2009 Can-Am Spyder GS SM5/SE5 And Spyder GS Service Repair Manual

WHAT’S NEWSPublished weekly by the Dealer Support Group
April 24, 2008
®, ™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.
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CONFIDENTIALITY NOTICE
This e-mail transmission contains confidential information and may be legally privileged. If you are not the intended recipient you are hereby notified that
any disclosure, copying, distribution or use of any of the information contained in or attached to this transmission is STRICTLY PROHIBITED.
LATEST BULLETINS
No new bulletins
BOSSWeb Tricks & Tips
How to open the 08 Can-Am
spring and summer promotion banner
1- Click on the banner from the home page
2- It will bring up a file download box, click "run"
3- It will bring up a security warning box, click "run"
again
4- A WinZip self-extractor box will come up, click
"browse", choose "desktop", and then click "OK" and
"unzip".
It will unzip 4 PDF files and an Excel sheet on your
desktop.
Accessory Terminal Locations
There are two accessory power terminal locations you
may be looking for on SpyderTM
. One is "un-switched"
battery power, and the other is "switched" battery
power. Fuse locations for both are found in the front
fuse block under the storage compartment lid.
The "un-switched terminal" can be found under the
service cover inside the storage compartment, plugged
to a blank white block, and has Violet / Orange and
Black wires.
The "switched" terminals are located inside a boot,
inside the left front upper shock tower weldment, and
have Violet / Yellow and Black wires. Trouble Shooting
Please don’t forget that all recent Technical Update
Books contain a handy trouble shooting index for past
models. You'll find the index on page 54-56 in the 2008
book. When confronted by service issues on 2002 and
subsequent models, check the index to find past
Update Books that may help you.
D.E.S.S.TM
Post Interface
Many of you may be using the new MPI-2 now that they
supersede the VCK and have been auto-shipped to all
Can-Am and Spyder dealers. Please keep in mind that
the D.E.S.S.TM
Post Interface (529036019) is needed
for programming keys on older boats, and the MPI-2
will not allow diagnostic functions on DI models without
the interface connected. The Interface was not auto-
shipped and must be ordered separately. The older
VCK will continue to be useful for many years.
Sport Boats
Effortless returns!
There is a new program supplier for Sport Boats radios,
CD players, and remote controls. If you should run
across a Jensen®
, Voyager®
, or Audiovox®
product
issue, have your repair technician call ASA's
experienced troubleshooting team and they'll help you
sort out the problem. Further information can be found
on page 9 of the 2008 Seadoo Technical Update book.

April 9, 2008
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Batteries
Please be reminded that you MUST adhere to the
proper battery PDI procedure as detailed in the PDI
Bulletin. Failure to do so may result in cosmetic
damage to your customer's new Spyder®
Roadster. We
will not accept claims for damaged plastic due to
improperly serviced batteries. After filling, the batteries
must sit upright so the electrolyte can absorb into the
plates. Also see "What's News" from Nov. 21, 2007.
You will see a running change to a pre-filled battery
coming soon.
Xenon lighting system & Fog Light kit
If the Xenon lighting system & Fog Light kit are both
installed as accessories, the customer will need to
purchase the optional wiring harness part number
710001327. Other wise there will not be enough wire
plugs for the system to work.
This is listed in both sets of instructions.
The part numbers for the optional kits are as follow:
Xenon Lighting System 219 400 083
Fog Light Kit 219 400 084
Safety Recall
Please be sure campaign 2008-0002 is completed on
all of your applicable Spyders®
. This is a SAFETY
campaign, and should not be over-looked. See
Roadster Warranty bulletin 2008-2
Dealer Certification
PROGRAM
DUE APRIL 15TH
!!!
2008-2009 SKI-DOO MEDIA PLAN
Parts and Accessories Managers: We want
to hear from you!
Complete our Satisfaction Survey by April 16th
and you
could win $1000 in cash! Go to BOSSWeb's Home
page, click on the "Dealer Survey – Parts and
Accessories Manager" banner (shown below) and voice
your opinion. We want to better serve you and need
your feedback to do so. We count on you!
Can I delete a sub user account?
No, at this moment it is not possible to delete a sub
user account for fiscal reason (Government regulation).
However, you can close a sub user account by putting
an expiration date in the sub user profile. We are
presently looking into a way to hide the sub user
account when it is not active. More info to come.
LATEST BULLETINS
Can-AmTM
ATV:
Service Bulletin 2008-11 A) Fault Code Displayed on
Gauge B) B.U.D.S. Setting Screen Discrepancies
Competition Bulletin 2008-2 DS 450 / Engine
Overheat Limp Home Modification
Ski-Doo®
:
Warranty Bulletin 2008-17 (Safety) Fuel Hose
Replacement
Sea-Doo®
PWC:
Warranty Bulletin 2008-2 A) Exhaust Hose Coming
Off on 255 H.O. B) Supercharger Outlet Hose Coming
Off on 255 H.O.
Sea-Doo®
Sportboat:
Service Bulletin 2008-5 Missing Compass in Cluster

Page 1 of 2 October 2, 2008
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Important Technical Training Info
In June 2008, every Roadster dealership was auto-
shipped a training package. This material provided
critical information for every dealership including those
who had received earlier training. The material is the
most accurate and includes valuable SE5 training not
before presented.
You must have someone at your dealership complete
this training no later than October 31st
to ensure and
demonstrate your expertise and authority as a trained
Roadster repair and service facility.
DVD Volume 7 Can-Am Roadster Technical Overview /
Roadster Can-Am P/N 219 701 329
Can-Am Roadster Technical Overview Workbook
P/N 219 600 032 /
You can order these items if you cannot locate your
Roadster materials using the part numbers above.
To demonstrate the training is complete, log on to the
BRPTI training site and complete the following course.
Course 56002 - Can-Am Roadster Technical Overview
(DVD 7)
To achieve Technician Status in Roadster you may also
use your Original set of technical DVDs 1-5 to complete
the following exams on BRPTI:
Course 0050 Can-Am Roadster Technician Level (DVD
1-5)
Due date for Roadster training is October 31, 2008.
2009 Ski-Doo®
Technical Update Exam
After receiving the 2009 Ski-Doo Technical Update
book, at the one-day school or in the mail after schools
are finished, the following exam MUST be compleated
no later than December 31, 2008.
Course 52006 - 2009 Ski-Doo Technical Update
Course 52506 – 2009 Ski-Doo Mise à jour technique
550 Fan Summit Calibration
Don't forget the 550 Fan Summits are calibrated for
6000 ft. If not ridden at this altitude the clutching AND
carburetor jetting must be changed at the time of
PDI!!!
This is the selling dealer's responsibility. Failure to do
so will likely cause engine damage that is NOT
covered under warranty.
Starting with 2006 MY (model year) we have added a
large removable Mylar decal to the speedometer to
remind customers and technicians of this fact
New Version P2.3.21
This new version merges all previous versions and
product lines into one version. It is no longer necessary
to use different B.U.D.S. version for different product
lines. It is now available on BOSSWeb, go to:
ComCenter = Document
Document Type = Diagnostic Software
Category = B.U.D.S.
As always it is a good idea to keep at least the
previous version on your computer until total validation
is done with the new version.
LATEST BULLETINS
Can-AmTM
ATV:
Service Bulletin 2009-8 Throttle Plate Opening

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Page 2 of 2 October 2, 2008
SKI-DOO 2009 – popular part numbers
Shop manuals
P/N Model ETA
219100330 REV XP/XR™ 2 stroke mid November
219100332 REV XR™ 4-stroke 1200 end of December
219100334 REV XU™ end of January 2009
PS: One free copy will be auto-shipped automatically to your dealership around the mentioned dates.
800R rebuilt short block
MY Chassis P/N
2009 REV-XP™ N/A this season
2008 REV-XP™ 421000650
2007 & prior REV® 421000645
Belts
P/N Engine
417300197 500SS / SUMMIT 600 carb / Legend V800, Tundra V800
417300383 all 600 HO E-tec, all 1200 4-tec, MXZ® 800R
417300377 SUMMIT® 800R
605348425 all Skandic® & Expedition® models except Tundra™
415060600 all 550F
417300288 MXZ®X® 600 RS RACING
417300326 Tundra™ 300F
Spark plugs
P/N Type Engine
512060354 BR10ECS 500SS, 600 carb
415129375 PZFR6F 600 HO E-TEC
512059552 BR9ECS-5 MXZ® X 600 RS RACING
415129429 CR8EKB 1200 4-TEC
512060029 BR8ECS 0.8MM Expedition® TUV 600 HO SDI
414961100 BR9ES all 300F & 550F
707000246 DCP-R8E all V800
415128524 BR9ECS-8 800R
Selling Demo Units
When selling a demo unit to a customer please note that the demonstrator sales form & change of ownership form
need to be filled out and forwarded to your regional sales coordinator in order to complete the change of ownership
and render the unit eligible for current promotions. The following forms can be found on BOSSWeb in your dealer
binder under dealer /consumer forms as follows:
Demo Sales Form................................................5-3
Change of Ownership Form................................ 5-4
This e-mail transmission contains confidential information and may be legally privileged. If you are not the intended recipient you are hereby notified that any
disclosure, copying, distribution or use of any of the information contained in or attached to this transmission is STRICTLY PROHIBITED.

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September 18, 2008
Service Managers: We want to hear from
you!
Complete our Satisfaction Survey by September 28th
and you could win $1000 in cash! Go to BOSSWeb's
Home page, click on the "Dealer Survey – Service
Manager" banner (shown below) and voice your
opinion. We want to better serve you and need your
feedback to do so. We're counting on you!
LATEST BULLETINS
Can-AmTM
ATV:
Warranty Bulletin (SAFETY) 2009-2 DS 90TM
XTM
Engine Tether Shutoff Switch
Can-AmTM
Roadster:
Warranty Bulletin 2008-4 GS Wheel Trim Ring
Drive Axles Shipping
We will start shipping drive axles to early snowfall
areas this week. If looking in BOSSWeb you will find a
shipping date of December. Please be assured you will
start to see axles well before this date though an exact
date yours will be shipped is hard to tell as we will ship
smaller quantities to all dealers as they become
available from our supplier.
E-TEC®
Spark Plugs
Proper orientation or "indexing" is critical for an
E-TEC®
engine to perform properly. Please make sure
you are using spark plugs received from BRP p/n
415129375 as these are specially indexed for the
E-TEC®
engine. If using plugs from any other supplier
special care will be needed to "index" the sparkplugs
properly.
Bombardier Recreational Product's Guide
to Service Fundamentals and Principles
This 480 page book is the only textbook of its kind as it
teaches basic theory and principles, using BRP's
products as examples. Your technicians can learn the
basics while applying the knowledge directly to our
Products. It was sent to your dealership free of charge
as part of your BRPTI training kit. This valuable text
book should be kept in a place where all technicians
will have access to it so they can refer to it when
questions arise. Please read "the book" and share it
with all your employees. Part number of the book is
484800168 (English) and a picture of the cover is
below.
When replacing the GBPS (gearbox position sensor)
on a Spyder™ Roadster it is not necessary to remove
the countershaft sprocket. The 2008 Service Manual
incorrectly states it must be removed yet the flat rate
(0.3 hr) does not include sprocket removal. The 2009
Service Manual will be corrected.

August 29, 2008
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LATEST BULLETINS
Ski-Doo®
:
Service Bulletin 2009-6 Spring Chart
Sea-Doo®
PWC:
Service Bulletin 2008-9 Battery Care Reminder
PROGRAM
2008 Certification Program Reminders
Can-Am™ Roadster Technical Overview (DVD 7) is
due by August 31, 2008
Can-Am™ Roadster Technician Level (DVDs 1-5) is
due by October 31, 2008
New B.E.S.T. Price Lists Effective
September 1st
!!
Your current B.E.S.T. price lists are no longer valid
since September 1st. Do take a moment to go to
BOSSWeb / ComCenter / B.E.S.T. Guide and print our
latest price lists!
When you sell a B.E.S.T. plan, do not forget to fill out a
B.E.S.T. contract form (P/N: 484800210 in the USA and
484800212 in Canada) and register the service contract
on BOSSWeb.
You can also order our customer brochures (P/N:
219700533 in the USA and 219700709 in Canada),
desk mats (P/N: 219701170 in the USA and 219700535
in Canada) on BOSSWeb or by calling our team at 1-
800-366-6992.
Axle Caps
Spyder™ Roadsters produced prior to June 2008 were
shipped without rear axle caps. We have auto shipped
caps in sufficient quantity to retrofit all Spyder™ GS
units delivered to your dealership. These caps have
been shipped and will arrive at your dealership within
the next few days. Please install them on your
customers Spyder™. If more caps are required, they
may be ordered directly from PAC (Right – 705501022,
Left – 705501081)
Three Roadster Items Now Available
• The sporty looking, great sounding, lighter
weight Performance Silencer exhaust system
219400073
• The cast aluminum, polyurethane padded
passenger Adjustable Backrest with up to 5 cm
of forward and rear adjustment 219400082
• The Rear Sport Rack required to install the
backrest featuring a unique mounting system
that allows the backrest to click in instantly
219400081
Place your orders on BOSSWeb today!
QRS Adjuster Tool
We still have in stock quite a few "shop grade" QRS
adjuster tools for the polymer style belt deflection
adjusters found on 2008 and early 2009 Rev XP™'s.
The part number is 529036127.

August 14th, 2008
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LATEST BULLETINS
Can-AmTM
Roadster:
Warranty Bulletin 2008-3 Parking Brake Pedal
PROGRAM
Mandatory section online exams:
• Course # 81010 Sales
• Course # 81011 Financial
• Course # 81012 Service
• Deadline: Nov 30th
CSI online exam (course # 81009):
• Must complete exam to complete CSI criteria
• Deadline Nov 30th
Signage:
• If you have received your signs from our supplier,
please send us your pictures at brp-cert-
photos@brp.cpm.
Warranty Campaigns:
• Completion of minimum 65% of campaigns with a
"start date" between Sept 1st
2007 and Sept 1st
2008.
• Measurement date: Nov 30th
2008
2008-2009 Spader Schedule is now available on their
website: www.spader.com.
Sport Boat wiring diagrams
Please note that we omitted to mention the 150
Speedster™ and 180 Challenger™ model on the cover
page of the 2008 Sea-Doo®
Sport Boats wiring diagram
booklet but the diagrams are included in it.
Trouble Shooting
Please don’t forget that all recent Technical Update
Books contain a handy trouble shooting index for past
models. You'll find the index on page 54-56 in the 2008
book. When confronted by service issues on 2002 and
subsequent models, check the index to find past
Update Books that may help you.
Parking Brake
As you can see in our LATEST BULLETINS section,
we have published a Warranty Bulletin concerning the
parking brake. We are also calling each of your
dealerships and asking that you concentrate on the
SE5 models at this time. There is a limited number of
SE5's in the field so we are also asking you to control
your parts orders. Parts are coming from supply on a
regular basis, but in order to reduce the risk of creating
a back order, please spread your orders over a
reasonable time period that matches your projected
completion rate.
Again, please concentrate on the SE5 first.
One Day Technical Update School
As you may or may not know, we are doing regional
Ski-Doo update schools this year. If you have not seen
a registration form that we have faxed to each
dealership, please look at the "alerts" on the front page
of BOSSWeb. Be sure to get you registration in soon.

Page 1 of 1 July 31st, 2008
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PROGRAM
Mandatory section online exams:
• Course # 81010 Sales
• Course # 81011 Financial
• Course # 81012 Service
• Deadline: Nov 30th
CSI online exam (course # 81009):
• Must complete exam to complete CSI criteria
• Deadline Nov 30th
Signage:
• If you have received your signs from our supplier,
please send us your pictures at brp-cert-
photos@brp.cpm.
Warranty Campaigns:
• Completion of minimum 65% of campaigns with
a "start date" between Sept 1st
2007 and
Sept 1st
2008.
• Measurement date: Nov 30th
2008
2008-2009 Spader Schedule is now available on their
website: www.spader.com.
LATEST BULLETINS
No bulletins this week
.
Minimum Requirements
Computer technology is moving forward at an
aggressive pace. Many of the issues we face together
can be traced directly to out-dated equipment and
software. Please take the time to read the alert posted
on your home page of BOSSWeb to fully understand
theses challenges. This is a "must read". The name of
the document is:
Minimal Requirements
Valve Adjustment
Some customers may be approaching a mileage where
their Spyder is due for a valve clearance adjustment, or
inspection. In order for you to be prepared for this, you
need to stock an assortment of valve shims. The shims
most frequently used are in the 2.6 to 2.8 millimeter
range, so if you at least stock this range of shim you
should be covered. It is not necessary to stock all of the
available shims.
Beep, Beep, Beep
Many of you are now receiving your first SE5 electric
shift models. Please be aware that when you shut down
an SE5 engine without applying the parking brake the
warning beeper will sound for approximately 20
seconds. This is to warn the customer that his Spyder
could potentially role downhill until the parking brake is
set. Stopping it in gear is not effective as on SM5
because of the centrifugal clutch.
Wake Ballast System:
Further to the 2008 Sea-Doo®
Catalog update zip
bulletin, this is just a quick reminder that the Wake
Ballast System 295501072 part number has been
cancelled and has been replaced with the following part
numbers: 295100322 – GTX, RXT (2006 – 2008) and
295100334 – GTX, RXT (2002-2005). The board rack
as well at the electric VTS are not included in this
system. Please refer to the instruction sheet for the
concerned kit for more details
† Trademark of Castrol Limited used under license.

In the last few weeks, we d about flat rates, how they are compiled and the importance of using the appropriate job
code. This week, we will discuss how to submit multiple repair claims on one vehicle.
First, how do I submit for multiple repairs? In order to add a repair you only need to click on the sign at the end
of the Trouble part number line:
When you add a repair it will say Repair 1 of 2 and the number will change with the number of repairs you add.
Second, when do I submit for multiple repairs? When you do more than one repair in different systems or different
areas of the unit; by doing a multiple repair claim you will be able to claim for the appropriate job code for each
repair. Many dealers choose to submit 1 repair for multiple repairs done on a vehicle and use one job code and
then lump all the remaining labor on the extra labor line. By doing this you greatly increase your risk of being cut
on your warranty claim since the logic between the job codes and the parts required for the multiple repairs will only
show as a lump operation.
If you have any other questions concerning multiple repair claims contact the Warranty Department at (800) 361-
9980 (Canada) or (800) 366-6992 (US), select 3 for Warranty and then 5 for Policies and Procedures.
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Page 2 of 2 July 24th
, 2008
Change of ownership/ address
BRP receives change of ownership requests and change of address requests regularly. You can help us keep
registration information updated by completing the modifications online on BOSSWeb under the Sales tab. Don't
hesitate to verify your customer information when servicing their vehicle, and make the required modifications. BRP
uses this information to reach vehicle owners when releasing Safety campaigns but also when sending advertising
material. In both situations, your dealership will benefit of future business opportunities.

, 2008
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LATEST BULLETINS
Ski-Doo®
:
Predelivery Bulletin 2009-2 REV-XPTM
Predelivery
Inspection
Can-AmTM
Roadster:
Predelivery Bulletin 2008-1 Rev.2 Can-AmTM
SpyderTM
GS Predelivery Inspection
Use of appropriate job codes
In the last few weeks, we have been talking about flat
rates and how they are compiled. This week, we will
discuss the importance of using the appropriate job
code which will pay you the accurate flat rate when
filing a warranty claim. With some manufacturers, you
need to compile all the job codes and then submit for
the total time. BRP has simplified this process by
combining the job codes so you will only be claiming for
the longest lasting operation as per the repair
procedure in the Shop Manual. By claiming the job
code for the longest lasting operation you will greatly
reduce the risk of being cut on the claim.
So remember that with BRP, FLAT RATE TIME IS
NOT CUMULATIVE. You must use the job code for the
longest lasting operation.
If you have any questions concerning flat rates and job
codes contact the Warranty Department at (800) 361-
9980 (Canada) or (800) 366-6992 (US), select 3 for
Warranty and then 5 for Policies and Procedures.
Brake Noise
Although some brake noise or "squeal" can be
considered as normal in almost any vehicle, we have
had reports of "excessive" brake noise from some of
our Roadster customers. We want you to know that we
are fully aware of the situation and are currently
working with our Engineering team to find solutions. In
the interim, we have discovered that it is possible to
drastically reduce the brake noise in severe cases, by
using commercially available automotive products
designed to address such complaints. We are hereby
authorizing you to use these products in order to satisfy
any customers you may have with the complaint. We
have found that in the US, a product made by CRC
works very well. Avoid the aerosol types as they are
much thinner in viscosity.
Following the brake pad replacement procedures
outlined in the shop manual remove the pads and apply
the material only to the contact areas on the back side
of the pads. Naturally avoid getting any material on the
brake pad surface or brake discs.
The time allowed to perform this will be .7 hours and
may be claimed on a normal warranty claim.
Parking Brake
We also receive reports from customers experiencing
parking brake difficulties. Be sure to maintain the
parking brake adjustment per the shop manual or
training DVD, and also use a spray lube to clean and
lubricate the brake locking mechanism. This will keep
the brake operating as designed.
Be sure to instruct customers to not "over apply" the
brake. Only set it tight enough to prevent the vehicle
from rolling. When releasing the brake, be sure to let it
return "sharply" so that it can reset the ratchet locking
device.

, 2008
The top 10 most wanted list
Here is a list of our 10 most popular part number
requests according to calls received from the dealer
network from March to June:
1) Watercraft ladder for RXP®
, GTX†
4-TEC®
, GTX†
DI
2002, RXT®
& RXT®
-XTM
: 295100307 (check the
instruction sheet on BOSSWeb for additional parts
needed for the RXT®
-XTM
).
2) Watercraft cover for 2-stroke GTX†
, GTX†
LTD,
GTX†
RFI, GTX†
DI 1996-2003 and 2-stroke GTI™
1997-2000: 280000389
3) Retractable Ski-Pylon for GTX†
4-TEC and RXT®
(but not for RXT®
-X®
): 295100251. Please note that
BRP does not offer a retractable ski-pylon for the
RXT®
-X®
this year. This accessory is being developed
for MY 2009 only. Additional parts are required for the
following 2 applications: 2002 GTX†
4-TEC®
–
274001036 (exhaust hose), 2003 GTX†
4-TEC®
supercharged – 274001066 (exhaust hose)
4) Windshield kit for Outlander™ 400 2003-2008:
703500444.
5) Spyder®
shop manual: 219100283
6) Supercharger rebuilt kit for 215 hp BVIC with
titanium coated steel washers: 420881100
7) Depth sensor for GTX†
4-TEC®
& RXT®
2003-2008,
GTI™ 2008, RXT®
-X®
2008: 295100324
8) 2008 Sea-Doo®
shop manual: 219100313 (still no
ETA)
9) 2004 ATV Outlander™ shop manual: 219100180
10) Sport Boats cover for 150 Speedster®
& Sportster®
4-TEC®
2003-2008: 280000387
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For increased efficiency, and to give you the
opportunity to offer the best support to your customers,
BRP offers you exclusive and direct contact to various
departments such as parts, technical, sales, technology
and consumer services, and prioritizes calls, even at
the consumer service level. Please post near your
phones, the contact numbers found in Section 1 of any
Technical Update Book under the heading "It's Easy to
Reach Us."
Keep in mind also that our consumer services
representatives are not trained to answer questions that
are technical or related to parts and sales; thus,
consumers calling BRP on these subjects will be
redirected to contact your dealership in order to
increase your business opportunities.

June 5th, 2008
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LATEST BULLETINS
Can-Am™ ATV:
Predelivery Bulletin 2009-1 DS250®
Predelivery
Inspection
Predelivery Bulletin 2009-2 Outlander TM
and
Renegade TM
Predelivery Inspection
Predelivery Bulletin 2009-3 DS70 TM
/ DS90 TM
/ DS90
TM
X TM
Predelivery Inspection
Service Bulletin 2009-1 Batteries Activation, Charging
and Maintenance
Service Bulletin 2009-2 B.U.D.S. Software and
Communication Tools
Warranty Bulletin 2009-1 A) Operator's guide B)
Missing mirrors – European community only
Sea-Doo®
Sportboat:
Warranty Bulletin 2008-2 Shifter / throttle mechanism
improvement
Invalid Variant
During PDI of 2008 Sea-Doo
®
's, or shortly thereafter,
you may encounter the message Invalid Variant type
Conversion while trying to communicate with B.U.D.S.
2.3.17. This message will prevent you from
communication and therefore you will be unable to
program keys, add the customer's name or perform
diagnostic functions. If you encounter this, go to
BOSSWeb and download B.U.D.S. version 2.3.19.
Another option if you have a customer waiting is to un-
plug the instrument cluster and re-read the MPEM data.
When finished with B.U.D.S. plug the cluster back in.
Warning, Enter Model Number
When programming a new ECM for any 4 Tec PWC, be
sure to list the proper model number on the vehicle
page in BUDS After registering the VIN number &
engine number, the screen will open & ask for the
proper model number. The screen will also allow you to
enter S BOAT at that time. Do not do this unless it
really is a Sport Boat.
S Boat is for Sport Boats and will deactivate the
speedometer mode of the ECM for a PWC.
This is a 1 time entry and can not be changed after the
initial entry. Be sure to enter the proper model number.
If you have accidentally deactivated a speedometer in
this way, contact a Service Representative.
"SENSOR"
As you are summarizing watercrafts please be
reminded that the cluster warning "SENSOR " will show
on units that have a depth finder & are run when out of
the water.
See page 3-19 in the 2004 Tech Update Book.
TRAINING COMING!
Within a few days you will be receiving two separate
training materials for the Can-AmTM
Roadsters.
Technical DVD Vol. 7 and the Can-AmTM
Roadster
Technical Overview workbook will be arriving in
separate envelopes. Also a Roadster exam will be
placed on the B.R.P.T.I. training site. Please read the
letters enclosed with both mailings for instructions on
how to complete the training. You will need the DVD, a
Shop Manual (previously shipped), and the Workbook
all together at one time. Watch your mail box and enjoy
the DVD!
Fuel Level Sensor Test
If you need to test the fuel level sensor on SpydersTM
,
the following test procedure may be used.
The testing may be performed between the Blue wire
[terminal A] at the pump and the Black/Beige wire
[terminal D] at the pump.
Fuel level empty should be approx. 290 ohm resistance
Fuel level full should be approx. 80 ohm resistance

May 8, 2008
Please route to:
Initial
GM
Service
Parts
Warranty
di l i di t ib ti f f th i f ti t i d i tt h d t thi t i i i STRICTLY PROHIBITED
LATEST BULLETINS
Can-AmTM
ATV:
Service Bulletin 2008-13 Service Bulletin 2008-13 V-
Twin Engines Coolant Reservoir Vent
PAC
New Part Smart 8.6
The all new electronic parts catalog software PartSmart
8.6 is arriving. We will mail it to you very soon. This new
version includes the new Sea-Doo®
Sport Boats and
PWC models. Something completely new to this new
version is something called "Thumbnails". This new
option will give you the possibility of pre-visualizing the
assemblies and give you the possibility to find what you
are looking for faster. Watch for the new PartSmart 8.6
in the next days.
Riser Block Kit Revisited
When Installing Riser Block Kit 219400087 please be
reminded that the instructions have been updated. You
may have kits with previous version instruction sheets,
and will need to update them with the following…
Steering Column Hub retaining nut – The correct
torque for the retainer nut is 19-24 lb/ft - 26-32 Nm
(previously 32 lb/ft - 44 Nm). Please make corrections
in the 2008 Spyder GS Shop Manual P/N 219 100 283
on page 342 & 356. The instruction sheet (P/N 487 800
332) on BOSSWeb has already been updated.
Also, add an additional procedure to both the Shop
Manual and the Instruction Sheet - The hub should be
pressed in-place before tightening the retaining nut.
Do not use the nut to "install" the hub on the
steering shaft.
Depth Finder Reminder
As your technicians are summarizing watercrafts
please be reminded that the cluster warning SENSOR
will show on units that have a depth finder and are run
when out of the water. Tech update 2004 page 3-19
Wakeboard Tower Sound System
Our service department frequently receives calls about
the installation of the Wake model Sport Boats sound
system parts. Please note that the towers for these
models come with a piece of rope already inside the
tubes, which your technician must use to pull the
supplied wires through the tubes when doing repairs or
installing kits. The wires supplied are a predetermined
length, with a special connector on each end, and this
is where the confusion occurs for some technicians,
when they finish pulling the wires through and there is
too much wire left over. Simply stuff any excess wire
into the top of the tower and all should be fine. There is
also a significant amount of information to be found in
the technical update books from 2006, 2007, and 2008
regarding the Infinity sound systems. We hope this will
help to alleviate some of your questions about these
models.
PROGRAM
DUE MAY 31st
!!!
Sea-Doo Technician Level Training
1 technician DVD 1-6 + Update Exam

May 1, 2008
Please route to:
Initial
GM
Service
Parts
Warranty
LATEST BULLETINS
Sea-Doo®
PWC:
Service bulletin 2007-17 Fuel Pump Activating
Procedure
Can-AmTM
ATV:
Service Bulletin 2008-13 V-Twin Water Pump Seals
Removal and Installation Revised Procedure
BOSSWeb Tricks & Tips
Where to find all B.U.D.S. single file available
a. In BOSSWeb click on Comcenter
b. Choose 'Document" in the menu
c. Then pick "Diagnostic Software" in Document
Type
d. Enter "single" in "Search by Keyword"
e. Then click on the submit arrow
SpyderTM
Battery PDI
We are finding some people are still confused about
proper prep time of the Spyder battery. The absolute
minimum time to prep the battery before
installation is 7 hours! After you fill the battery it will
take at least that long to follow all the procedures
detailed in the PDI sheet. Failure to allow this much
time may cause the battery to leak acid all over your
customers new Spyder. Until the new pre-filled
batteries arrive in later production, we highly
recommend filling and charging the batteries at least a
full day before installing them.
New Replacement Engines
Be absolutely certain to read and fully understand
service Bulletin 2007-9 when estimating customer costs
for replacing a 1503 engine. Failure to do so will cause
delayed repair times, inaccurate cost estimation, and
possibly engine operating failures, or severe damage. If
you have questions call the service department.
.
2009 Drive belt info
Many of you are completing PAC IO's. Please be
aware that there will be some new drive-belt strategies
next year.
a. Summits®
will use the new 417300377 belt. It
is 4 mm shorter and 1.5 mm wider than the
166. It may be considered as a high
performance option for all REV-XPTM
's but will
obviously cost more.
b. Most other REV-XPTM
, and REV-XRTM
models,
including the 1203 Four Strokes, will use a
new belt, 417300383 which is the same length
as the 166 but 1.5 mm wider. This belt would
be a good choice for all previous years REV-
XPTM
, because it is wider and would offer more
adjustability. The new belt will be available
around mid-October.
c. The 417300166 is, and always will be a good
belt for all ZX and REV®
models.
d. If you want to do any changes in your Ski-Doo
initial order, contact your PAC Representative
before May 15.

MONO SEAT COWL
Yellow (Kit P/N 219 400 079)
Full Moon (Kit P/N 219 400 080)
Black (Kit P/N 219 400 092)
Roadster Red (Kit P/N 219 400 093)
WARNING
– For safety reasons, this kit must be installed by an authorized BRP dealer.
– This kit is designed for specific applicable modelsonly (authorized BRP dealers will confirm mod-
el(s)). It is not recommended for units other than the one (those) for which it was sold.
– This instruction sheet MUST be given to the purchaser.
WARNING
– 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.
The following symbols may be used in this document:
SYMBOL DESCRIPTION
ƽWARNING
Indicates a potentially hazardous situation which, if not avoided, could result in serious
injuries or death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components.
NOTE: Indicates supplementary information needed to fully complete an instruction.
FASTENER GRADE/TORQUE TO BE USED WHEN TORQUES ARE NOT SPECIFIED IN TEXTFASTENER
SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
M4
1.5 — 2 N•m
(13 — 18 lbf•in)
2.5 — 3 N•m
(22 — 27 lbf•in)
3.5 — 4 N•m
(31 — 35 lbf•in)
4 — 5 N•m
(35 — 44 lbf•in)
M5
3 — 3.5 N•m
(27 — 31 lbf•in)
4.5 — 5.5 N•m
(40 — 47 lbf•in)
7 — 8.5 N•m
(62 — 75 lbf•in)
8 — 10 N•m
(71 — 89 lbf•in)
M6
6.5 — 8.5 N•m
(58 — 75 lbf•in)
8 — 12 N•m
(71 — 106 lbf•in)
10.5 — 15 N•m
(93 — 133 lbf•in)
16 N•m (142 lbf•in)
M8 15 N•m (11 lbf•ft) 24.5 N•m (18 lbf•ft) 31.5 N•m (23 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 72.5 N•m (53 lbf•ft)
M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)
NOTE: 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.
NOTE: Installation time is approximately 0.1 hour.
Printed in Canada (rsi2008-008 en DM/md)
©2008 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
Instruction Sheet P/N 487 800 204 1 / 3
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

PARTS TO BE INSTALLED
rsi2008-008-001_a
P/N
ITEM 219 400 079
yellow
219 400 080
full moon
219 400 092
black
219 400 093
roadster red
DESCRIPTION QTY
P1 708 000 521 708 000 524 708 000 633 708 000 634 Mono Seat Cowl 1
P2 293 850 090 Strap 2
P3 293 850 091 Strap 2
INSTRUCTIONS
rsi2008-008-004_a
1. Installshortstraps[P2] infrontclipofmonoseat
cowl.
2. Insert key in ignition switch.
3. Push and turn clockwise.
4. Pull seat upward while maintaining the key.
rsi2008-008-003_a
5. Insert long straps [P3] in rear holes underneath
seat and slide toward the side [1].
rsi2008-008-005_a
6. Install mono seat cowl above passenger seat.
7. Lift up front part of cowl.
2 / 3

8. Install rear straps [P3] in rear clip of mono seat
cover [2].
9. Move down front part of cowl.
10. Insert front straps [P2] in holes underneath seat
and slide toward the side [1].
Make sure straps are properly secured in place.
WARNING
Never sit on seat cover
3 / 3

REAR SPORT RACK
FULL MOON (Kit P/N 219 400 081)
ROADSTER RED (Kit P/N 219 400 101)
YELLOW MILLENNIUM (Kit P/N 219 400 128)
ƽ WARNING
– 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.
ƽ WARNING
Symbol Description
ƽWARNING
Indicates a potentially hazardous situation which, if not avoided, could result in
serious injury or death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle
components.
FASTENER GRADE/TORQUE TO BE USED WHEN TORQUES ARE NOT SPECIFIED IN TEXT.FASTENER
M4
1.5 — 2 N•m
(13 — 18 lbf•in)
2.5 — 3 N•m
(22 — 27 lbf•in)
3.5 — 4 N•m
(31 — 35 lbf•in)
4 — 5 N•m
(35 — 44 lbf•in)
M5
3 — 3.5 N•m
(27 — 31 lbf•in)
4.5 — 5.5 N•m
(40 — 47 lbf•in)
7 — 8.5 N•m
(62 — 75 lbf•in)
8 — 10 N•m
(71 — 89 lbf•in)
M6
6.5 — 8.5 N•m
(58 — 75 lbf•in)
8 — 12 N•m
(71 — 106 lbf•in)
10.5 — 15 N•m
(93 — 133 lbf•in)
16 N•m (142 lbf•in)
NOTE: 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.
Printed in Canada. (rsi2008-010 en JPM) Instruction Sheet P/N 487 800 252 1 / 6

Item Part Number Description Quantity
705 003 255 Upper cover - Full Moon
705 003 256 Upper cover - Roadster Red
705 003 387 Upper cover - Yellow Millennium
1
705 003 257 Lower cover - Full Moon
705 003 258 Lower cover - Roadster RedP1.1
705 003 388 Lower cover - Yellow Millennium
1
P1
P1.2 205 461 060 Bolt M6 x 10 2
P2 705 002 609 Extrusion 1
P3 705 002 610 Plate 2
P4 230 082 044 Bolt M8 x 120 1
P5 233 281 414 Elastic nut M8 2
P6 250 000 327 Bolt M8 x 75 1
P7 705 002 648 Cable 1
P8 205 582 560 Bolt M8 x 25 4
705 003 259 Lid Full - Moon
705 003 260 Lid Roadster - RedP9
705 003 389 Lid - Yellow Millennium
1
INSTRUCTIONS
Removal
rsi2008-010-001_a
Bottom Tail Cover Removal
Remove screws [1] securing the bottom tail cover
to rear panels.
Remove screw [2] securing bottom tail cover to
upper tail cover.
Remove bottom tail cover.
rsi2008-010-002_a
Upper Tail Cover Removal
Using a small screwdriver, release the upper tail
cover tabs [3].
Remove upper tail cover.
NOTE: Upper tail cover will be replaced by rear
rack. It should be kept in case of rear rack option
removal.
2 / 6 Instruction Sheet P/N 487 800 252

INSTRUCTIONS
Rear Panel Removal
Unlatch and lift seat.
Remove upper side panels.
rsi2008-010-003_a
Remove screws [4] securing front part of rear panel
(right side shown).
rsi2008-010-004_a
Remove the reusable plastic rivets [5] securing rear
panel (right side shown).
Disconnect and remove battery.
ƽ WARNING
Always disconnect the BLACK (-) cable first.
This will open the battery circuit and remove the
possibility of causing a spark, or a short circuit
with the vehicle when disconnecting the RED (+)
battery cable. Electrolyte or fuel vapors can be
present and a spark may ignite them possibly
causing an explosion which could result in
equipment damage, severe personal injuries, or
death. Do not place tools on battery.
Unplug turn signal connectors.
rsi2008-010-107_a
Remove and discard rear handle assembly bolt [13].
rsi2008-010-106_a
Before beginning installation of rear sport rack,
remove the 2 M6 bolts [P1.2] to separate lower
cover [P1.1] from upper cover [P1].
Installation
rsi2008-010-005_a
Locate hole [6] for lid cable [P7] under seat.

INSTRUCTIONS
rsi2008-010-100_a
Route cable [P7] from under seat toward rear end
of vehicle through frame channel [7].
rsi2008-010-200_a
Fasten knob cable end [2] to frame using spliced
plastic nut [3] supplied with cable [P7]. Torque nut
just enough to avoid fuel tank cover to be warped
[1].
NOTE: Writings on knob must be horizontal in
order to be readable.
rsi2008-010-201_a
Place cable sheath into its groove [1]. As an
adjustment, leave about 12.5 mm (1/2”) of cable
sheath past the groove [2].
Tight cable length adjustment nuts to 4.5 N•m
(40 lbf•in).
rsi2008-010-101_a
Slide extrusion [P2] into frame channel with cable
routed over extrusion [9].

INSTRUCTIONS
rsi2008-010-102_a
Fasten extrusion to passenger handle assembly
with M8 bolt [P6] from upside down.
Torque bolt at 9 N•m (7 lbf•ft).
Place and screw a nut [P5] on passenger handle
assembly bolt and torque nut at 25 N•m (18 lbf•ft).
Fasten extrusion to frame with M8 bolt [P4] and
nut [P5].
Hold bolt and torque nut at 25 N•m (18 lbf•ft).
NOTE: Bolt head must be toward battery rack.
rsi2008-010-202_a
Bring upper cover close to extrusion with front
facing up.
Connect cable to latch [10].
Lay upper cover in position over extrusion.
rsi2008-010-103_a
Slide plates [P3] into end of extrusion.
rsi2008-010-104_a
Fasten upper cover [P1] to extrusion using 4 M8
bolts [P8].
NOTE: The lid [P9] must be installed to make
sure latch works properly and to set proper cable
adjustment.
rsi2008-010-016_a
Install lid by aligning lid hooks into rear rack
openings [12], then push lid forward and down to
lock in position.
NOTE: The latch is designed with dual hook
position like automobile doors. Make sure lid is
correctly latched or it will be secure but loose.
Confirm proper cable unlatching function.

INSTRUCTIONS
Cable must have a free play of about 2 mm
(3/32”) before unlatching lid. If latch doesn't work
properly, upper cover must be removed and cable
readjusted.
If cable is too loose, more cable sheath must be
past extrusion groove.
If cable is too tight, less cable sheath must be past
extrusion groove.
When cable is properly adjusted, Torque upper
cover to extrusion bolts in a criss cross pattern at a
torque of 25 N•m (18 lbf•ft).
rsi2008-010-105_a
Apply Loctite† 243 thread locker (P/N 293 800 600)
on lower cover bolts [P1.2] and fasten lower cover
[P1.1] to upper cover [P1].
Torque bolts to 10 N•m (95 lbf•in).
Reinstall and reconnect battery.
ƽ WARNING
Always connect RED (+) cable first then BLACK
(-) cable.
Reconnect turn signal connectors.
CAUTION: Always test light operation after
reconnecting turn signal connectors.
Reinstall rear panels by fastening screws securing
front part and reinstalling reusable plastic rivets.
Reinstall upper side panels.
Reinstall bottom tail cover.
Warning Label
This product comes with a warning label containing
important safety information.
The label should be considered permanent part of
the product. If the label comes off or becomes
hard to read, please contact an authorized BRP
dealer for free of charge replacement.
Any person who intends to use this product should
read and understand the information contained on
the warning label before doing so.
rsi2008-010-250
(P/N 704 901 871)
Location of the Warning Label
rsi2008-010-300
Under lid.
† Loctite is a registered trademark of Loctite Corp.

REAR RACK BAG
(Kit P/N 280 000 317)
ƽ WARNING
– 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.
ƽ WARNING
Symbol Description
ƽWARNING
Indicates a potentially hazardous situation which, if not avoided, could result in
serious injury or death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle
components.
FASTENER GRADE/TORQUE TO BE USED WHEN TORQUES ARE NOT SPECIFIED IN TEXT.FASTENER
M4
1.5 — 2 N•m
(13 — 18 lbf•in)
2.5 — 3 N•m
(22 — 27 lbf•in)
3.5 — 4 N•m
(31 — 35 lbf•in)
4 — 5 N•m
(35 — 44 lbf•in)
M5
3 — 3.5 N•m
(27 — 31 lbf•in)
4.5 — 5.5 N•m
(40 — 47 lbf•in)
7 — 8.5 N•m
(62 — 75 lbf•in)
8 — 10 N•m
(71 — 89 lbf•in)
M6
6.5 — 8.5 N•m
(58 — 75 lbf•in)
8 — 12 N•m
(71 — 106 lbf•in)
10.5 — 15 N•m
(93 — 133 lbf•in)
16 N•m (142 lbf•in)
NOTE: 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.
Printed in Canada. (rsi2008-021 en DM) Instruction Sheet P/N 219 800 041 1 / 2

ITEM P/N DESCRIPTION QTY
P1 280 000 317 Rear Rack Bag 1
P2 861 777 500
Anchor Kit (Rivets
included)
1
INSTRUCTIONS
rsi2008-021-001_a
Remove screws [1] that hold rear rack lower cap [2].
Remove rear rack lower cap [2] from vehicle.
rsi2008-021-002_a
From inside rear rack lower cap, locate side punch
marks [3].
Drill ø5 mm (13/64”) holes into the center of side
punch marks [3].
Clean off burrs on edge of holes.
rsi2008-021-003_a
Align plastic anchor [P2] with lower cap hole.
Install rivet [P2] through plastic anchor and lower
cap.
NOTE: As per the above picture, make sure plastic
anchors are installed with lever opening toward
upside.
– Top : [A].
– Bottom : [B].
Repeat operation for the other side.
rsi2008-021-004_a
Install bag on vehicle rear rack.
Stretch front bag straps [4] around the vehicle rear
grab bars.
Stretch rear bag straps [5] into the plastic anchors
[P2].
Adjust straps tension as needed.
NOTE: Prolonged exposure to direct sunlight and
heat can result in a breakdown of the fibers in the
bag.
NOTE: Do not store vehicle in direct sun with bag
on.
Attention / Caution Label
This product come with the following fabric label
containing important information.
MAXIMUM LOAD: 3 lbs (1,36 kg) evenly distributed.
CHARGE MAXIMALE : 3 lbs (1,36 kg) bien répartie.
ATTENTION/CAUTION
rsi2008-019-009
Any person who intends to use this product
should read and understand the MAXIMUM LOAD
information contained on the fabric label before
doing so.

Phantom Body Kit (Kit P/N 219 400 090)
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION Indicatesahazardsituationwhich, ifnotavoided, couldresultinminorormoderatein-
jury.
NOTICE Indicates an instruction which, if not followed, could severely damage vehicle components
or other property.
WARNING
– This kit is designed for specific applicable modelsonly (authorized BRP dealers will confirm mod-
el(s)). It is not recommended for units other than the one (those) for which it was sold.
WARNING
FASTENER GRADE/TORQUE TO BE USED WHEN TORQUES ARE NOT SPECIFIED IN TEXTFASTENER
M4
1.5 — 2 N•m
(13 — 18 lbf•in)
2.5 — 3 N•m
(22 — 27 lbf•in)
3.5 — 4 N•m
(31 — 35 lbf•in)
4 — 5 N•m
(35 — 44 lbf•in)
M5
3 — 3.5 N•m
(27 — 31 lbf•in)
4.5 — 5.5 N•m
(40 — 47 lbf•in)
7 — 8.5 N•m
(62 — 75 lbf•in)
8 — 10 N•m
(71 — 89 lbf•in)
M6
6.5 — 8.5 N•m
(58 — 75 lbf•in)
8 — 12 N•m
(71 — 106 lbf•in)
10.5 — 15 N•m
(93 — 133 lbf•in)
16 N•m (142 lbf•in)
NOTE: 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.
Printed in Canada (rsi2008-026 en JPM)

Thank you very much
for your reading.
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2009 Can-Am Spyder GS SM5/SE5 And Spyder GS Service Repair Manual

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