800R E-TEC - Piston Replacement 2012-22 (For Vehicles Used .
Campaign no.: 2012–0022August 15, 2013YEARSubject: 800R E-TEC - Piston Replacement(For vehicles used at an Altitude Below1200m (4000ft))MODELPACKAGEMODEL NUMBER137VACA, VACB, VACC, VACD, VACEVBCA, VBCB, VBCC, VBCD,VBCEVCCA, VCCB,VCCC, VCCD, VCCEVDCA (racing)146Freeride 800R E-TEC154GSX 800R E-TECSEDPCA, DPCBTNTUCCB, UCCCMZCB, MZCC, MZCD, MZCE,MZCF, MZCG, MZCH, MZCJMXCA, MXCB, MXCC, MXCD,MXCE, MXCF, MXCH, MXCJ,MXCKUFCA, UFCBXMX Z 800R E- TECX-RS2012Renegade 800R E-TECAdrenalineBackCountryBackCountry XXSPSummit 800R E-TECXNo.2012-22SERIAL NUMBERSee list attachedUGCA, UGCBUKCA, UKCB, UKCC, UKCE,UKCF, UKCG, UKCH, UKCJBACA, BACB, BACC, BACDCTCA, CTCCCUCB, CUCDCWCA, CWCCUNCA, UNCB,UNCC, UNCD, UNCEUPCA, UPCB,UPCC, UPCD, UPCEURCA, URCB, URCC, URCDPrinted in Canada. (mbg2012-028 en AP) 2013 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.1 / 14
PROBLEMPROCEDUREUnder certain sea-level riding conditions, the piston ring groove may wear prematurely leading toperformance loss and possible engine damage.PROCEDURE HIGHLIGHTSReplace piston as described in the appropriate shopmanualSOLUTIONPerform piston projection measurementReplace pistons, if the vehicle meets both of thefollowing requirements:– Vehicle used generally at an altitude below1 200 m (4,000 ft).– Vehicle has reached 5 000 km (3,125 mi).Perform a fuel system leak testREQUIRED PARTSErase fault codesRe-initialization engine break-in B.U.D.S.Piston ReplacementFor piston replacement procedure, refer to appropriate shop manual.Inside North AmericaDESCRIPTIONPARTNUMBERQTYPiston Kit415 129 8441Coolant219 700 3624 litersSHOP MANUALPART NUMBER2012 Shop ManualREV-XP/REV-XR(P/N 219 100 561)Piston Projection MeasurementREQUIRED TOOLSOutside North AmericaDESCRIPTIONPARTNUMBERQTYPiston Kit619 400 0971Coolant619 590 1834 litersPISTON PROJECTION(P/N 529 036 215)TDC DIAL INDICATOR(P/N 295 000 143)Parts need to be ordered through regular channels.NOTE: The Piston Kit includes enough gaskets torepair the majority of vehicles. If different thickness are required, you need to order them separately.GASKETTHICKNESSPARTNUMBERINCLUDED INTHE KIT0.5 mm420 430 080NO0.6 mm420 430 081NO0.7 mm420 430 082YES0.8 mm420 430 083YES0.9 mm420 430 084YES1.0 mm420 430 085YES1.1 mm420 430 086NO1.2 mm420 430 087NO1. Install the TDC dial indicator on the piston projection tool.2. Place piston projection tool on a flat steel surface.3. Rotate dial indicator face to position the 0 in linewith needle.mmr2011-010-002 aSETTING THE ZERO4. Install tool on PTO cylinder.2 / 142012-22WARRANTY CAMPAIGN
5. Center tool with cylinder to ensure that dial indicator reads piston dome.mmr2011-010-004TYPICAL8. Check if piston projection is according to specification.mmr2011-010-003PISTON PROJECTION SPECIFICATIONTOOL PROPERLY CENTERED6. Ensure that PTO piston is set to TDC.7. Read dial indicator as follows:7.1 Calculate the number of notches thepointer traveled.NOTE: The gauge pointer will move clockwise. Read the pointer travel, NOT thenumber where the pointer stops.7.2 Note measurement.Example:MODELSERVICE LIMITENGINE BLOCKIDENTIFICATIONNUMBERFreeride(CAN/USA) 1.82 mm to 1.92 mmSummit(.072 in to .076 in)(CAN/USA)64130411.62 mm to 1.72 mm(.064 in to .068 in)6413046All OtherThe cylinder block identification number is locatedon the intake flange of cylinder block.mmr2012-021-001 ammr2012-035-004 b1. Pointer travel: 64 notches, which means .064 inchNOTE: In the example above, the correct measureis .064 inch, (NOT .036 inch).WARRANTY CAMPAIGN1. Identification numberNOTICE Take care to use the proper specifica-tion according to the type of engine and themodel of vehicle.9. If piston projection is out of specification, replace base gasket.2012-223 / 14
NOTE: A thicker base gasket will lower the pistonprojection measurement.Refer to CYLINDER BASE GASKET table in TOPEND (800R ENGINES) subsection of the 2012SHOP MANUAL REV-XP/REV-XR10. Reinstall engine parts.Fuel System Leak TestREQUIRED TOOLSFUEL HOSE ADAPTER(P/N 529 036 023)mmr2008-030-003PRESSURE GAUGE WITH FUEL HOSE ADAPTERPRESSURE GAUGE(P/N 529 035 709)1. Ensure there is enough gas in fuel tank.2. Install a rag under the ECM hose quick connectto catch fuel spillage.3. Disconnect fuel supply hose from ECM.mmr2009-071-003 aTYPICAL1. ECM2. Fuel pressure hose fitting3. Fuel hose adapter to ECM fitting4. Fuel hose adapter to pressure gaugeWARNINGWhen carrying out this test, ensure fuel is notleaking from test equipment onto electricalcomponents.mmr2009-071-002 aTYPICAL1. ECM2. Fuel pressure hose3. Release button, quick disconnect fitting4. Install the fuel hose adapter and the pressuregauge between fuel pressure hose and ECM.4 / 14NOTE: The pump should be activated for 15 sec-onds to ensure proper bleeding of the system.5. Connect the emergency engine stop switch(D.E.S.S. post) to the vehicle.6. Install the tether cord cap (D.E.S.S. key) on theemergency engine stop switch.7. Connect vehicle to the latest version ofB.U.D.S.8. Perform calibration or software update if askedfor.9. Select the ECM and Activation tabs.10. Click on the Fuel Pump (Click/Hold) button inthe Activate field.2012-22WARRANTY CAMPAIGN
18. Reinstall the fuel pressure hose on ECM andgently but firmly pull on hose to ensure quickdisconnect fitting is properly locked and secure on the ECM.Fault Codes Erasing1. Connect vehicle to the latest applicable versionof B.U.D.S., refer to the COMMUNICATIONTOOLS AND B.U.D.S. subsection.2. Select the Faults tab.3. Click on Clear Occurred Faults.mmr2009-071-001 b1. Activation tab2. Fuel Pump (Click/Hold) buttonNOTE: The fuel pump will run as long as you holdthe Fuel Pump (Click/Hold) button in B.U.D.S.11. Monitor the pressure gauge.Fuel pressure should rise to approximately303 kPa (44 PSI).12. Release the Fuel Pump (Click/Hold) buttonFuel pressure should decrease and stabilize to approximately 210 kPa (30 PSI).Fuel pressure should remain stable.13. Check fuel system for leaks, especially aroundthe injector hose fittings.14. Remove tether cord cap (D.E.S.S. key).15. Place the end of the adapter waste hose in thefuel tank filler neck.16. Carefully bleed away fuel system using thebleed valve on the fuel hose adapter.Engine Break-inRe-InitializationIMPORTANT: Re-Initialize break-in period inB.U.D.S.1. Select the Setting and ECM tabs.2. Click on the Restart button in Restart Break-inbox.mmr2009-017-004 aen1. Click on RestartNOTE: The oil consumption is purposely increasedduring break-in period.3. Install all remaining parts.WARRANTYPiston ReplacementSubmit a warranty claim using the following information.For claiming procedure, refer to the DEALER/DISTRIBUTOR WARRANTY GUIDE.The involved units for the piston replacement appear in the Campaign Monitoring and Unit Historysections of BOSSWeb.mmr2009-071-003 b1. Pressure gauge bleed valveCAMPAIGN NUMBER2012-0022Claim TypeCampaign ClaimActionRepairFlat Rate Time4.0 hourExpiry DateAugust 15, 2016CAUTION The fuel system is pressurized.Open valve slowly.17. Remove pressure gauge and fuel hoseadapter.WARRANTY CAMPAIGN2012-225 / 14
Click in the REPAIR BOX while completing yourclaim on BOSSWeb.mbg2012-010-004 benParts ReturnDealers and distributors are required to return removed parts to support their claims.Shipping AddressesUSA DEALERSCANADIANDEALERSOTHERSCOUNTRIESBRPc/o Warranty Department7575 Bombardier CourtWausau, WI 54401BRPWarranty Parts Inspection Center565 de la MontagneValcourt, QC, J0E 2L0Contact your local distributoror BRP Regional Office.Warranty Shipping Address DecalsWarranty shipping address decals can be orderedif needed.6 / 14COUNTRYPART NUMBERU.S.A.480 901 601Canada484 500 0012012-22WARRANTY CAMPAIGN
SERIAL NUMBER LISTING OF 2012 INVOLVEDVEHICLESModel: BACAModel: CTCA (cont’d)Model: CTCA (cont’d)From 000001 to 000202From 000238000245000251000256000262From 000268From 000271000274000278000280000282000289000291From 000293From 000297From 000302From 000306From 000310000313From 000315From 000319000332From 000336000339000341From 000344From 000353000356From 000359000363000368000372000390From 000394000416000419From 000473000480From 000482000488000492From 000499000509From om 000585000608000636000640From 000645 to 0739000763000771000777000789000798Model: BACBFrom 000001 to 000047Model: BACCFrom 000001 to 000309Model: BACDFrom 000001 to 000071Model: 54000067000070From 000072000080000083000088From 0142000146000148000151000154000166000169From 000173000178From 000181000192From 000194From 000197000200000207000214000219From 000222000231From 000233to 000073to 000092to 000174to 000182to 000195to 000198to 000228to 000234WARRANTY CAMPAIGNto 000240to 000269to 000272tototototo000295000299000304000307000311to 000317to 000327to 000337to 000346to 000354to 000360to 000396to 000474to 000483to 000500to 000520to 0005872012-22Model: CTCC000006000011000013000015000018000020000022From 000024From 000027From 000033000036000038000041000044From 000046From 000051000056From 000059From 000064From 000069From 000072From 000075From 000080000084000086From 000088000093From 000095From 000101From 000105000113From 000115From 000122From 000125000128to 000025to 000030to 000034to 000049to 0082to 000091to 000099to 000103to 000111to 000119to 000123to 0001267 / 14
Model: CTCC (cont’d)000130000135000139000142From 000145000148000150From 000152000158000161From 000164From 000170From 000175From 000179From 000186000193From 000195From 000198000201From 000203000206000208From 000210From 000214000218From 000221000224From 000231000240From 000243From 000246000251000254From 000256From 000264From 000267000273From 000278From 000286From 000291000294000299From 0393From 000395From 000401000410000415From 0004248 / 14to 000146to 000153tototototo000167000172000176000183000188to 000196to 000199to 000204to 000211to 000216to 000222Model: CTCC (cont’d)000428From 000435000442000444From 000449000453000458000460From 000463000466From 000471000474000488000496000501From 000509From 000513000517000528000537From 000539From 000546000550000553000555000561000563to 000436to 000451to 000464to 000472to 000511to 000514to 000542to 000547to 000235Model: CUCBto 000244to 000247to 000261to 000265to 000271to 000283to 000287to 000292to 000302to 000396to 000403to 000426From 000001From 000004From 000007From 000016From 000020000026From 000029000034From 000036000040000043From 000046From 000052From 000057From 000061From 000067000072000074From 000076From 000085From 000089From 000092From 000102From 000108From 000111000121From 000129tototototo000002000005000011000018000024to 000032to 13to 0001302012-22Model: CUCB (cont’d)000132From 000134From 000137000140000142000144From 000147000155000158000162000168000170000176From 000182From 000189From 000192From 000199From 000205000208From 000210From 000217000221000223From 000226From 000230000233000235000239000241000244000246From 000248000251000253000255From 000262From 000272000275From 000277000280000283From 000286From 000290000293000295000302From 000304000308From 000310000313to 000135to 000138to 000150tototototo000183000190000193000200000206to 000215to 000219to 000228to 000231to 000249to 000270to 000273to 000278to 000288to 000291to 000305to 000311Model: to000004000010000016000020WARRANTY CAMPAIGN
Model: CUCD (cont’d)000022From 000024From 000028000032From 000039From 000043000048From 000053000057From 000060000063From 000065From 000091From 000098000102000104From 000109From 000114From 000117000122000124000126000128From 000130000139From 000142From 000148000154000156From 000158000162000164From 000166From 000170From 000173000176000178From 000180From 000183From 000186From 000189From 000196From 000201From 000211000216000218000221From 000227From 000233000239From 000247From 000251From 000258From 000264From 000268to 000026to 000030to 000041to 000046to 000055to 000061to 000088to 000094to 000100to 000112to 000115to 000120to 000136to 000146to 000149to 000159to 000167to 000171to 000208000214Model: CUCD totototo000276000281000284000292Model: CWCAFrom 000007 to 000008000013000033From 000038 to 000039000045000049From 000055 to 0247000270000316000354Model: CWCC000007000018From 000031 to 000032000036From 000038 to 0135000138Model: DPCAFrom 000001 to 000159Model: DPCBFrom 000001 to 000249Model: MXCEFrom 000001 to 000072Model: MXCFFrom 000001 to 000190Model: MXCHFrom 000001 to 000277Model: MXCJFrom 000001 to 000102Model: MXCKFrom 000001 to 000028Model: MZCBFrom 000001 to 000178Model: MZCCFrom 000001 to 000037Model: MZCDFrom 000001 to 000172Model: MZCEFrom 000001 to 000096Model: MZCFFrom 000001 to 000353Model: MZCGFrom 000001 to 000068Model: MZCHFrom 000001 to 000314Model: MZCJFrom 000001 to 000125Model: UCCBFrom 000001 to 000197Model: UCCCFrom 000001 to 001012Model: UFCAFrom 000001 to 000143Model: UFCBFrom 000001 to 000923Model: MXCAto 000229to 000237Model: UGCAFrom 000001 to 000188From 000001 to 000176Model: MXCBModel: UGCBtototototoFrom 000001 to 000035From 000001 to 000682Model: MXCCModel: UKCAFrom 000001 to 000269From 000001 to 000029Model: MXCDModel: UKCBFrom 000001 to 000432From 000001 to 000018000248000254000262000266000272WARRANTY CAMPAIGN2012-229 / 14
Model: UKCCFrom 000001 to 000038Model: UKCEFrom 000001 to 000190Model: UKCFFrom 000001 to 000066Model: UKCGFrom 000001 to 000213Model: UKCHFrom 000001 to 000083Model: UKCJFrom 000001 to 000353Model: 99000117Model: 39000049000051000066000072000076From 000082 to 000083000097000111From 000135 to 000136000172000189000193From 000210 to 00021200021600023500025000026000027100027710 / 14Model: UNCB (cont’d)000288From 000302 to 43Model: 73000075From 000079000083From 000092From 000097From 000102From 000107From 000120From 000123000132000136000139000141From 000143000149to 0129From 000132From 000137From 000144From 000151000160From 000162From 000166000169From 000172From 000175From 000180000186From 0232000236000244000247000249From 000255000259From 0326totototo000135000141000149000155to 000164to 000167to 000173to 000177to 000181to 000190to 000256to 000263Model: UNCEFrom 000001 to 000148Model: UPCAto 000144Model: UNCD000017000042From 000069000077000083000087000089From 000091From 000096From 000100From 000111From 000114Model: UNCD (cont’d)to -22000003From 000014000023000027From 000029000041From 000047000054000066000068000070From 000074000080000082000089000096to 000015to 000030to 000049to 000075WARRANTY CAMPAIGN
Model: UPCA (cont’d)000101000104From 000106000123From 000126From 0174From 000176000182000186000188000190000192From 000195From 000200000203000205000207From 000210to 000107to 000127to 000131to 000177to 000196to 000201to 000212Model: UPCBFrom 000002From 000007From 000013000024000027From 000034From 000037From 000041From 000047000051From 000059From 000062000065From 000067From 000072From 000077From 000083From 000086000091From 000094From 000099From 000106000111000113From 000115From 000123From 000128000135to 000004to 000008to 000015totototo000035000038000043000048to 000060to 000063tototototo000070000075000079000084000088to 000097to 000103to 000107to 000116to 000124to 000129WARRANTY CAMPAIGNModel: UPCB (cont’d)From 000139000153From 000163000174From 0228From 000230000234000246000248From 000250From 000254000260From 000264From 000268000273From 000280000294From 000297From 000303From 000306000312000324000326From 000328000331From 000333From 000340000344From 0403000408From 000423000427000429From 000433000438000449000452000468000472to 000140to 000164to 000179to 000232to 000251to 000255to 000266to 000271to 000288to 000298to 000304to 000310to 000329to 000335to 000341to 000348to 000424to 000434Model: UPCCFrom 000002From 000014000018From 000020From 000023000027000029000032000036000039From 000044000047000050000052000056From 000058000062From 000064000071000075000081From 000085From 000090From 000095From 000101From 000104000107000111From 000113000121000124000128From 000130000133000135From 000137000142From 000145From 000149From 000154000161From 000163000167From 000169From 000173From 000176000184From 000189to 000021to 000025to 000045to 000060to 000067tototototo000088000091000099000102000105to 000114to 000131to 000140to 000147to 000151to 000155to 000164to 000171to 000174to 000178to 000191Model: UPCDFrom 000002From 000007From 000016From 0000200000240000292012-22to 000003to 000015totototo00000400001100001700002111 / 14
Model: UPCD (cont’d)000031From 000039000044000047000050From 000052000057From 000059000065From 000068000071From 000074From 000082From 000086000091000093From 000104From 000107From 000116000123000126000129000133000135From 000137000140From 000145From 000151000156From 000159From 000166000169000171From 000173000178000184000187From 000192From 000200000203000205000208000210000218From 000220000228000230From 000232000235000240000244From 00025000025900026400026900028412 / 14to 000040to 000055to 000061to 000069to 000076to 000083to 000087to 000105to 000113to 000118Model: UPCD (cont’d)000286000288000290000292From 000298From 000305From 000312000317From 000319000322From 000325000329000339000341000344From 000346000352From 000359From 000363000373000377From 000379to 000301to 000307to 000314to 000320to 000326to 000348to 000360to 000364to 000148to 000152to 000160to 000167to 000175to 000193to 000201to 000221to 000251From 000001000005From 000007From 000011From 000018From 000025000036From 000039From 000051From 000055to 000081to 000090to 000100to 000106to 000110to 000120to 000131Model: URCCto 000033Model: URCDModel: URCAto 000004to 000011to 000042to 000050to 000056to 000064Model: URCBto 000233to 000062to 000065to 000070to 000022to 000380From 000001 to 000340From 000342 to 000354From 000356 to 000513From 000002From 000006000013000016000019From 000021000024From 000027000037From 000040000045From 000047000052From 000054000058From 000060From 000060From 000064From 000069000074From 000078000086From 000088000094From 000097From 000103From 000109000114000117From 000119000126000128From 000130From 000001From 000012From 000016000024From 000027000030000032000034000036000039From 000041From 000054From 000058000064From 000067From 000077Model: UPCEto 000138Model: URCB (cont’d)to 000003totototo000009000016000022000034to 000047to 000053to 0000572012-22000001From 000003From 000007000011000013000015From 000017From 000030From 000037000041From 000045From 000049From 000056From 000062000069From 000072From 000079From 000082From 000086From 000090to 000010to 000014to 000022to 000028to 000051to 000056to 000062to 000075to 000095to 000004to 000009to 000028to 000035to 0077000080000084000088000094WARRANTY CAMPAIGN
Model: URCD (cont’d)From 000096000102From 000108From 000114000117From 000119000134to 000100to 000112to 000115Model: VACE (cont’d)From 000053 to 000056From 000058 to 000060From 000062 to 0000
For claiming procedure, refer to the DEALER/DIS-TRIBUTOR WARRANTY GUIDE. The involved units for the piston replacement ap-pear in the Campaign Monitoring and Unit History sections of BOSSWeb. CAMPAIGN NUMBER 2012-0022 Claim Type Campaign Claim Action Repair Flat Rate Time 4.0 hour Expiry Date August 15, 2016 WARRANTY CAMPAIGN 2012-22 5 / 14
PADI Independent Study Assignments Tec 40 Tec 40 Knowledge Development One Manual Supported Content Study assignment: Tec Deep Diver Manual, pgs xi, pg xiii Your Obligations and Responsibilities, pg xiv Diver Accident Insurance, pg 1-9 including Tec Exercise 1.1. Disregard Tec Deep a
Temperature at the center of piston head T. c 260. 0. c to 290. 0. c Temperature at the edge of piston head T. e 185. 0. c to 215. 0. c Maximum gas pressure p 15.454N/mm. 2 Bore or outside diameter of piston D 57mm Thickness of piston headt. h 5.45mm. Piston rings
Intake valve Outlet valve Piston Cylinder Piston rod Crank shaft. 5 Industry and trade need safe solutions: Therefore, BOGE piston compressors . Piston compressor Compressed air receiver Refrigerant dryer Piston Compressors. 6 The K Series: compact, cost efficient, consistently oil free.
for the simple piston and reduced skirt length piston. by changing the geometry of the piston and it is suggested that which piston is better for same thermal load. Steady state thermal analysis of the Piston have been done in ANSYS 14.5. KEYWORDS . Thermal stress, ANSYS 14.5, Heat flux, Thermal analysis. 1.INTRODUCTION
surface of the piston. Pistons fail mainly due to mechanical stresses and thermal stresses. Analysis of piston is done with boundary conditions, which includes pressure on piston head during working condition and uneven temperature distribution from piston head to skirt. Jadhav failure of piston due to various thermal and mechanical stresses is
For the analysis of piston input conditions and process of analysis, a lot of literature survey has been done. Comparative study is done to select best material. . gas pressure and the working condition may cause the failure of piston such as piston side wear, piston head or crown cranks and piston over heating-seizure and so on. Therefore .
A piston is a component of reciprocating IC engines. It is the moving component with in a cylinder and is made of gas-tight by piston rings. In an engine, piston is used to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod. Piston endures the cyclic gas pressure and the inertial forces at work, and this working
4 ASTM D 4255 Two-Rail Shear Test 4 5 ASTM D 4255 Three-Rail Shear Test 5 6 Iosipescu (V-Notched) Shear Test Fixture and Specimen 6 7 Compact Shear Test Fixture and Specimen 6 8 Orientation of Finite Element Model 8 9 Initial Rectangular Specimen Investigated 10 10 Initial Trapezoidal Specimen Investigated 10 11 Standard Tab Specimen Configuration 12 12 Extended Tab Specimen Configuration 12 .
