Can-Am Roadster RT-622 2010 Service Manual
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Can-Am Roadster RT-622 2010 Service Manual

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2010
Service Manual
Roadster
RT-622 Trailer

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Summary of Contents for Can-Am Roadster RT-622 2010

  • Page 1 2010 Service Manual Roadster RT-622 Trailer...
  • Page 2 Legal deposit: National Library of Quebec National Library of Canada 2010 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. (BRP) Bombardier Recreational Products Inc. (BRP) 2010 ©...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTICE ......................III INTRODUCTION ..
  • Page 4 TABLE OF CONTENTS 03 ELECTRICAL SYSTEM (cont’d) (cont’d) 01 – LIGHTS AND HARNESS (cont’d) PROCEDURES ................. . . 39 LICENSE PLATE LIGHT .

  • Page 5: Safety Notice

    SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to cor- Although the mere reading of such information rectly service the Roadster RT-622 trailer as de- does not eliminate the hazard, your understand- scribed in the model list in the INTRODUCTION ing of the information provided will promote its correct use.

  • Page 6: Introduction

    INTRODUCTION INTRODUCTION GENERAL INFORMATION The information and component/system descrip- tions contained in this manual are correct at time of writing. BRP however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured.
  • Page 7 INTRODUCTION rmr2010-061-101_aen rmr2010-061...
  • Page 8 INTRODUCTION rmr2010-061-200_aen rmr2010-061...
  • Page 9 INTRODUCTION TIGHTENING TORQUES Tighten fasteners to torque mentioned in exploded views and/or text. When they are not specified, refer to following table. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, cotter pins, etc.) must be replaced. In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the following pro- cedure: 1.
  • Page 10 VIII rmr2010-061...

  • Page 11: Maintenance

    Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) MAINTENANCE SCHEDULE Maintenance is very important for keeping your trailer in safe operating condition. The mainte- nance schedule does not exempt the pre-ride inspection. Every year: – Check coupler condition and tighten coupler fasteners.

  • Page 13: Storage And Preseason Preparation

    Section 01 MAINTENANCE Subsection 02 (STORAGE AND PRESEASON PREPARATION) STORAGE AND PRESEASON PREPARATION If trailer will not be in use for several months, the following steps will help ensure proper perfor- mance when removed from storage and extend trailer life. –...

  • Page 15: Wheels And Wheels Hubs

    Section 02 CHASSIS Subsection 01 (WHEELS AND WHEELS HUBS) WHEELS AND WHEELS HUBS rmr2010-064-100_a rmr2010-064...

  • Page 16: General

    Section 02 CHASSIS Subsection 01 (WHEELS AND WHEELS HUBS) GENERAL Push and pull the wheel from the upper edge to feel the play. During assembly/installation, use the torque val- If any play is felt, replace wheel hub bearings. See ues and service products as in the exploded view. WHEEL BEARING REPLACEMENT WARNING Check if the wheel turns freely.

  • Page 17: Wheel Hubs

    Section 02 CHASSIS Subsection 01 (WHEELS AND WHEELS HUBS) 10. Adjust the bearing gap. 7. Place hub on the spindle and secure it loosely using the hub nut and its washer. 10.1 Using a torque wrench, tighten hub nut to 17 N•m (150 lbf•in) to seat hub prop- 8.

  • Page 19: Suspension

    Section 02 CHASSIS Subsection 02 (SUSPENSION) SUSPENSION SERVICE TOOLS Description Part Number Page 529 036 184 ........... 11 SPRING COMPRESSOR ............... rmr2010-065-100_a rmr2010-065...

  • Page 20: General

    Section 02 CHASSIS Subsection 02 (SUSPENSION) GENERAL Spring preload general guidelines. SPRING PRELOAD GUIDELINE During assembly/installation, use the torque val- ues and service products as in the exploded view. CAM ADJUSTER TRAILER LOAD POSITION WARNING Empty Torque wrench tightening specifications Combination of loaded must be strictly adhered to.

  • Page 21: Spring

    Section 02 CHASSIS Subsection 02 (SUSPENSION) SPRING Spring Removal SHOCK AB- 1. Remove shock absorber. See SORBER REMOVAL 2. Secure the SPRING COMPRESSOR (P/N 529 036 in a vise. 184) smr2009-041-090_a 1. Zone where presence of rust is normal Spring Installation The spring installation is the reverse of the re- moval procedure.
  • Page 22 Section 02 CHASSIS Subsection 02 (SUSPENSION) rmr2010-067-017 3. Remove the top retaining screw from shock. rmr2010-067-018 4. Remove hub cap. 5. Remove cotter pin. 6. Remove nut. 7. Remove shaft. 8. Remove bearing. 9. Install new bearing. 10. Lubricate shaft and housing with suspension grease.

  • Page 23: Body

    Section 02 CHASSIS Subsection 03 (BODY) BODY SERVICE PRODUCTS Description Part Number Page 293 600 041 ........17–18 CABLE LUBRICANT ..............293 600 016 ........... 17 XPS LUBE..................293 550 010 ........... 28 XPS SYNTHETIC GREASE............. rmr2010-066...
  • Page 24 Section 02 CHASSIS Subsection 03 (BODY) rmr2010-066-100_a rmr2010-066...
  • Page 25 Section 02 CHASSIS Subsection 03 (BODY) rmr2010-066-101_a rmr2010-066...
  • Page 26 Section 02 CHASSIS Subsection 03 (BODY) rmr2010-066-102_a rmr2010-066...

  • Page 27: General

    Section 02 CHASSIS Subsection 03 (BODY) GENERAL Apply a soapy water solution to new decal and carefully position it. Using a sponge or a During assembly/installation, use the torque val- squeegee, remove the air bubbles and water ues and service products as in the exploded working from the center toward the edges.
  • Page 28 Section 02 CHASSIS Subsection 03 (BODY) NOTICE Using another type of lubricant 3. Disconnect both latch cables from the latch could cause the cable sticking or stiffness. mechanism assembly. INNER FAS- 1. Remove inner fascias. Refer to CIAS in this section. 2.
  • Page 29 Section 02 CHASSIS Subsection 03 (BODY) rmo2010-005-039_a 1. Front latch cable 7. Reinstall new cables. rmr2010-066-236 8. Use pliers to hold spring while attaching cable REAR LATCH CABLE ADJUSTER KNOB to lock mechanism. rmr2010-066-237 rmr2010-066-233 FRONT LATCH CABLE ADJUSTER KNOB HOLD SPRING WITH PLIERS WHILE INSTALLING CABLE 3.

  • Page 30: Lock Pins

    Section 02 CHASSIS Subsection 03 (BODY) LOCK PINS Lock Pin adjustment NOTICE Always leave both covers open when adjusting lock pins to ensure trailer access in case a lock pin does not operate properly. 1. Start with a pin height set at 22.5 mm (.886 in) for the front cover.

  • Page 31: Front Access Cover

    Section 02 CHASSIS Subsection 03 (BODY) LH and RH Inner Fascias Installation The installation of the inner fascias is essentially the reverse of the removal procedure. RH inner fascia has to be installed first. Finger tight all inner fascia screws. FRONT ACCESS COVER Front Access Cover Removal 1.

  • Page 32: Rear Access Cover

    Section 02 CHASSIS Subsection 03 (BODY) REAR ACCESS COVER Rear Access Cover Removal (with hinges) 1. Open rear access cover. 2. Remove 4 retaining screws from bridge. 3. Remove rear access cover from trailer with the hinges. rmr2010-066-239 Rear Access Cover Installation Installation is the reverse of removal procedure.
  • Page 33 Section 02 CHASSIS Subsection 03 (BODY) 5. Pull main control handle assembly out of its lo- cation towards inside of trailer. rmr2010-066-214 COMPONENT SUPPORT COVER PLATE 3. Disconnect both latch cables. They can be rmr2010-066-217 pulled up to ease removal. MAIN CONTROL HANDLE ASSEMBLY 6.
  • Page 34 Section 02 CHASSIS Subsection 03 (BODY) 10. Hold latch place in place while removing the 2 lower retaining screws as the plate is spring loaded. NOTICE Holding plate prevents losing spring and ball located behind. 11. Remove the spring and ball. rmr2010-066-219 PIVOT 8.
  • Page 35 Section 02 CHASSIS Subsection 03 (BODY) 6. Carefully hold in place and install the latch plate 2 bottom retaining screws. Screws should not be tight yet. 7. Install the center blank cover and hold in place with the other 2 retaining screws. rmr2010-066-247_a 1.
  • Page 36 Section 02 CHASSIS Subsection 03 (BODY) rmr2010-066-228 PULL LATCH CABLES 12. Install latch cables before installing the latch mechanism assembly in its location. rmr2010-066-232 PULL LATCH CABLES 14. Secure latch mechanism assembly with 4 retaining screws. Torque to 7 N•m ± 1 N•m (62 lbf•in ±...

  • Page 37: Body

    Section 02 CHASSIS Subsection 03 (BODY) rmr2010-066-213 rmr2010-067-007 COMPONENT SUPPORT COVER PLATE REMOVING INNER LINER 6. Remove 4 screws attaching body to bridge sec- BODY tion. Body Removal 1. Using the tongue as a lifting tool, lift front of trailer until rear touches ground. NOTICE Install foam protection on the floor to protect lower rear section.
  • Page 38 Section 02 CHASSIS Subsection 03 (BODY) 8. Remove 8 retaining screws attaching body to frame. rmr2010-067-015 CAREFULLY LAY ON A FLAT SURFACE Body Installation 1. Put a small amount of XPS SYNTHETIC GREASE rmr2010-067-005_a on the 8 rubber washers (P/N 293 550 010) 1.
  • Page 39 Section 02 CHASSIS Subsection 03 (BODY) 3. With an assistant, carefully lift trailer body sec- tion. Grab section under wheel fender. 4. Carefully lower body on frame using bridge studs as a guide. 5. Use small screwdriver to align holes in lower section of body with holes in frame.

  • Page 41: Frame

    Section 02 CHASSIS Subsection 04 (FRAME) FRAME rmr2010-067-100_a rmr2010-067...

  • Page 42: General

    Section 02 CHASSIS Subsection 04 (FRAME) GENERAL 4.2 Remove the protective trims and push the connector into the tongue by its rectangu- During assembly/installation, use the torque val- lar opening. ues and service products as in the exploded view. 4.3 Remove and discard 2 retaining bolts and nuts.
  • Page 43 Section 02 CHASSIS Subsection 04 (FRAME) rbl2010-004-011_a 1. Tongue connector in rectangular opening rbl2010-004-031_a 2. Push the connector using the opposite hole 1. M10 elastic flanged nut 3.3 Pull approximately 15 cm (6 in) of harness 6. Tighten front and rear tongue nuts to 42.5 N•m out of tongue.

  • Page 44: Coupler

    Section 02 CHASSIS Subsection 04 (FRAME) COUPLER Arc Welding on Frame Arc Welding Specifications Coupler Inspection When arc welding, use the following specifica- Check tightness of coupler bolts. If bolts are tions: loose, check coupler and tongue for damages. 1. Amperage: 70 - 110 A Retighten bolts to 42.5 N•m (31 lbf•ft).

  • Page 45: Electrical System

    Section 03 ELECTRICAL SYSTEM Subsection 01 (LIGHTS AND HARNESS) LIGHTS AND HARNESS HARNESS DESCRIPTION rmr2010-068-100_a rmr2010-068...
  • Page 46 Section 03 ELECTRICAL SYSTEM Subsection 01 (LIGHTS AND HARNESS) HARNESS LOCATION rmr2010-068-103_a rmr2010-068...
  • Page 47 Section 03 ELECTRICAL SYSTEM Subsection 01 (LIGHTS AND HARNESS) WIRING DIAGRAM rmr2010-068-102_a rmr2010-068...

  • Page 48: General

    Section 03 ELECTRICAL SYSTEM Subsection 01 (LIGHTS AND HARNESS) GENERAL POSITION LIGHT Position Light Bulb Replacement During assembly/installation, use the torque val- ues and service products as in the exploded view. The position lights are built with LEDs. The com- plete light must be replaced.

  • Page 49: License Plate Light

    Section 03 ELECTRICAL SYSTEM Subsection 01 (LIGHTS AND HARNESS) 5. Install the new bulb by pushing it in. 6. Reinstall the lens. 7. Reconnect connector. HARNESS Harness Inspection Check trailer harness and connector for damages. Repair or replace as required. Wiring and Connector Identification When making wiring or connector repairs, follow the diagram below to identify the appropriate and...
  • Page 50 Section 03 ELECTRICAL SYSTEM Subsection 01 (LIGHTS AND HARNESS) Tongue Harness Installation FRAME 1. Refer to subsection to remove the fol- lowing parts. – Tongue – Rubber support – Coupler. 2. Gently route harness in tongue until harness connector is visible through the rectangular hole.

  • Page 51: Technical Specifications

    Section 04 TECHNICAL SPECIFICATIONS Subsection 01 (RT-622 TRAILER SPECIFICATIONS) RT-622 TRAILER SPECIFICATIONS ELECTRICAL SYSTEM Taillight/brake light (LED) 2 X .6 W / 2 X 3.1 W Turn signal lights 2 X 21 W Position lights 4 X .75 W License plate light SUSPENSION Suspension type Coilover Independant Trailing Arm...

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