PARTS TO BE INSTALLED - Goodwin Performance · ELECTRIC STARTER (Kit P/N 860 200 627) 600 HO E-TEC, 800R Power TEK, 800R E-TEC The following symbols may be used in this document:
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ELECTRIC STARTER (Kit P/N 860 200 627)600 HO E-TEC, 800R Power TEK, 800R E-TEC
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.
NOTE: The illustrations in this document show typical construction of the different assemblies and maynot reproduce the full detail or exact shape of the parts; however, they represent parts that have thesame or similar function.NOTE: Installation time is approximately 1.3 hours.
PARTS TO BE INSTALLED
ITEM DESCRIPTION PART NUMBER QTY
P1 Electric Starter 515 177 389 1
P2 M8 x 25 Bolt 250 000 248 2
P3 M8 x 35 Bolt 207 583 544 1
P4 M8 Flat Washer 250 200 008 1
P5 Spacer 515 176 500 1
P6 Starter Cable 515 177 208 1
P7 M6 Nut 232 561 434 3
P8 M6 Flat Washer 234 061 410 1
P9 Battery Support 515 177 264 1
P10 M6 Nut 233 261 414 4
P11 M6 x 20 Bolt 207 662 044 2
P12 M6 Flat Washer (18 mm OD) 250 200 082 2
P13 Battery 296 000 295 1
P14 Battery Strip 515 177 266 1
P15 Starter Solenoid 278 003 012 1
P16 M6 x 16 Bolt 207 661 644 3
P17 BLACK Battery Cable 515 176 358 1
P18 M6 Lock Washer 250 200 041 1
P19 RED Battery Cable 515 176 535 1
P20 Fuse Wire 515 176 744 1
P21 Solenoid wiring Harness (long) Not availableseparately 1
1.3 Push securing tab of primary air intakesilencer and pull silencer out of adapterplate.
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1. Primary air intake silencer2. Securing tab
Drive Pulley Removal
All Models1. Remove belt guard.2. To hold drive pulley for removal, use the DRIVE
PULLEY HOLDER (P/N 529 035 674):
529035674
2.1 Install holder on a sliding sheave arm.
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1. Sliding sheave2. Drive pulley holder
2.2 Remove the drive pulley bolt and discardconical spring washer.
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1. Drive pulley bolt2. Discard conical spring washer
2.3 Thread the DRIVE PULLEY PULLER (P/N 529000 064) in drive pulley.
529000064
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1. Drive pulley holder2. Drive pulley puller
2.4 Tighten the puller to extract drive pulley.2.5 Pull out the drive pulley and belt.
4 / 15 Instruction Sheet P/N 487 801 505
INSTRUCTIONS
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Tuned Pipe and Muffler Removal
E-TEC models1. Disconnect the Exhaust Gas Temperature Sen-
sor (EGTS) from muffler and/or exhaust tunedpipe.
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RH SIDE1. EGTS connector
All Models1. Use SPRING INSTALLER/REMOVER (P/N 529 035
983) and remove:
529035983
– Tuned pipe– Muffler
Electric Starter Installation1. Remove and discard the M8 bolt from LH front
engine support.
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1. LH front engine support bolt
2. Remove and discard the M8 bolt from LH rearengine support.
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1. LH rear engine support bolt
3. Remove and discard the three M6 bolts secur-ing engine stopper.
4. Remove engine stopper.
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1. M6 bolts2. Engine stopper
5. Bring starter to its location and position its elec-tric post toward front of vehicle.
6. Loosely install a bolt [P2] as shown.
Instruction Sheet P/N 487 801 505 5 / 15
INSTRUCTIONS
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1. Bolt [P2]
600 HO E-TEC7. Install spacer [P5] as shown.8. Loosely install a bolt [P3] and washer [P4] to
starter.
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TYPICAL1. Starter
Other Models9. Loosely install a bolt [P3] and washer [P4] to
starter.
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1. Starter
All Models10. Place a pry bar between engine and frame (un-
der a crankcase bolt).
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1. Pry bar2. Crankcase bolt
11. Raise engine just enough to loosely install theremaining bolt [P2].
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PRYING ENGINE UP
6 / 15 Instruction Sheet P/N 487 801 505
INSTRUCTIONS
NOTICE Do not raise engine more thanneeded. Damage to others engine supportsmay occur.
12. Torque starter bolts to specification in the in-dicated order.
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TORQUING SEQUENCE — SOME PARTS REMOVED FORCLARITY
TIGHTENING TORQUE
28.5 N•m ± 1.5 N•m (21 lbf•ft ± 1 lbf•ft)
13. Reinstall engine stopper using 3 new bolts[P28]. Torque bolts to specification.
TIGHTENING TORQUE
10 N•m ± 2 N•m (89 lbf•in ± 18 lbf•in)
14. Secure engine support:14.1 Use the original washers.14.2 Use NEW bolts (see table).14.3 Apply LOCTITE 243 (BLUE) (P/N 293 800
060) on bolt threads.
ENGINE SUPPORT BOLT TO USE
Front [P26]
Rear [P25]
15. Torque bolts to specification.
TIGHTENING TORQUE
24.5 N•m ± 3.5 N•m (18 lbf•ft ± 3 lbf•ft)
Starter Cable Connection andRouting1. Connect starter cable [P6] to starter post. Use:
– Washer [P8]– Nut [P7]
2. Position starter cable terminal at an angle of 35°as shown.
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1. Starter post2. 35° angle
3. Torque post nut to specification.
TIGHTENING TORQUE
7.5 N•m ± 1 N•m (66 lbf•in ± 9 lbf•in)
4. From starter location (bold arrow), route startercable [P6] behind oil tank toward battery/sole-noid location.
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TYPICAL
5. Secure cable to engine bay floor using lockingtie [P24] as shown.
6. Secure cable to side member using 3 lockingties [P23], as shown.
Instruction Sheet P/N 487 801 505 7 / 15
INSTRUCTIONS
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TYPICAL1. Locking tie [P24]2. Locking tie[P23]
CAUTION Ensure all terminals are prop-erly crimped on wires/cables and that all con-nector housings are properly fastened. Keepwires/cables away from any rotating, moving,heating, vibrating and sharp edge parts. Useproper fastening devices as required.
Solenoid, Battery and Support
CAUTION Do not connect the BLACK neg-ative cable to the battery until instructed to.That will be done only when all the installationwill be completed.1. Locate the ground wire above the RH footrest.2. Remove and keep M6 screw and washer secur-
ing ground wire to frame.
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RH FOOTREST1. Ground wire2. M6 screw and washer
3. Install battery support [P9] on top of RHfootrest:3.1 Install BLACK battery cable [P17] to
footrest. Position the lock washer [P18]against footrest.
3.2 Install 2 new bolts [P11].NOTE: If there is no threaded inserts on vehi-cle, install nuts [P10] and washers [P12].
3.3 Secure ground wire to battery support[P9]. Use previously removed M6 boltand lock washer. Position the lock washeragainst battery support.
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1. Ground wire2. Previously removed lock washer. WASHER AGAINST BATTERY
SUPPORT3. Previously removed boltP18: LOCK WASHER AGAINST FOOTREST
4. Torque all bolts to specification.
TIGHTENING TORQUE
7 N•m ± 1.5 N•m (62 lbf•in ± 13 lbf•in)
5. Install battery [P13] in its support. Position thenegative post as shown.
7. Pass eyelet of solenoid wiring harness [P21]through the protective cap of the straight bat-tery cable end.
8. Connect battery cable and eyelet to solenoidpost. Secure with nut [P7]. Torque nut to spec-ification.
TIGHTENING TORQUE
4 N•m ± .25 N•m (35 lbf•in ± 2 lbf•in)
9. Cover solenoid terminal with the protector cap.10. Connect the other end to the battery positive
post. Torque bolt to specification.
TIGHTENING TORQUE
3.25 N•m ± .25 N•m (29 lbf•in ± 2 lbf•in)
11. Coat battery posts and connectors with DI-ELECTRIC GREASE (P/N 293 550 004).
12. Cover battery positive terminal with the pro-tector cap.
13. Connect the 2-pin connector of solenoidwiring harness [P21] to solenoid.
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1. 2-pin connector
Starting Relay JumperRemovalE-TEC XP 2009 to 2013 Models1. Detach red jumper from oil tank using long nose
pliers.
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1. Red jumper
2. Disconnect jumper.3. Fold back wire and secure it to loom with lock-
ing tie [P23].
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Starting Relay InstallationE-TEC XP 2009 to 2013 Models1. Recover relay from the unused solenoid wiring
harness [P21].
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1. Recover the relay
2. Connect that relay to the unused connector onvehicle main wiring harness.
Instruction Sheet P/N 487 801 505 13 / 15
INSTRUCTIONS
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VIEW FROM LH SIDE1. Oil reservoir2. Relay connector
3. Secure relay to oil reservoir with a locking tie[P23].
Ignition SwitchThe “Start/RER” button on LH side of handlebarwill now serve its dual purpose of selecting re-verse and starting engine.
Finalizing Assembly1. Connect the BLACK battery cable [P17] to bat-
tery post. Torque bolt to specification.
TIGHTENING TORQUE
3.25 N•m ± .25 N•m (29 lbf•in ± 2 lbf•in)
CAUTION Always connect battery cablesexactly in the specified order. Connect REDpositive cable first, then BLACK negativeground cable.
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2. Reinstall tuned pipe and muffler.
E-TEC ModelsReconnect temperature sensor to muffler.Reinstall primary air intake silencer.– Guide the primary air intake silencer into the
adapter plate groove– Make sure that the primary air silencer is
pushed to the end of adapter plate and that thesecuring tab is fully engaged.
800R ModelsReinstall belt support using a locking tie [P23].
REV XM, REV XSReinstall:– Bottom pan cover– Upper body module– Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of stainless steel screws.
All Models3. Clean pulley sheaves and shaft with fine steel
wool and dry cloth. Do not use any other typeof abrasive.
4. Using a paper towel with PULLEY FLANGECLEANER (P/N 413 711 809), clean crankshafttapered end and the taper inside the fixedsheave of the drive pulley, crankshaft threadsand retaining screw threads. Avoid contactbetween cleaner and crankshaft seal be-cause damage may occur.
5. Remove all hardened oil deposits that havebaked on crankshaft and pulley tapered sur-faces with coarse or medium steel wool and/orsand paper no. 600.
6. Reclean mounting surfaces with paper toweland cleaning solvent.
7. Wipe off the mounting surfaces with a clean,dry paper towel.
NOTICE Mounting surfaces must be free ofany oil, cleaner or towel residue.Do not apply antiseize or any lubricant oncrankshaft and drive pulley tapers.
8. Install drive pulley on crankshaft extension.9. Install drive belt.10. Install a new conical spring washer [P29].11. Position its domed side against drive pulley
bolt
14 / 15 Instruction Sheet P/N 487 801 505
INSTRUCTIONS
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1. Drive pulley bolt2. Conical spring washer3. Domed side here
NOTICE Always use BRP genuine parts forconical spring washer and bolt.
12. Use the DRIVE PULLEY HOLDER (P/N 529 035674) to retain drive pulley.
13. Tighten drive belt bolt strictly as follows:13.1 Torque bolt to specification.
TIGHTENING TORQUE
120 N•m ± 5 N•m (89 lbf•ft ± 4 lbf•ft)
13.2 Install drive belt guard.13.3 Raise the rear of the vehicle and support
it with a mechanical stand.
WARNING
Ensure that the track is free of particleswhich could be thrown out while trackis rotating. Keep hands, tools, feet andclothing clear of track. Ensure nobodyis standing near the vehicle.
13.4 Accelerate the vehicle at low speed (ma-ximum 30 km/h (19 MPH) and apply thebrake. Repeat 5 times.
13.5 Re-torque drive pulley bolt to specifica-tion.
TIGHTENING TORQUE
120 N•m ± 5 N•m (89 lbf•ft ± 4 lbf•ft)
WARNING
After 10 hours of operation the trans-mission system of the vehicle must beinspected to ensure drive pulley bolt isproperly torqued.