Rotax 600 H.O. E-TEC Engine for Ski-Doo snowmobiles

BACKGROUNDER

Rotax 600 H.O. E-TEC Enginefor Ski-Doo snowmobiles

Already the undisputed leader in advanced two-stroke snowmobile engines with its SDI andPower T.E.K. technologies, BRP is taking lightweight two-strokes to the next level with theintroduction of the Rotax® 600 H.O. E-TEC� engine for its Ski-Doo® snowmobiles..

BRP pioneered E-TEC direct injection two-stroke technology – where the fuel is injected directlyinto the cylinder under extremely high pressures – in its Evinrude® outboard engines, where itwon the Clean Air Technology Excellence Award from the US Environmental Protection Agency,as well as several prestigious third party customer satisfaction awards. The Rotax E-TECsystem delivers several benefits:

15% better fuel economy than the current 600 H.O. SDI engine.

Half the oil consumption of the SDI, meaning most owners will need to add oil onlyonce per season.

As the cleanest two-stroke snowmobile engine by a wide margin (see chart page 4),there’s virtually no smoke or smell.

Lightweight – An MX Z TNT snowmobile with the 600 H.O. E-TEC engine weighs just415 pounds (188 kg).

Hassle-free ownership – super smooth idle, one-pull start in all conditions, built-inbreak-in, three-year spark plug warranty, built-in summerization program and addedgauge readings.

While the 600 H.O. E-TEC is based on the 600 H.O. SDI engine, it is much more than just theaddition of the E-TEC injectors. E-TEC is an entire system of cutting edge technologies –engine control unit, injectors, fuel system, oil system, 3-D R.A.V.E. exhaust valves and more.

How high tech is this system? The engine control computer can process more than 8,000calculations per second and must be fuel-cooled. Yes, a liquid-cooled ECM.

2009 Ski-Doo Press Kit: E-TEC Backgrounder Page 2 of 10

BENEFITS

Fuel EconomyThe 600 H.O. E-TEC engine uses the least fuel of any current two-stroke engines in theindustry:

21 mpg / 25 mpg CDN

Sled/Engine mpg diff.mpg

mpgCDN

diff.mpgCDN

%diff.

$ savingsseason

MX Z 600 H.O. E-TEC 21 25MX Z 600 H.O. SDI 18.3 -2.7 22 3 15% $31Polaris� Fusion 600 CFI 12.5 -8.5 15 10 78% $137Arctic Cat 600 EFI 11.6 -9.4 14 11 92% $164Yamaha Nytro� 130 EFI 18.3 -2.7 22 3 15% $31*Based on 1,242 miles, $3.42/gallon premium fuel, assumes US$ and CDN$ are equal

Source: Ski-Doo Engineering Test Procedure 2006-2007


Oil EconomyThe 600 H.O. E-TEC engine uses the least oil of any current industry two-stroke – mostriders will need to add oil only once per season (500km/l X 3.8l oil tank=1,850km)

Source: BRP Engineering test procedure, 2006-2007

Comparatively, the 600 H.O. E-TEC engine uses just: Half the oil of the 600 H.O. SDI Half the oil of the Polaris 600 CFI One Third the oil of the Arctic Cat 600 EFI

Other benefits: Most riders will add oil just once per season (assuming 1,850 km, 3,8 l oil/season) E-TEC oil is designed to be combusted – and this environmental impact factor is

accounted for in the low US EPA rating The engine is constantly lubricated with fresh, uncontaminated oil


EmissionsThe 600 H.O. E-TEC engine is the cleanest two-stroke in the industry – directlytranslating into virtually NO smoke and smell

Carbon Monoxide and Hydrocarbon EmissionsFEL (gr/Kw-hr)

Source: EPA Web Site, Certification Information Center

Comparatively, the 600 H.O. E-TEC engine emits: Half the smoke and smell of the 600 H.O. SDI Half the smoke and smell of the Polaris 600 CFI One third the smoke and smell of the Arctic Cat 600 EFI

Resulting in an EPA rating of 2.6

Source: EPA Web Site, Certification Information Center


Hassle-Free Ownership FeaturesThe E-TEC system’s sophistication offers many benefits of ownership:

Super smooth, refined idle Built-in break-in period One-pull start – even in cold start conditions Three year 10,000 km/6,200 mile warranty on the platinum-tipped spark plugs Automatic summerization function for protection in off-season; an industry first. A push

of the button starts the engine, the oil pump coats the cylinders with oil then shuts downautomatically.

Added Multi-function gauge readings, such as average fuel consumption


SYSTEMS

InjectorsOn an E-TEC engine, the fuel injectors are positionedadjacent to the spark plug in the cylinder head,producing a very complete burn. Injecting fuel into thecombustion chamber as the piston is compressingrequires extremely high pressure. E-TEC electronicinjectors deliver the fuel at 35 BAR – or more than 500PSI.

How They Work

Each E-TEC voice-coil injector has a metal cylinder wrapped with wire, aspring-loaded piston and a spring-loaded plunger. Running a currentthrough the coil of wire creates a magnetic field that repels the pistondown. This pressurizes the fuel and then pushes the plunger open,releasing the fuel into the cylinder. The injection is fine-tuned by varyingthe frequency, duration and timing of the electrical charges.

This technology is called “voice coil” because this is exactly how audiospeakers work.

Notable

Incredible Precision. As hardware, these injectors are incredibly precise; and they aremade even more exacting through software. Each injector is tested on a flow bench forvariances less than 1%. When it is installed onto the engine, the injector is scanned intothat engine’s ECM, where it is assigned one of 33 different injection programs. Thesoftware compensates for manufacturing tolerances to achieve extreme precision.

Homogeneous vs. Stratified Charge. BRP uses the extreme precision and control ofthe system in unique ways. At higher RPM, a tight cone of fuel is injected into thecylinder, where it mixes with air for a split second before being combusted by the spark.This is a homogeneous – or mixed – charge. “The power charge.”

At lower RPM, a tight cone of fuel is also injected into the cylinder but one-third less fueland right before the spark. The fuel combusts before it gets a chance to disperse. Thebenefit of this stratified charge – or the “run charge” – is that this 600cc engine runs withthe fuel of a 200cc engine at idle.

In addition to the significant reduction of fuel consumption, this also virtually eliminatessmoke and smell and produces a perfectly flat idle.

Fuel-cooled injectors. As the E-TEC voice-coil injectors run quite hot due to theirspeed and electro-magnetic nature, they are cooled by fuel in the open loop fuel system.


Oil SystemNearly as sophisticated as the injection system, the E-TEC oilsystem uses just half the oil as the 600 H.O. SDI engine.

How It Works

The pump itself consists of an electronic solenoid similar to thevoice-coil injectors, which activates four pistons. Targeted oilinjection supplies oil right where it is needed – two lines lubricatekey crankcase areas, two lubricate the R.A.V.E. valves.

Notable

Incredible Precision. Each oil pump is bench flow testedfor manufacturing tolerances and the ECM programmedwith a 3-D map to match the pump’s performance.Software makes the hardware more precise.

No Maintenance. Because the system is electronic, thereare no cable adjustments needed.

Tailored performance. The software matches oil deliveryto many factors, including a break-in period, the way therider drives, and changes in altitude. This system andsoftware includes the industry’s first built-in summerizationfunction.


3-D R.A.V.E. Exhaust ValvesTightening the tolerances even more foradded performance, emissions and fueleconomy, compelled BRP to use anelectronic version of the 3-D R.A.V.E.exhaust valves. The 3-D R.A.V.E. systemdebuted for the 2007 model year on the800R Power T.E.K. engine. 3-D stands for:

three-opening positions; the valves control three exhaust port

openings per cylinder; and the 3-D mapping that determines

their operation.

How it WorksBy changing the height and size of theexhaust ports as RPMs change, exhaustvalves produce a fuel efficient and torque-yengine at lower rpm, and higher performingengines at mid- and high- rpm.

At idle and at low speeds, a vacuum ofcrankcase pressure sucks the secondaryvalve closed so all ports are closed. Then,at mid-range engine speeds, the ECM opensthe secondary valve to its neutral position byreleasing the vacuum. At higher speeds, theECM orders crankcase pressure to pushopen the primary valve for the highestperformance.

Notable

Added features for added precision. While based on the 3-D R.A.V.E. valves on the800R Power T.E.K. engine, BRP added an electronic position sensor linked to the ECMand a bar linking the two valves.

Oil. The electronic oil pump has lines to each R.A.V.E. valve to lubricate the guillotine,ensuring crisp, dependable performance. For instance, if the valve becomes stuck orslow because of residue build-up, the ECM will know that the valve is closed when itshould be open (thanks to the new position sensor). It then will send a message to thegauge.

Pioneer. BRP introduced exhaust valves to production snowmobiles in 1989.


ECMControlling and coordinating all of the E-TEC system’ssophisticated technologies is extremely complex and requires alot of computing power, which is handled by a powerful newengine control module.

Notable

Supercomputer. The E-TEC engine's ECM canperform 8,000 calculations per second.

Liquid-cooled. As running so many calculations generates a lot of heat, the ECM iscooled by the open-loop fuel system. Even when running in a snowmobile in winterconditions!

Fuel PumpIn the E-TEC system, the fuel pump does more than justdeliver fuel to the engine. It also is a cooling system for theECM and injectors – so it is an open loop system.

Notable

High fuel delivery rate. Because it must cool theECM and injectors, as well as supply fuel forcombustion, the E-TEC system fuel pump has a veryhigh delivery rate.

Battery-less. The pump runs right off the magneto, so it needs no battery, savingweight.

Ignition SystemThe ignition system’s fast rise time inductive digital ignition (IDI)means a super smooth idle, virtual elimination of plug fouling andoutstanding combustion stability.

Notable

One-pull starts – EVERY time. The fast rise time IDIenables the engine to easily start with just one pull of therecoil rope – regardless of the conditions.


®, ™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its subsidiaries.

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www.brp.comwww.ski-doo.com

For product information:Canada & U.S.:Steve CowingCompetition and Media Relations [email protected]

International:Philippe NormandProduct Manager, BRPQuad, PWC, Sport Boat, Roadster,[email protected]

Documents

Rotax 600 H.O. E-TEC Engine for Ski-Doo snowmobiles