BRP SSV KIT 850 W Magneto Kit Installation Guide
- June 15, 2024
- BRP
Table of Contents
SSV KIT – 850 W Magneto Kit
SSV KIT 850 W Magneto Kit
| Product: | Side-by-side |
|---|---|
| Project no: | 487803394 |
| Instruction Sheet P/N: | 487803394 |
| Revision no: | |
| Revision date: | |
| Item covered: | 850 W Magneto 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
– 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.
– 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.
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.
GRADE
| 5.8 | 8.8 | 10.9 | 12.9 |
|---|---|---|---|
| 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) | ||
| M8 15.3 ± 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) | ||
| 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) |
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.
Installation time is approximately 3.0 hours.
parts to be installed
| ITEM | DESCRIPTION | Part number | QTY |
|---|---|---|---|
| P1 | 850W Rotor ass’y | 420685705 | 1 |
| P2 | Stator plate | 420686365 | 1 |
| P3 | Voltage Regulator | 710006824 | 1 |
| P4 | Voltage Regulator Support | 710007523 | 1 |
| P5 | Cable Support | 420251889 | 1 |
| P6 | Gasket (magneto) | 420651201 | 1 |
| P7 | Spacer | 705503238 | 1 |
| P8 | M8 X 16 Flanged Torx Screw | 420440854 | 3 |
| P9 | M6 X 30 Flanged Torx Screw | 420440647 | 3 |
| P10 | M4 X 8 Socket Head Screw | 205063044 | 2 |
| P11 | M6 X 16 Flanged Hex Screw | 207661644 | 1 |
| P12 | M6 Elastic Nut | 234062670 | 5 |
| P13 | 7603 DIN Washer | 504082900 | 1 |
| P14 | 3/16 Black Anodised Pop Rivet | 293150186 | 1 |
| P15 | 371 mm Locking Tie | 293750018 | 5 |
instructions Vehicle Preparation Tilt the bed.
WARNING
Use the designated BRP tool (P/N 529036494) to secure the platform on long
box models
required tool
LONG BOX RETAINER (P/N 529 036 494)
Remove the battery cover.
Disconnect battery.
NOTICE Always disconnect battery before doing any electrical modifications. Do
not place tools on battery. Proceed exactly in this specific order:
- Disconnect BLACK cable (-) first.
- Disconnect RED cable (+) after.
- Secure battery by covering poles with isolating material.
Properly secure the bed and remove bed cylinder. Keep hair pins.
Crankshaft Locking Procedure
NOTE: When crankshaft is locked, the rear piston no. 2 is at TDC. Crankshaft
can not be locked at piston no.1 TDC.
NOTICE To see if the rear piston no. 2 is at TDC ignition refer to
CAMSHAFT TIMING GEAR in the TIMING CHAIN subsection of the SHOP MANUAL.
Remove:
- Spark plug cables and spark plugs of both cylinders.
- Plug screw and O-ring of magneto cover.
- Plug screw
- O-ring
- Crankshaft position sensor.
- Crankshaft position sensor
- Screw
- Plug screw and discard sealing ring.
Crankcase PTO side, front side
- Sealing ring
- Plug screw
Use a 14 mm Allen key to turn crankshaft until piston no. 2 is at TDC.
- 14 mm Allen key
- Flat screwdriver
When rear piston is at TDC marks on magneto flywheel “2” and on the magneto cover are aligned.
- Mark “2” on magneto flywheel
- Notch on magneto cover
- Crankshaft position sensor location
Use a screwdriver to check if the groove in the crankshaft is aligned with the hole.
- Flat screwdriver
- 14 mm Allen key
Lock crankshaft.
required tool
- Crankshaft locking bolt
Gradually insert the tool in the crankshaft groove. Make sure that the tool tip enters the groove and does not jam on the crankshaft balancer surface.
Removing the Magneto CoverDrain engine oil.
Remove dipstick and oil level tube with O-rings.
Disconnect oil pressure switch (OPS) connector.
- Dipstick
- Oil level tube
- Oil pressure switch (OPS) connector
Disconnect stator connector from voltage regulator/ rectifier.
Remove magneto cover retaining screws.
Pull out magneto cover.
Discard the gasket.
Removing the Rotor
Heat screw in order to break the threadlocker.
Remove screw and washer securing rotor to crankshaft.
- Screw M16
- Washer
Remove rotor.
required tools
MAGNETO PULLER (P/N 529 035 748)
CRANKSHAFT PROTECTOR (P/N 529 036 034)
NOTE: Use grease to place protector on crankshaft end prior to screw on
the magneto puller.
-
Magneto puller
Screw magneto puller bolt to remove rotor.
Removing the Sprag Clutch
Install sprag clutch housing in vise. Ensure to use soft jaws in vise to avoid damage.
Heat sprag clutch housing screws in order to break the Loctite.
Loosen screws.
-
Sprag clutch housing
-
Soft jaws
Remove sprag clutch gear.
Remove sprag clutch housing screws and sprag clutch housing.
- Sprag clutch housing screws
- Rotor
- Sprag clutch
- Sprag clutch housing
Removing the Stator
Remove:
– Holding strip screws
– Stator retaining screws
– Stator.
- Holding strip screws
- Wire holding strip
- Stator retaining screws
- Stator
Parts Installation
Installing the Sprag Clutch
For installation, reverse the removal procedure. Pay attention to the following details.
Use service product to clean the following:
– Threads in sprag clutch housing
– Threads of sprag clutch housing screws.
service product
CLUTCH AND PULLEY FLANGE CLEANER PRO S1 (P/N 779244)
Apply service product on threads of M8 X 16 flanged Torx screws [P8].
service product
LOCTITE 648 (GREEN) (P/N 413 711 400)
Install screws but do not torque yet.
Apply engine oil on sprag clutch and sprag clutch gear needle bearing.
Install sprag clutch housing M8 X 16 flanged Torx screws [P8] and sprag clutch
housing. Tighten to specification.
tightening torque
M8 X 16 flanged Torx screws [P8] 30 ± 2 N•m (22 ± 1 lbf•ft)
- M8 X 16 flanged Torx screws [P8]
- Rotor [P1]
- Sprag clutch
- Sprag clutch housing
Installing the Rotor
The installation is the reverse of the removal procedure. However, pay attention to the following.
Clean these components:
– Crankshaft taper
– Oil passage in crankshaft taper
– Thread in crankshaft
– Rotor taper
– Oil bore in rotor.
Service product
CLUTCH AND PULLEY FLANGE CLEANER PRO S1 (P/N 779244)
NOTICE Taper on crankshaft and rotor must be free of grease.
Oil sprag clutch and install sprag clutch gear.
- Apply engine oil here
- Sprag clutch
- Sprag clutch housing
- Sprag clutch gear
Slide rotor onto crankshaft. The woodruff key and the keyway must be aligned.
Rotate starter double gear counterclockwise to align intermediate gear teeth with sprag clutch gear. Ensure the starter gears are completely engaged.
Secure the rotor using the previously removed M16 X 35 screw.
Ensure the threads are clean and Loctite is applied as shown to ensure proper
oil flow for generator cooling. The first three (3) threads must be clean and
free of Loctite.
Tightening torque
Rotor retaining screw
150 ± 10 N•m (111 ± 7 lbf•ft) +
LOCTITE 648 (GREEN) (P/N 413 711 400)
Installing the Stator Plate
Clean inside surface of magneto cover.
Clean fixation holes of any Loctite remaining.
Install spacer [P7] in magneto cover.
Assemble stator plate [P2] using M6 X 30 screws [P9]. Tighten to
specification.
Tightening torque
M6 X 30 screws [P9] 10 ± 1 N•m (89 ± 9 lbf•in)
Install cable holder using two (2) M4 X 8 socket head screws [P10]. Tighten to
specification.
NOTE: Ensure the cable is tight enough so it will not come in contact
with other components.
Tightening torque
M4 X 8 socket head screws [P10] 4 ± 0.5 N•m (35 ± 4 lbf•in)
- Holding strip screws [P10]
- Wire holding strip
- Stator retaining screws [P9]
- Stator [P2] Installing the Magneto Cover
The installation is the reverse the removal procedure. However, pay attention to the following.
Install the NEW magneto cover gasket [P6].
Apply sealant on stator cable grommet as shown in next illustration.
Service product
LOCTITE 5910 (P/N 293 800 081)
OR
DREI BOND SEALING COMPOUND (P/N 420 297 906)
Tighten screws using the following
sequence.
tightening sequence
Tightening torque
Magneto cover screws 10 ± 1 N•m (89 ± 9 lbf•in)
Install locking tie [P15] on stator cable approximately 125 mm (5 in) from
grommet.
Install two (2) locking ties [P15] on the engine
harness.
Install another locking tie [P15] on the yellow
marked position of the stator cable to the engine harness.
Remove CRANKSHAFT LOCKING BOLT (P/N 529 035 617).
Reconnect the oil pressure switch, CPS oil level tube and dipstick.
- Dipstick
- Oil level tube
- Oil pressure switch (OPS) connector
Refill engine with recommended oil.
Voltage Regulator
Remove the 650W regulator and support.
MY20 and later
MY19 and prior
MY19 and prior only
Following the template, drill the first hole for the new support [P4].
NOTE: You will need to pre-drill with a spot drill first because the
hole is at an angle.
Using the support as a template, drill the second hole.
All
models
Install the support [P4].
- On MY20 and later, secure using M6 nut [P12] and M6 X 16 screw [P11]
- On MY19 and prior, secure using M6 nut [P12] and the pop rivet [P14]
- M6 nut [P12]
- M6 X 16 screw [P11] OR pop rivet [P14] Install the 850W regulator [P3]. Secure using M6 elastic nuts [P12].
Remove the factory regulator positive wire (BK/YE) from the
starter relay.
NOTE: Ensure to make a continuity test on the wire
to ensure you removed the correct factory wire.
Connect the negative wire of the new regulator ([P3]) to the battery and the
positive one on the starter relay.
Put dielectric grease on the connector of
the old regulator and tape it.
Connect the regulator to the magneto.
Reinstall all the removed parts.
Template.pdf
(https://brp.secure.force.com/consumer/servlet/fileField?entityId=ka03x000000ZnkaAAC&field=AttachmentBodys)