2.5 — 3 N•m(22 — 27 lbf•in)

3.5 — 4 N•m(31 — 35 lbf•in)

4 — 5 N•m(35 — 44 lbf•in)

M5 3 — 3.5 N•m(27 — 31 lbf•in)

4.5 — 5.5 N•m(40 — 47 lbf•in)

7 — 8.5 N•m(62 — 75 lbf•in)

8 — 10 N•m(71 — 89 lbf•in)

M6 6.5 — 8.5 N•m(58 — 75 lbf•in)

8 — 12 N•m(71 — 106 lbf•in)

10.5 — 15 N•m(93 — 133 lbf•in) 16 N•m (142 lbf•in)

M8 15 N•m (11 lbf•ft) 24.5 N•m (18 lbf•ft) 31.5 N•m (23 lbf•ft) 40 N•m (30 lbf•ft)

M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 72.5 N•m (53 lbf•ft)

M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 127.5 N•m (94 lbf•ft)

M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)

NOTE: The illustrations in this document show typical construction of the different assemblies andmay not reproduce the full detail or exact shape of the parts; however, they represent parts that havethe same or similar function.

NOTE: Installation time is approximately 0.9 hour.

Printed in Canada. (vsi2006-019 ) Instruction Sheet P/N 415 129 062 1 / 6©2005 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.* Trademark of Bombardier Inc. used under license.

PARTS TO BE INSTALLED

PARTS TO BE INSTALLED

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ITEM PN DESCRIPTION QTYP1 205 484 060 M8 x 40 Socket Head Screw 4P2 233 281 414 M8 Flanged Elastic Nut 4P3 293 150 104 4.8 mm (3/16 x .565 in) Rivet 2P4 708 000 480 Spring 1P5 732 610 072 Push Nut 1P6 207 064 544 M6 x 45 Hexagonal Screw 1P7 232 160 600 M6 Hexagonal Jam Nut 2P8 234 062 600 M6 Flat Washer 4P9 291 000 468 Seat Hook 1

P10 703 500 605 Attachment Kit, consisting of:— a) Latch Base (qty 1)— b) Latch (qty 1)— c) Latch Support (qty 1)— d) Anchor (qty 2)— e) Anchor Plate (LH Side) (qty 1)— f) Anchor Plate (RH Side) (qty 1)

1

P11 250 000 198 M8 x 16 Torx† Head Screw 2P12 232 581 414 M8 Elastic Stop Nut 2P13 211 000 121 M6 x 16 Phillips†† Head Screw 4P14 517 302 265 Flat Washer 4P15 233 261 414 M6 Flanged Elastic Nut 6P16 704 901 170 Warning Label (English) 1P17 704 901 171 Warning Label (French) 1

† Torx is a trademark of Camcar Textron — †† Phillips is a registered trademark of Phillips Screw Ltd

2 / 6 Instruction Sheet P/N 415 129 062

PARTS TO BE INSTALLED

NOTE:This kit is used withRear Cargo Box kit(P/N 703 500 532).

INSTRUCTION

Box Preparation

vsi2006-019-002_a

Locate pre-marked places (shown by arrows) todrill holes at the bottom of the box.

Drill six 6.3 mm (1/4 in) holes.

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Screw both M6 hexagonal jam nuts [P7] ontoseat hook [P9].

Slide 2 M6 flat washers [P14] onto seat hook andinsert seat hook by underneath box in rear holes.

Secure hook inside box using M6 flanged elasticnuts [P15]. Do not tighten yet.

Secure both anchors [P10d] on each side at front,underneath box, using M6 x 16 Phillips headscrews [P13] with M6 flat washers [P14] insertedfrom the inside, and M6 flanged elastic nuts [P15],from underneath box.

Luggage Rack Preparation

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Onto outer luggage rack tubing, secure right sideanchor plate [P10f] and left side anchor plate[P10e] using M8 x 40 socket head screws [P1]inserted sideways, and M8 flanged elastic nuts[P2]. Do not tighten yet.

NOTE: Next action is not required on OutlanderMAX where the use of the existing screws isrequired.

Secure anchor plates at their inner ends, usingM8 x 16 Torx head screws [P11], inserted fromtop, and M8 flanged elastic nuts [P2]. Do nottighten yet.

Instruction Sheet P/N 415 129 062 3 / 6

INSTRUCTION

Latching System Assembly

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Assemble latch base [P10a], latch [P10b] andspring [P4] with M6 x 45 hexagonal screw [P6]and push nut [P5].

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Install latch support [P10c] onto luggage rack withlatch assembly [1], aligning top groove [2] ofsupport with welding spot on rack.

NOTE: With a screw driver, hook up latch spring[P4] in support groove and make sure latch baseworks properly.

Secure support with latch assembly onto luggagerack using M8 x 40 socket head screws [P1],inserted from top, and M8 elastic stop nut [P12].

4 / 6 Instruction Sheet P/N 415 129 062

INSTRUCTION

Fit and Adjustment

— At Front —

Latch box to the rack.

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Slide left side [P10e] and right side [P10f] anchorplates backward until box no longer moves frontto rear.

Tighten anchor plates retaining screws to givenvalue (refer to first page of this document).

— At Rear —

Latch box to the rack.

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Adjust hook [P9] with jam nuts [P7] until box nolonger moves up and down.

Tighten hook retaining screws to given value (referto first page of this document).

Final Setting

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Validate positioning of box on luggage rack.— Validate latching/unlatching operation.— Ensure proper torquing of all screws/nuts.

Using latch support as template, drill two 5 mm(13/64 in) holes in luggage rack tubing.

Secure latch support with two 4.8 mm(3/16 x .565 in) rivets [P3].

Stick warning labels [P16] and [P17] onto latchsupport.

Installation is now complete.

Instruction Sheet P/N 415 129 062 5 / 6

INSTRUCTION

Warning Labels

This product comes with warning labels containingimportant safety information.

The labels should be considered permanent part ofthe product. If the labels come off or become hardto read, please contact an authorized BRP dealerfor free of charge replacement.

Any person who intends to use this product shouldread and understand the information contained onthe warning labels before doing so.

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(P/N 704 901 170) [P16]

— English warning label —

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(P/N 704 901 171) [P17]

— French warning label—

Location of the Warning Labels

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— On Latch Support—Illustration shows location of warning labels [P16]and [P17].

6 / 6 Instruction Sheet P/N 415 129 062