BRP MY19 SSV KIT Smart Locker Kit Installation Guide
- June 17, 2024
- BRP
Table of Contents
BRP MY19 SSV KIT Smart Locker Kit
INSTALLATION GUIDE
Specifications:
- Product: Smart-Locker Kit Maverick MY19
- Project no: 487802963
- Instruction Sheet P/N: 487802963
- Revision no: N/A
- Revision date: N/A
SSV KIT – Smart-Locker Kit Maverick MY19
- Product: Side-by-side
- Project no: 487802963
- Instruction Sheet P/N: 487802963
- Revision no:…………………….
- Revision date:………………………..
- Item covered: Smart-Locker Kit Maverick MY19
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
componentsor 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)). Itis not recommended for units other than the
one (those) for which it was sold.
– 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.
WARNING
Some important safety information and/or operating instructions dedicated to
the end user might be included inthis instruction sheet. Make sure to give the
kit part number as well as the instruction sheet included with thiskit to the
customer. Verify that the customer has access to all the information required
for proper use of theaccessory.
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 reproducethe full detail or exact shape of the parts; however, they represent parts that have the same or similar function.
In the pictures below, parts may have been removed for clarity purposes.
Installation time is approximately 3.0 hour.
PARTS TO BE INSTALLED
ITEM| DESCRIPTION| Part
number| QTY
---|---|---|---
P1| FDM module| 710006479| 1
P2| Front differential wiring harness| 710006201| 1
P3| FDM support| 710005807| 1
P4| 4×4 Mode differential switch| 710006040| 1
P5| Cotter pin| 211400017| 4
P6| Cotter pin| 250400084| 2
P7| M10 x 20 Flanged screw| 207502046| 4
P8| PT type K-50 x 16 Screw| 250000959| 4
P9| M12 Elastic flanged nut| 207582044| 4
P10| M10 Elastic flanged nut| 233201416| 3
P11| 368mm Locking tie| 293750008| 15
INSTRUCTIONS
Vehicle Preparation
1. Disconnect the battery.
NOTICE
Always disconnect battery before doing any electrical modifications. Do not
place tools onbattery. Proceed exactly in this specific order:
– Disconnect black cable (-) first.
– Disconnect red cable (+) after.
Differential Installation
1. Drain the differential. Refer to PERIODIC MAINTENANCE PROCEDURES
subsection in the shop manual.
2. Remove both drive shafts. Refer to FRONT DRIVE subsection in the shop
manual.
3. Remove the RH upper suspension arm. Refer to FRONT SUSPENSION subsection
in the shop manual.
4. Remove the propeller shaft of the differential.
5. Remove the four retaining screws from the bottom skid plate.
6. Remove the differential from the RH side of vehicle.
7. Install the new Smart-Lok differential and fix it with the four new bolts
in this kit.
8. Install the new differential with associated half-shafts (sold separately)
and reinstall all previously removedparts with provided hardware.
Harness Installation
1. Connect the harness (P/N 710006201) to the vehicle and connect the connectors to the Smart-Lokdifferential.
NOTE : A connector is identified with a yellow tape as shown to avoid confusion and ensure proper wiring.
1. Differential
2. Connector with a yellow tape
2. Disconnect and remove the factory installed 4×4 switch.
1. Mode 4×4 switch
3. Connect the 4×4 differential switch [P4]. Connect the 4×4 mode selector switch (sold separately) in thedesignated connector identified by a yellow tape on the harness.
1. Mode 4×4 differential switch [P4] 2. Smart-Lok switch location
Module Installation
1. Remove all installed switch on the dash.
2. Remove the seven screws and the two Tuflok plastic rivet retaining the
dash.
1. Screw
2. Tuflok plastic rivet
3. Remove the clip holding the dash and remove the dash.
4. Apply pressure on the FDM module [P1] to clip it on the FDM support [P3].
5. Install the FDM support [P3]with four PT type K-50 x 16 Screw [P8].
Tightening torque
PT type K-50 x 16 Screw [P8]| 6 to 6.5 N•m (53 to 58 lbf•in)
6. Reinstall the vehicle dash. The installation is the reverse of the removal
procedure.
7. Connect the connector of the FDM module [P1].
8. Secure all wires using locking ties [P12].
9. Reconnect the battery.
NOTICE
Connect RED cable (+) first then BLACK cable (-).
10. Turn on the vehicle.
11. Verify on the multifunction dial for any error message.
12. Put the switch in 4×4 position. The switch should lit up.
13. Verify on the multifunction dial for any new error message.
14. If the switch doesn’t light up:
14.1 Turn off the vehicle.
14.2 Verify all connections (module, switches, differential, power, etc.)
14.3 Turn the vehicle back on.
14.4 Repeat step 11 and 12. If switch doesn’t turn on, contact your local BRP
dealer fore a more in-depthtroubleshooting.
NOTICE
Make sure power harness does not come into contact with any sharp edge, mobile
partsand hot surfaces before securing it in place.
Use
This switch selects 2 wheel drive or 4 wheel drive mode when the vehicle is
stopped and the engine is running.
The front diff. lock can be activated on the fly, no need to stop the vehicle
to engage. To deactivate, push again on the switch. When the vehicle is turned
off, the front diff lock will be deactivated.
NOTICE The vehicle must be stopped to engage or disengage the 2WD/4WD switch. Mechanical damage may occur if switch is engaged or disengaged while driving. ALWAYS unlock the front diff. before disengaging 4WD.
The front differential is fully locked when the switch is pushed upward. It’s a momentary position. When the front diff is locked, the switch light will illuminate and a message will appear in the cluster for 2 seconds to say “DIFFLOCK”. The light will turn off when the differential is unlocked and a message in the cluster will appear and show “SMARTLOK”, meaning that you are back in the automatic mode.
When the front differential is locked, the effort to turn the steering wheel might be higher and the response might be slower.
WARNING
Abruptly changing direction can cause loss of control or injury. Never engage Front Diff Lock before entering a turn or when turning.
The 4WD mode is engaged when the switch is in the middle position.
The 2WD mode is engaged when the switch is pushed downwards. The vehicle is
then rear wheel drive only.
Frequently Asked Questions (FAQ):
Q: How long does it take to install the Smart-Locker Kit Maverick MY19?
A: The installation time is approximately 3.0 hours.
Q: What should I do if I encounter any hazardous situation during
installation?
A: If you encounter any hazardous situation, refer to the WARNING symbols in the document and take appropriate precautions to avoid any risks.
References
- brp--c.vf.force.com/apex/Article_Detail_Instruction_Sheet_Print?id=kA00c000000y9Nr&lang=en_US
- brp--c.vf.force.com/apex/Article_Detail_Instruction_Sheet_Print?id=kA00c000000y9Nr&lang=en_US#googtrans(en|en)