BOMBARDIER outlander max 800 Operator's Manual
  1. Manuals
  2. Brands
  3. BOMBARDIER Manuals
  4. Offroad Vehicle
  5. outlander max 800
  6. Operator's manual

BOMBARDIER outlander max 800 Operator's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading

Related Manuals for BOMBARDIER outlander max 800

Summary of Contents for BOMBARDIER outlander max 800

  • Page 2 This ATV may exceed the performance of other ATVs you may have ridden in the past. This is a high performance ATV designed for use by experienced operators. Printed in the E.U. (Outlander 800 MAX EN 2006.fm) Trademarks of Bombardier Recreational Products Inc. or its affiliates. ®TM ©...

  • Page 3: Important Information

    All content of the Safety Information section should be interpreted by the reader as a warning which, if not followed, may result in injury including the possibility of death. In Canada, products are distributed by Bombardier Recreational Products Inc. (BRP). In USA, products are distributed by BRP US Inc.
  • Page 4 It is backed scriptions contained in this document are cor- by the BRP warranty and a network of autho- rect at the time of publication. Bombardier rized Bombardier ATV dealers ready to pro- Recreational Products Inc. however, main-...

  • Page 5: Table Of Contents

    LOCATION OF THE IMPORTANT LABELS ............SAFETY TRAINING INTRODUCTION....................Objective....................Sections Covered ................... Time Required ..................SECTION I - GENERAL SAFETY INFORMATION ..........Objective....................Outline ....................Expected Results..................SECTION II - BOMBARDIER 2-UP VEHICLE SAFETY VIDEOCASSETTE ..Objective....................Outline ....................
  • Page 6 Expected Results..................DRIVING MANEUVER LIST ................INSTRUCTOR’S CHECK LIST ................Introduction:..................... Section I: General Safety Information............Section II: Bombardier 2-Up Vehicle Safety Videocassette..... Section III: Operator’s Guide Review ............Section IV: Hands-On Riding..............Trainee’s Scoring Chart................VEHICLE INFORMATION HOW TO IDENTIFY YOUR ATV .................
  • Page 7 22) Tool Kit ..................... 100 23) Dipstick..................... 100 24) Winch ....................100 25) Winch Control Switch ............... 100 26) Fairlead .................... 101 LIQUIDS....................... 102 Fuel......................102 Engine/Transmission Oil ................ 102 Gearbox Oil..................... 104 Engine Coolant ..................104 Brake Fluid....................105 Battery ....................
  • Page 8 Engine Area..................... 145 Hitch/Trailer Ball Condition ..............145 Chassis Fasteners................... 145 Seat Fasteners ..................145 Vehicle Cleaning and Protection ............. 145 WARRANTY BRP INTERNATIONAL LIMITED WARRANTY: 2006 BOMBARDIER ATV PRODUCTS....................148 PRIVACY OBLIGATION/DISCLAIMER .............. 151 CHANGE OF ADDRESS/OWNERSHIP ............. 153...

  • Page 9: Notice

    NOTICE This Operator’s Guide has been prepared to acquaint the owner/operator of a new vehicle with the various vehicle controls, mainte- nance and safe operating instructions. It is in- dispensable for the proper use of the product. This Operator’s Guide uses the following symbols.

  • Page 10: Introduction

    INTRODUCTION Your dealer should have provided you with some basic information on the particular controls and features of your new vehicle. Please take the time to study this Operator’s Guide and all on- product warning labels as well as the Safety Videocassette that came with this vehicle. They more completely describe what you should know about this vehicle before riding it.

  • Page 11: Safety Information

    SAFETY INFORMATION...
  • Page 12 WARNING Operator: • A person under 16 years old should never operate this vehicle. • Never carry more than one passenger on this vehicle. • Passenger must be seated on the designated passenger seat and hold on to the grab handles at all times.

  • Page 13: Special Safety Messages

    Never operate this vehicle without proper instruction. Take a training course offered by BRP. All operator should receive training from a certified instructor. See your authorized Bombardier ATV dealer for more informations. Always follow this age recommendation: A person under 16 years old should never operate this vehicle.
  • Page 14 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating this vehicle. Always keep in mind that you are carrying a passenger. Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control this vehicle on such terrain.
  • Page 15 Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described further in this Operator's Guide. Do not forget, the operator is responsible for the safety of the passenger.

  • Page 16: Operation Warnings

    Beginning and inexperienced operators should complete the training course offered by BRP. They should then regularly practice the skills learned in the course and the operating tech- niques described further in this Operator’s Guide. For more information about the training course, contact an authorized Bombardier ATV dealer.
  • Page 17 WARNING V00A01Q POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN A lack of respect for this age recommendation can lead to severe injury or death of the child. Even though a child may be within the age group for which this vehicle is recommended, he may not have the skills, abilities, or judgment needed to operate this vehicle safely and may be involved in a serious accident.
  • Page 18 WARNING V00A1BQ POTENTIAL HAZARD Failure to follow the age recommendations for the passenger. WHAT CAN HAPPEN A child, under 12, may not have the ability needed to ride safely and may be involved in a serious accident. HOW TO AVOID THE HAZARD No one under 12 should be riding on this vehicle.
  • Page 19 WARNING V00A1CQ POTENTIAL HAZARD Carrying more than one passenger on this vehicle. WHAT CAN HAPPEN Carrying more than one passenger reduces your ability to balance and control this vehicle. Could cause an accident, resulting in harm to you and/or your passengers. HOW TO AVOID THE HAZARD Never carry more than one passenger.
  • Page 20 WARNING V00A2DQ POTENTIAL HAZARD Allowing passenger to sit in a location other than the designated passenger’s seat. WHAT CAN HAPPEN Passenger seated in a location other than the designated passenger’s seat could: - impair vehicle stability which could lead to a loss of control - suffer injury from impact on hard surfaces.
  • Page 21 WARNING V00A1DQ POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN The ATV’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
  • Page 22 WARNING V00A1EQ POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states or provinces it is illegal to operate ATVs on public streets, roads and highways.
  • Page 23 WARNING V00A1FQ POTENTIAL HAZARD Riding this vehicle without wearing an approved helmet, eye protection and protective cloth- ing. Passenger should also have an approved helmet with a rigid chin guard. WHAT CAN HAPPEN The following items concern the operator and the passenger: - riding without an approved helmet increases the chances of a severe head injury or death in the event of an accident - riding without eye protection can result in an accident and increases the chances of a severe...
  • Page 24 WARNING V00A07Q POTENTIAL HAZARD Riding this vehicle after consuming alcohol or drugs. WHAT CAN HAPPEN Could cause the passenger to fall off. Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident or death of passenger and/or operator.
  • Page 25 WARNING V00A08Q POTENTIAL HAZARD Operating this vehicle at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the vehicle, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions, and your experience.
  • Page 26 WARNING V00A1GQ POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, for the operator and the passenger, including an over- turn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Do not try to show off.
  • Page 27 WARNING POTENTIAL HAZARD Failure to inspect this vehicle before operating. Failure to properly maintain this vehicle. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition.
  • Page 28 WARNING V00A1HQ POTENTIAL HAZARD Removing hands from handlebars for the operator and from grab handles for the passenger, or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the vehicle or could cause you to lose your balance and fall off the vehicle.
  • Page 29 WARNING V00A1IQ POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the vehicle overturning, passenger ejection or loss of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain.
  • Page 30 WARNING V00A1JQ POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn or passenger ejection. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control this vehicle on such terrain.
  • Page 31 WARNING V00A1KQ POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Vehicle could go out of control, causing a collision, an overturn or a passenger ejection. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described further in this Operator's Guide. Practice turning at low speeds before attempting to turn at faster speeds.
  • Page 32 WARNING V00A1LQ POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice, without and with passenger, on smaller hills before attempting larger hills.
  • Page 33 WARNING V00A1MQ POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or cause vehicle to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described further in this Operator's Guide.
  • Page 34 WARNING V00A1NQ POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or cause vehicle to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described further in this Operator's Guide.
  • Page 35 WARNING V00A1OQ POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or cause vehicle to overturn. HOW TO AVOID THE HAZARD Never attempt this maneuver when the passenger is on board. Always disembark him before executing.
  • Page 36 WARNING V00A1PQ POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in vehicle overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Operator and passenger must keep their weight uphill.
  • Page 37 WARNING V00A1QQ POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or a collision. Could cause the vehicle to overturn. HOW TO AVOID THE HAZARD The operator is responsible for the safety of his passenger. In doubt, disembark him before riding over obstacles.
  • Page 38 WARNING V00A1RQ POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this vehicle. You may also regain traction unexpectedly, which may cause the vehicle to overturn or pas- senger ejection. HOW TO AVOID THE HAZARD Never slide or skid with passenger.
  • Page 39 WARNING V00A1SQ POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this vehicle in fast flowing water or in water deeper than that specified further in this Operator's Guide.
  • Page 40 WARNING V00A1TQ POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind the vehicle, resulting in serious injury. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no obstacles or people behind the vehicle. When it is safe to proceed, go slowly.
  • Page 41 WARNING V00A0OQ POTENTIAL HAZARD Operating this vehicle with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this vehicle, or operation of this vehicle with improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified further in this Operator's Guide for this vehicle.
  • Page 42 Never modify this vehicle through improper installation or use of accessories. All parts and accessories added to this vehicle should be approved by BRP and should be installed and used according to instructions. If you have questions, consult an authorized Bombardier ATV dealer.
  • Page 43 WARNING V00A1UQ POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle including operator and passenger, as well as other loads and added accessories.
  • Page 44 WARNING V03M01Q POTENTIAL HAZARD Transporting inflammable or dangerous material can lead to explosions. WHAT CAN HAPPEN This can cause serious injury or death. HOW TO AVOID THE HAZARD Never transport inflammable or dangerous material. While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death.

  • Page 45: Safety Warning

    SAFETY WARNING To fully appreciate the pleasures and excitement of riding this vehicle, there are some basic rules and tips that you should follow. Some may be new to you while others may be common sense or obvious. Irrespective, we ask that you take a few minutes to read this Operator's Guide com- pletely before you operate this vehicle.
  • Page 46 Activate the brake lever and brake pedal Correct any problem you may have found be- to make sure the brakes fully apply. Lever fore riding. See an authorized Bombardier and pedal must fully return when released. ATV dealer as necessary.

  • Page 47: Clothing

    Clothing Actual weather conditions should help you decide how to dress. However, it is important that the operator and the passenger always wear the appropriate protective clothing and apparel, includ- ing an approved helmet, eye protection, boots, gloves, long sleeved shirt and pants. The pas- senger should have an approved helmet including a rigid chin guard.

  • Page 48: Carrying Loads/Passenger

    A variety of accessories are available from your authorized Bombardier ATV dealer. However, always respect the load and capacities of the vehicle. Over- loading of the vehicle can overstress the components and cause failure. To prevent possible injury, it is equally important to follow the instructions and warnings that accompany the acces- sory.

  • Page 49: Recreational Riding

    Recreational Riding Respect the rights and limitations of others. Stay away from areas designated for other types of off road use. This includes snowmobile trails, equestrian trails, cross country ski trails, mountain bike trails etc. Never assume there are no other users on the trail. Always stay to the complete right of the trail and do not zig zag to one side of the trail then the other.

  • Page 50: Off-Highway Operation

    Off-Highway Operation The very nature of off-highway operation is dangerous. Any terrain, which has not been specially prepared to carry vehicles, presents an inherent danger where angularity, terrain substance and exact steepness are unpredictable. The terrain itself presents a continual element of danger, which must be knowingly accepted by anyone venturing over it.

  • Page 51: Downhill Driving

    Downhill Driving This vehicle can climb slopes that are steeper than it can safely descend. Therefore, it is essen- tial to assure that a safe route exists to descend a slope before you climb it. Decelerating while negotiating a slippery downhill slope could “toboggan” the vehicle. Maintain steady speed and/or accelerate slightly to regain control.
  • Page 52 V00A1VL Even though there is an adequate suspensions system on this vehicle there are “washboard” or rough terrain conditions that will make you feel uncomfortable and even cause back injury. “Post- ing” or riding in a crouched position will often be required. Slow down and allow your flexed legs to absorb impact.
  • Page 53 V00A25L Water will affect the braking ability of your vehicle. Make sure you dry the brakes by applying them several times after the vehicle leaves the water. The vehicle braking distance may be affected when riding with a passenger. Safely reduce speed when riding with a passenger. Allow greater distance for braking.
  • Page 54 Riding on loose stones or gravel is very similar to riding on ice. They will affect the steering of vehicle... possibly causing it to slide or cause passenger ejection and tipover especially at high speeds. In addition, braking distance may be a effected. Remember that “gunning”...
  • Page 55 Uphill Do not forget, the operator is responsible for the safety of the passenger. In doubt, disembark him before climbing hill. Always remember that the vehicle handling, stability and braking dis- tance may be affected when riding with a passenger. If you decide to keep your passenger, he must synchronize his movements with yours.
  • Page 56 Downhill Do not forget, the operator is responsible for the safety of the passenger. In doubt, disembark him before going down the hill. Always remember that the vehicle handling, stability and braking distance may be affected when riding with a passenger. If you decide to keep your passenger, he must synchronize his movements with yours.
  • Page 57 Side-Hilling Do not forget, the operator is responsible for the safety of the passenger. In doubt, disembark him before proceeding. Always remember that the vehicle handling, stability and braking dis- tance may be affected when riding with a passenger. If you decide to keep your passenger, he must synchronize his movements with yours. This is one of the most risky types of riding since it may drastically change the balance of the vehicle.

  • Page 58: Routine Maintenance

    If further assistance is required your authorized Bombardier ATV dealer is always willing to help. Modification of the vehicle to increase speed and performance may violate the terms and con- ditions of your vehicle limited warranty.

  • Page 59: Hang Tag

    DESIGNED FOR USE BY EXPERIENCED • on public roads - a collision can occur with another ve- OPERATORS. hicle. BOMBARDIER 2-UP ATV SAFETY THE OPERATOR MUST ALWAYS TRAINING IS MANDATORY. MAKE • use proper riding techniques to avoid overturns on hills and rough terrain and in turns.

  • Page 60: Location Of The Important Labels

    LOCATION OF THE IMPORTANT LABELS The following labels are on your vehicle and should be considered permanent parts of the vehi- cle. If missing or damaged, they can be replaced free of charge. See an authorized Bombardier ATV dealer. NOTE: The following illustrations used in this Operator’s Guide are a general representation only.
  • Page 62 Label 1 Label 3 WARNING CAUTION Improper vehicle use can result in SEVERE INJURY or DEATH. • ATV MUST be stopped before shifting lever. ALWAYS USE NEVER USE NEVER CARRY NEVER RIDE AN APPROVED ON PUBLIC MORE THAN AFTER • Always apply foot brake to HELMET AND ROADS.
  • Page 63 Label 6 Label 9 WARNING Improper loading of a trailer may cause loss of vehicle control, resulting in severe injury or death. • Maximum towing weight: 500 kg (1100 lb). • Maximum tongue weight: 14 kg (30 lb). Label 7 WARNING INTERNATIONAL MODELS ONLY •...
  • Page 64 ENGINE OIL ENGINE OIL IDLE SPEED IDLE SPEED SPARK PLUG TYPE SPARK PLUG TYPE SPARK PLUG GAP SPARK PLUG GAP SEE OPERATOR’S GUIDE FOR MAINTENANCE SPECIFICATIONS / SEE OPERATOR’S GUIDE FOR MAINTENANCE SPECIFICATIONS BOMBARDIER RECREATIONAL PRODUCTS INC. LOCATED UNDER SEAT...

  • Page 65: Safety Training

    SAFETY TRAINING...

  • Page 66: Introduction

    INTRODUCTION Objective The objective of this course is to give the Bombardier 2-UP vehicle owner the informa- tion required to operate a 2-UP vehicle safely. The course will be offered to all 2-UP vehicle buyers, and members of their immediate fam- ilies.

  • Page 67: Section I - General Safety Information

    – Do not allow a person unfamiliar with your Commission) Injury and Death Statistics. 2-UP vehicle to operate it. c) Discuss Bombardier's age and size rec- D) Protective Clothing that Should be Worn ommendation. by the Driver and the Passenger d) Discuss what protective clothing should be –...

  • Page 68: Expected Results

    E) Riding with a Passenger – Before riding with a passenger, the opera- tor should first become highly familiar with the operation of the 2-UP vehicle. – Once ready, the operator should begin riding with a passenger at very low speed and on familiar terrain.

  • Page 69: Section Ii - Bombardier 2-Up Vehicle Safety Videocassette

    Upon completion of this section, you should: – Know the content of the Bombardier 2-UP Body Posture vehicle Safety Videocassette. You and your passenger must position your body weight to lessen the hazard of tipping over.

  • Page 70: Section Iii - Operator's Guide Review

    SECTION III - OPERATOR'S GUIDE REVIEW Objective Expected Results The purpose of this section is to: Upon completion of this section, you should: a) Emphasize the importance of observing – Be familiar with the need to review the the warning and caution symbols. Operator's Guide frequently.

  • Page 71: Section Iv - Hands-On Riding

    SECTION IV - HANDS-ON RIDING Objective C) Basic Maneuvers – Drive the course performing all of the basic The purpose of this section is to: maneuvers described in the attached a) Familiarize you with the pre-operation DRIVING MANEUVER LIST, without a check.

  • Page 72: Driving Maneuver List

    DRIVING MANEUVER LIST Maneuver # 2 Hands-on riding practice should incorporate the maneuvers described below. Turning left and right - figure 8's (minimum Trainees are required to perform a minimum repetition: three times). number of repetitions of each of the eight driv- ing maneuvers.
  • Page 73 Maneuver # 3 Maneuver # 4 Sharp turns less than 90° - left and right. Cor- Slalom (minimum repetition: three times). ners 90 and less than 90 (minimum repetition: two clockwise and two counterclockwise). FINISH START START FINISH V01A4IY V01A4HY TYPICAL 1.
  • Page 74 Maneuver # 5 Maneuver # 6 Quick stop: large oval with panic maneuver Riding over obstacle (minimum repetition: (minimum repetition: two times). once with left wheels, once with right wheels, and once with both wheels). FINISH START START 1.5 m (5’) 1.2 m (4’) 1.8 m (6’) FINISH...
  • Page 75 Maneuver # 7 Maneuver # 8 Traversing hills (minimum repetition: once U-turn and K- turn (minimum repetition: one each direction). time). 9 m (30’) 2.4 m Uphill (8’) START FINISH V01A5SY TYPICAL U- TURN Uphill START FINISH V01A4LY 2.4 m TYPICAL (8’) 1.

  • Page 76: Instructor's Check List

    Random checks will be performed by a third party agency to ensure the training is being per- formed. Failure to perform the required training may constitute a violation of the Bombardier ATV dis- tributor/dealer agreement. If you would like further information on the 2-UP vehicle Safety Training course, please con- tact BRP.

  • Page 77: Section Iii: Operator's Guide Review

    Section III: Operator’s Guide Review ! Review the Operator’s Guide with your trainee. Emphasize the need for periodic and frequent reviews of the guide. ! Draw trainee's attention to the warning and caution symbols, and explain their meaning. Section IV: Hands-On Riding ! Perform the pre-operation check with your trainee.
  • Page 78 6) Riding Over Obstacles Riding over obstacles – 4 x 4 pieces of wood should be placed in vehicle’s path so rider can drive over them (minimum repetition: once with left wheels, once with right wheels, and once with both wheels). 7) Traversing Hills First, remind the trainee that sidehilling should be avoided if possible.

  • Page 79: Trainee's Scoring Chart

    Trainee’s Scoring Chart EXERCISE PASS FAIL 1. Starting and stopping 2. Turning 3. Sharp turns 4. Slalom 5. Quick stops 6. Riding over obstacles 7. Traversing hills (if there is no hill available, make sure to review the description of the maneuver in the Operator’s Guide with the trainee) 8.

  • Page 81: Vehicle Information

    VEHICLE INFORMATION...

  • Page 82: How To Identify Your Atv

    These numbers are required by the LABEL LOCATION authorized Bombardier ATV dealer to com- plete warranty claims properly. No warranty All Outlander MAX Under seat, on the will be allowed by BRP Inc.

  • Page 83: Emission Requirements

    EMISSION REQUIREMENTS The California Air Resources Board (CARB) requires that your ATV complies with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions supplied. A non-compliance Red Label (as well as a Green Label) is obtained annually during California Vehicle registration.

  • Page 84: Controls/Instruments/Equipment

    CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment are optional.
  • Page 85 While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death.

  • Page 86: Throttle Lever

    3) Brake Lever NOTE: This section gives basic functions of the various controls of your ATV. For more de- Located on the left side of handlebar. When tails of how to operate one control in conjunc- the brake lever is compressed, the front and tion with some others, refer to OPERATING rear brakes are applied.

  • Page 87: Brake Lever Lock

    4) Brake Lever Lock To release mechanism: Squeeze brake le- ver. Lever lock should automatically return to Located on left side of handlebar on the brake its original position. Brake lever should return lever. When applied, it prevents the vehicle to rest position.

  • Page 88: Multifunction Switch

    Headlamp Switch R: Reverse This allows the vehicle to go backward. The Located on the top of multifunction switch. vehicle speed is limited. Place headlamp switch to LO for the low beam and taillight. Place headlamp switch to WARNING HI for the high beam and taillight. Before moving vehicle in reverse, ensure the path behind is clear of obstacles or by- standers.

  • Page 89: Start Button

    NOTE: Place ignition switch to ON “without This switch can be used to stop engine and light” position to close the headlamp. as an emergency control. NOTE: While engine can be stopped by turn- ing ignition key OFF, we recommend the en- gine be stopped by the engine stop switch.

  • Page 90: Speedometer

    Override Button Speedometer This vehicle is equipped with an electronic Located below engine stop switch. multi-function speedometer. It is backlit every time the ignition switch is turned ON. V07I07Y TYPICAL 1. Override button 2. Engine stop switch TYPICAL This button is used to override the reverse 1.
  • Page 91 The speedometer pointer has two modes, it but it is possible to change it to kilometer read- can show vehicle speed or engine revolution ing. Contact an authorized Bombardier ATV per minute. dealer. NOTE: The unit modification is applied to the odometer and trip meter.
  • Page 92 LOW GEAR NOTE: If the letter “E” is displayed in the transmission position display, it means that there is a electrical communication error. Contact an authorized Bombardier ATV dealer. Multi-Function Display NOTE: Use the selector button to change dis- play to the desired mode.
  • Page 93 CAUTION: (1) If the light does not turn off right after engine starting, stop engine. Check engine oil level. Refill if necessary. If the oil level is good, see an authorized Bombardier ATV dealer. Do not use the vehicle until repaired.

  • Page 94: 12-Volt Power Outlet

    3. Check engine indicator lamp An auxiliary supply is available to connect ad- 4. High beam indicator lamp ditional accessories. Two wires are hidden in the wiring harness at the rear of vehicle. See an authorized Bombardier ATV dealer for more details.

  • Page 95: Ignition Switch

    Ignition Switch 10) Fuel Tank Cap Located on the console. The fuel tank cap is located on the left side of the rear fender. Key-operated, 3-position switch: OFF, ON with lights and ON without lights. CAUTION: Never place anything over fuel tank cap because the vent hole on the top of fuel tank cap can be blocked and the engine could misfire.

  • Page 96: Brake Pedal

    11) Brake Pedal 13) Grab Handles Located on the right footrest. When pressed The grab handles are located on each side of down, the rear brake is applied. When re- passenger's seat. leased, the brake pedal should return to its original position.
  • Page 97 Passenger’s Seat Installation The conversion of the vehicle is easy, remove the passenger’s seat then install the storage – Insert passenger's seat positioning tubes box or vise versa. Use the procedure de- into rear fender provided holes. scribed below to remove and install the fea- tures correctly.

  • Page 98: Operator's Seat

    Storage Box Removal 15) Operator’s Seat NOTE: To remove the operator’s seat, the – Pull storage box strap to release from ve- passenger’s seat or storage box removal is hicle. necessary. – Remove storage box. Seat Removal To remove the operator’s seat, push its latch forward.

  • Page 99: Access Panel

    Seat Installation 16) Access Panel The access panel is located on the front fend- Insert front tabs of seat into frame hooks. er, between front racks. To open the panel, When seat rests in its position, firmly push unlatch, lift then remove it completely. seat down to latch.

  • Page 100: Rear Storage Compartment

    17) Rear Storage Compartment 18) Cargo Racks Located in rear of vehicle. Convenient loca- Located on top of chassis at front and rear. tion to carry personal articles such as a spare Convenient racks to carry gear. spark plugs, first aid kit, etc. Unlatch cover, WARNING gently lift then remove cover.

  • Page 101: Radiator Cap

    20) Radiator Cap Located in service compartment, under ac- cess panel. WARNING In order to avoid getting burned do not re- move the radiator cap when the engine is hot. To remove the radiator cap, press and turn it counterclockwise. Reverse the removal pro- cedure to install.

  • Page 102: Tool Kit

    22) Tool Kit The tool kit is located in the rear storage com- partment. It contains tools for basic mainte- nance, this Operator’s Guide and the ATV Winch Operator's Manual with the XT models. The tools included in the tool box are: –...

  • Page 103: Fairlead

    26) Fairlead XT Models Located on the front of skid plate. The fairlead is used to prevent the damages to the vehicle and guide the wire rope into the winch. 1. Winch 2. Front skid plate 3. Fairlead 4. Winch hook...

  • Page 104: Liquids

    LIQUIDS While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death. NOTE: Fuel Level This section specifies the recommend- ed liquids and procedures to check their levels. Refer to MAINTENANCE for procedures to re- WARNING place the liquids.

  • Page 105: Oil Level

    Oil Viscosity SAE 5W30 is recommended for all seasons. However, during the hottest days of the sum- mer and bitter cold days of the winter, refer to the following chart to select the proper viscos- ity. NOTE: For improved overall performance and wear protection use XP-S 5W40 synthet- ic 4-stroke oil (P/N 293 600 039).

  • Page 106: Gearbox Oil

    C o o l i n g s y s t e m m u s t b e f i l l e d w i t h Properly tighten dipstick. Bombardier premixed coolant (P/N 219 700 362) or with distilled water and antifreeze so- Gearbox Oil lution (50% distilled water, 50% antifreeze).

  • Page 107: Brake Fluid

    Do not use brake fluid tak- en from old or already opened containers. NOTE: A low level may indicate leaks or worn brake pads. See an authorized Bombardier ATV dealer. Brake Lever Fluid Reservoir Turn steering in the straight-ahead position to ensure reservoir is level.

  • Page 108: Battery

    Battery This vehicle is equipped with a dry type bat- tery that requires no maintenance. Refer to MAINTENANCE to removal/installa- tion instructions.

  • Page 109: Break-In Period

    10 hours, 300 km (185 mi) or 30 days after the accelerations, prolonged cruising speeds and purchase, whichever comes first, your vehicle engine overheating are detrimental during the be inspected by an authorized Bombardier break-in period. ATV dealer. This inspection will give you the opportunity to discuss the unanswered ques- tions you may have encountered during the first hours of operation.

  • Page 110: Operating Instructions

    . S e e a n a u t h o r i z e d • Activate throttle control lever several times Bombardier ATV dealer as necessary. to ensure it operates freely. It must return to idle position when released.

  • Page 111: Starting The Engine

    Starting the Engine 2WD/4WD Selector Insert key in ignition switch and turn to ON. The 4WD mode may be selected or deselect- ed when the vehicle is stopped. Place the engine stop switch to RUN. CAUTION: The vehicle must be stopped to Press the start button and hold until the en- engage or disengage 2WD/4WD selector.

  • Page 112: Winch Operation

    Metallic parts lubrication is highly rec- ommended. Use BOMBARDIER LUBE (P/N 293 600 016) or an equivalent. This must be performed at the end of each operat- ing day.

  • Page 113: Special Procedures

    Never refill cooling system when engine is continues to flood, see an authorized hot. Bombardier ATV dealer. See an authorized Bombardier ATV dealer as soon as possible. Turn Over When vehicle is turned over or stays tilted on the side, replace the vehicle in its normal op- erating position (on all four wheels) and wait 3 to 5 minutes before starting engine.

  • Page 114: Atv Immersion

    ATV Immersion Should the ATV become immersed, it will be necessary to take it to an authorized Bombardier ATV dealer as soon as possible. DO NOT START THE ENGINE! Immersion of the ATV can cause serious damage if the cor- rect restart procedure is not followed.

  • Page 115: Cargo And Transportation

    CARGO AND TRANSPORTATION While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death. Cargo WARNING The vehicle handling, stability and braking distance are affected when loading racks and using the vehicle.

  • Page 116: Transportation

    Transportation Front Location When transporting a vehicle, secure vehicle to trailer or in pickup box with suitable tie- downs. Using ordinary ropes is not recom- mended. WARNING V07A0EY TYPICAL Rear Location V00A174 Never tip this vehicle on end for transport- ing.

  • Page 117: Troubleshooting

    – Start engine with spark plugs grounded to the engine away from spark plug holes. If no spark appears, replace spark plugs. – If trouble persists, contact an authorized Bombardier ATV dealer. 4. Speedometer CHECK ENGINE indicator lamp is on and multi-function display shows CHECK ENGINE.
  • Page 118 6. Engine is under a protection mode. – Check speedometer multi-function display for messages. – Speedometer CHECK ENGINE indicator lamp is on and multi-function display shows CHECK ENGINE or LIMP HOME, contact an authorized Bombardier ATV dealer. Engine backfire 1. Exhaust system leakage.
  • Page 119 – Check speedometer multi-function display for messages. – Speedometer CHECK ENGINE indicator lamp is on and multi-function display shows CHECK ENGINE or LIMP HOME, contact an authorized Bombardier ATV dealer. Transmission lever is hard to move 1. Transmission gears are in a position that prevents the transmission lever to work.

  • Page 120: Specifications

    SPECIFICATIONS OUTLANDER MAX 800 ™ VEHICLE MODEL STANDARD ENGINE 800 cc, 4-stroke, V-twin, liquid cooled, Type 4-valves OHC Number of cylinder Number of valves 8 valves with mechanical lifters (adjustable) Displacement 800 cc (48.8 cu. in) Bore 91 mm (3.58 in) Stroke 62 mm (2.44 in) Compression ratio...
  • Page 121 OUTLANDER MAX 800 ™ VEHICLE MODEL STANDARD Type Dry type battery Battery Volt 12 volts, 18 Ah. Electric start Starting system Start on P, R, N, H or L position (with brake applied) Headlamp bulb 2 x 35 W Taillight bulb 8/27 W (F1) ignition coils (F2) fan...
  • Page 122 XP-S 5W40 synthetic 4-stroke oil. Refer to OIL VISCOSITY CHART for other grade. Gearbox oil type XP-S synthetic chaincase oil Ethylene-glycol/water mix (50% coolant, 50% distilled water). Use Bombardier premixed coolant Coolant or a coolant specially designed for aluminum engines...
  • Page 123 Regular unleaded gasoline Fuel Octane Inside North America: 87 (R + M)/2 or higher Octane Outside North America: 91 RON Front Bombardier differential oil or Synthetic polyester oil Differential 75W90 (API GL-5) Rear Brake Brake fluid, DOT 4 Propeller shaft joint grease...

  • Page 125: Maintenance Information

    MAINTENANCE INFORMATION...

  • Page 126: Maintenance Chart

    Bombardier ATV dealer. PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 300 KM (185 mi) (To be performed by an authorized Bombardier BRP ATV dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST...

  • Page 127: Periodic Maintenance Chart

    PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 300 KM (185 mi) (To be performed by an authorized Bombardier BRP ATV dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST 25 H OR 750 KM (470 mi)
  • Page 128 PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 300 KM (185 mi) (To be performed by an authorized Bombardier BRP ATV dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST 25 H OR 750 KM (470 mi)

  • Page 129: General

    Other items found in maintenance chart mu s t b e p erf orm e d by a n a u th or iz ed Bombardier ATV dealer. NOTE: Among other things, this section gives the procedures to replace the liquids. Refer to LIQUIDS for procedures to check levels and refill.

  • Page 130: Engine

    ENGINE Oil Change and Oil Filter Allow enough time for oil to flow out of oil filter. Remove the right engine cover. Replacement Unscrew the oil filter cover. Oil and filter are to be replaced at the same time. Oil change should be done with a warm engine.

  • Page 131: Oil Strainer Cleaning

    The oil strainer must be cleaned every WARNING 200 hours or every 2 years or every 6000 km (3730 m.). Contact an authorized Bombardier ATV In order to avoid getting burned, do not re- dealer. move the radiator cap or loosen the cool- ant drain plug if the engine is hot.

  • Page 132: Drive Belt

    Install radiator cap. Inspect all connections for leaks and check coolant level in the reservoir. Drive belt See an authorized Bombardier ATV dealer to check the width and the condition of drive belt. Valve Adjustment 1. Bleeding screw See an authorized Bombardier ATV dealer for Drain the system completely and reinstall the valves adjustment.

  • Page 133: Radiator

    ONLY. NEVER USE A HIGH PRESSURE and start engine. WASHER. Momentarily increase engine RPM several See an authorized Bombardier ATV dealer to times to purge accumulated carbon out of the check the performance of the cooling system. muffler. Stop engine and allow muffler to cool.

  • Page 134: Air Intake System

    AIR INTAKE SYSTEM Air Filter Removal Loosen clamp and remove air filter. CAUTION: Never remove or modify any com- ponent in the air box. Otherwise, engine per- formance degradation or damage can occur. The engine is calibrated to operate specifical- ly with these components.

  • Page 135: Electrical

    ELECTRICAL WARNING Unless otherwise indicated, always turn ignition switch to the OFF position before performing any maintenance or repair on electrical system. Spark plug Removal Remove side panels. Unplug the spark plug cable. Unscrew the spark plugs one turn. Clean the LH SIDE —...

  • Page 136: Battery

    Battery Installation Reinstall battery in vehicle. WARNING WARNING Never charge a battery while installed in Connect RED (+) cable first then BLACK vehicle. (-) cable. Always connect RED (+) cable first. Removal Disconnect BLACK (-) cable first then RED Fuses (+) cable.

  • Page 137: Bulb Replacement

    Bulb Replacement WARNING Always turn the ignition switch OFF before replacing a defective bulb. Always check light operation after replace- ment. Headlamps CAUTION: Never touch glass portion of an halogen bulb with bare fingers, it shortens its operating life. If glass is touched, clean it with isopropyl alcohol which will not leave a film on the bulb.
  • Page 138 Unplug connector from headlamp. NOTE: Use small locking tab to unlock connec- tor then pull on connector. V06G0SY PUSH ON LOCKING TAB TO UNLOCK TYPICAL CONNECTOR Properly reinstall removed parts in the re- NOTE: Concerning the following illustrations, verse order of their removal. the front fascia has been removed from the ve- hicle for a better comprehension.
  • Page 139 Taillight Unscrew lens screws to expose bulb. V07G04Y 1. Lens 2. Screws Push bulb in and hold while turning counter- clockwise to release. Install the new bulb by first pushing in while turning clockwise. Speedometer The speedometer is lighted with LEDs. If one LED burnt, replace the speedometer.

  • Page 140: Drive Train

    Push and pull the wheels from the upper edge t o f e e l t h e p l a y. S e e a n a u t h o r i z e d Bombardier ATV dealer if there is any play. V07H01Y TYPICAL —...

  • Page 141: Tires/Wheels

    Tires/Wheels Although the tires are specifically designed for off-road use, a flat may still occur. There- fore, it is recommended to carry a tire pump WARNING and a repair kit. Tire/Wheel Condition When the tires are replaced, never install Check tire for damage and wear. Replace if a bias tire with a radial tire.

  • Page 142: Steering System

    STEERING SYSTEM Throttle Cable Lubrication Separate the housing. Slide rubber protector back to expose throttle cable adjuster. Lubrication The throttle cable must be lubricated with sil- icone lubricant (P/N 293 600 041) or an equiv- alent. WARNING Always use a silicone-based lubricant. Us- ing another lubricant (like a water-based lubricant) could cause the throttle lever/ca- ble sticking or stiffness.
  • Page 143 – the cable from the throttle lever housing. NOTE: Slide cable in clip slot and remove the end of cable from clip. V07I0JY TYPICAL NOTE: Place a rag around the throttle cable adjuster to prevent the lubricant from splash- ing. V07I0IY Add lubricant until it runs out at carburetor end Remove the throttle body side cover.

  • Page 144: Throttle Lever Adjustment

    Throttle Lever Adjustment Slide rubber protector back to expose throttle cable adjuster. Loosen lock nut then turn the adjuster to ob- tain correct throttle lever free play. NOTE: Measure throttle free play at the tip of throttle lever. Tighten lock nut and reinstall protector. V07I010 1.

  • Page 145: Suspension

    Front Suspension Inspect the McPherson struts for oil leaks or other damages. Check tightness of fasteners. See an authorized Bombardier ATV dealer as necessary. Rear Suspension Inspect shock absorber for oil leaks and fas- teners for tightness.

  • Page 146: Brake

    Rear disc 4.3 mm (0.170 in) thickness Maximum discs 0.2 mm (0.010 in) warpage See your authorized Bombardier ATV dealer if a problem is detected concerning the brake system. Brake Fluid Replacement WARNING The brake fluid replacement or any brake system repairs should be performed by an authorized Bombardier ATV dealer.

  • Page 147: Body/Frame

    S e e a n a u th o ri z ed secured and no hose is cracked, kinked or Bombardier ATV dealer for parts replacement otherwise damaged. if damaged.

  • Page 149: Warranty

    WARRANTY...

  • Page 150: Brp International Limited Warranty: 2006 Bombardier Atv Products

    All genuine Bombardier parts and accessories, installed by an authorized Bombardier distribu- tor/dealer (as hereinafter defined) at the time of delivery of the 2006 Bombardier ATV product, carry the same warranty as that of the ATV.
  • Page 151 WARRANTY GIVES YOU SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY. Neither the distributor, any Bombardier ATV dealer nor any other person has been authorized to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against BRP.
  • Page 152 BRP or an authorized Bombardier ATV distributor/dealer receives a proof that the former owner agreed to the transfer of ownership, in addition to the coordinates of the new owner. The distrib- utor will then forward this information directly to BRP.

  • Page 153: Privacy Obligation/Disclaimer

    If you prefer not to have your name and address released, please let us know by writing to the address below: Bombardier Recreational Products Europe N.V. Customer Service...

  • Page 155: Change Of Address/Ownership

    BRP. STOLEN UNITS: If your personal ATV is stolen, you should notify BRP or an authorized Bombardier ATV dealer. We will ask you to provide your name, address, phone number, the vehicle identification number and the date it was stolen.
  • Page 156 AFFIX PROPER POSTAGE Bombardier Recreational Products Europe N.V. Customer Service Guldensporenpark 83, building I B-9820 Merelbeke, Belgium...
  • Page 157 BRP. STOLEN UNITS: If your personal ATV is stolen, you should notify BRP or an authorized Bombardier ATV dealer. We will ask you to provide your name, address, phone number, the vehicle identification number and the date it was stolen.
  • Page 158 AFFIX PROPER POSTAGE Bombardier Recreational Products Europe N.V. Customer Service Guldensporenpark 83, building I B-9820 Merelbeke, Belgium...
  • Page 159 ATV MODEL No. VEHICLE IDENTIFICATION NUMBER (V.I.N.) ENGINE IDENTIFICATION NUMBER (E.I.N.) Owner: ________________________________________________________ NAME ________________________________________________________ STREET ________________________________________________________ CITY STATE/PROVINCE ZIP/POSTAL CODE Purchase Date YEAR MONTH Warranty Expiry Date YEAR MONTH To be completed by the dealer at the time of the sale. DEALER IMPRINT AREA Please verify with your dealer to ensure your vehicle has been registered with BRP.

Table of Contents