BOMBARDIER outlander 800 Operator's Manual
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BOMBARDIER outlander 800 Operator's Manual

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  • 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 CE EN 2006.fm) Trademarks of Bombardier Recreational Products Inc. or its affiliates.

  • 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

    TABLE OF CONTENTS While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death. NOTICE........................ European Community ................INTRODUCTION....................SAFETY INFORMATION SPECIAL SAFETY MESSAGES ................. OPERATION WARNINGS ................... SAFETY WARNING.....................
  • Page 6 8) 12-Volt Power Outlet ................. 9) Ignition Switch ................... 10) Fuel Tank Cap .................. 11) Brake Pedal ..................12) Footpeg ..................... 13) Access Panel ..................14) Rear Storage Compartment .............. 15) Seat Latch ..................16) Cargo Racks ..................17) Trailer Hitch..................18) Radiator Cap ..................
  • Page 7 ATV Immersion ..................Storage and Preseason Preparation ............CARGO AND TRANSPORTATION ..............Cargo ...................... Transportation..................TROUBLESHOOTING..................SPECIFICATIONS ....................MAINTENANCE INFORMATION MAINTENANCE CHART ..................GENERAL......................101 ENGINE/GEARBOX .................... 102 Oil Change and Oil Filter Replacement ..........102 Oil Strainer Cleaning................103 Gearbox Oil Replacement ..............
  • Page 8 BODY/FRAME ....................119 Engine Area..................... 119 Hitch/Trailer Ball Condition ..............119 Chassis Fasteners................... 119 Seat Fasteners ..................119 Vehicle Cleaning and Protection ............. 119 WARRANTY BRP INTERNATIONAL LIMITED WARRANTY: 2006 BOMBARDIER PRODUCTS......................122 PRIVACY OBLIGATION/DISCLAIMER .............. 125 CHANGE OF ADDRESS/OWNERSHIP ............. 127...

  • Page 9: Notice

    NOTICE European Community This Operator’s Guide has been prepared to acquaint the owner/operator of a new vehicle This warning applies only in the European with the various vehicle controls, mainte- Countries where on road usage is allowed. nance and safe operating instructions. It is in- dispensable for the proper use of the product.

  • 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: Special Safety Messages

    Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Bombardier ATV dealer to find out about the available training course nearest you. Always follow this age recommendation: A person under 16 years old should never operate this vehicle.
  • Page 13 Operator’s Guide for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, contact an authorized Bombardier ATV dealer to find out about the available training courses nearest you.

  • Page 14: 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 15 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 16 WARNING V00A02Q POTENTIAL HAZARD Carrying a passenger on this vehicle. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this vehicle. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 17 WARNING V00A04Q POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. Paved surfaces may seriously affect handling and con- trol of the vehicle, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD If an road usage is allowed in your area, operate your vehicle on paved surface for short distance and for the only purpose of moving the vehicle from an off-road usage to another.
  • Page 18 WARNING V00A06Q POTENTIAL HAZARD Riding this vehicle without wearing an approved helmet, eye protection and protective cloth- ing. WHAT CAN HAPPEN The following items concern all ATV's operator: – riding without an approved helmet increases the chances of a severe head injury or death in the event of an accident.
  • Page 19 WARNING V00A07Q POTENTIAL HAZARD Riding this vehicle after consuming alcohol or drugs. WHAT CAN HAPPEN 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. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while riding this vehicle.
  • Page 20 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 21 WARNING V00A09Q POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Do not try to show off.
  • Page 22 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 23 WARNING V00A0BQ POTENTIAL HAZARD Removing hands from handlebar 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. If you remove a foot from the footrests, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
  • Page 24 WARNING V00A0CQ 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 or loss of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain.
  • Page 25 WARNING V00A0DQ 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. 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 the vehicle on such terrain.
  • Page 26 WARNING V00A0EQ POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Vehicle could go out of control, causing a collision or overturn. 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. Do not turn at excessive speed.
  • Page 27 WARNING V00A0QQ 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 the vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills.
  • Page 28 WARNING V00A0FQ POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control 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. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
  • Page 29 WARNING V00A0GQ POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control 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 30 WARNING V00A0HQ POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the vehicle around on any hill until you have mastered the turning technique as described further in this Operator’s Guide on level ground.
  • Page 31 WARNING V00A0IQ 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: Keep your weight uphill.
  • Page 32 WARNING V00A0JQ POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the vehicle to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described further in this Operator’s Guide.
  • Page 33 WARNING V00A0KQ 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. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.
  • Page 34 WARNING V00A0LQ 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 35 WARNING V00A0MQ 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.
  • Page 36 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 37 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 used according to instruc- tions. If you have questions, consult an authorized Bombardier ATV dealer. Do not install passenger seat or use the racks to carry a passenger.
  • Page 38 WARNING V00A0PQ 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, as well as other loads and added accessories.
  • Page 39 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 40: 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 completely before you operate this vehicle.
  • Page 41 Correct any problem you may have found be- i) Ensure transmission lever is working then fore riding. See an authorized Bombardier reset in PARK position. ATV dealer as necessary. j) Check fuel, oil and coolant levels.

  • Page 42: Clothing

    Clothing Actual weather conditions should help you decide how to dress. However, it is important that the operator always wears the appropriate protective clothing and apparel, including an approved helmet, eye protection, boots, gloves, long sleeved shirt and pants. This type of clothing will provide you protection from some of the minor hazards you may encounter en route.

  • Page 43: Carrying Loads

    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 44: 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 45: 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 46: 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 47 V00A0UL 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 48 V00A0VL 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. Mud or marsh lands may be encountered near water. Be prepared for sudden “holes” or changes in depth.
  • Page 49 Riding on loose stones or gravel is very similar to riding on ice. They will affect the steering of this vehicle… possibly causing it to slide and tipover, especially at high speeds. In addition, braking distance may be affected. Remember that “gunning” the throttle or sliding may cause loose stones to be ejected rearwards, into another ATV rider’s way.
  • Page 50 Uphill Keep your body weight forward towards the top of the hill. Keep your feet on the footpegs and shift into low gear then accelerate and when necessary, change gear quickly as you climb. Do not overspeed since this may cause the front of the vehicle to lift from the ground and fall back on you.
  • Page 51 Downhill Keep your body weight rearwards. Apply the brake gradually to prevent skidding. Do not “coast” down the slope using solely engine compression or in neutral gear. V00A0YL 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 52: 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 53: Hang Tag

    HANG TAG This vehicle comes with a hang tag and labels containing important safety information. Any person who rides this vehicle should read and understand this information before riding. WARNING RECREATIONAL MODEL THIS ATV IS FOR Improper ATV use can result in SEVERE injury or DEATH. RECREATIONAL USE.

  • Page 54: Location Of The Important Labels

    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 representa- tion only. Your model may differ.
  • Page 56 Label 1 Label 3 WARNING CAUTION Improper ATV use can result in SEVERE INJURY or DEATH. • ATV MUST be stopped before shifting lever. • Always apply foot brake to ALWAYS USE NEVER CARRY NEVER USE NEVER USE PASSENGERS. WITH DRUGS AN APPROVED ON PUBLIC shift from Park (P) and...
  • Page 57 Label 6 Label 9 WARNING Improper loading of a trailer may cause loss of vehicle control. • Maximum towing weight: 135 kg (298 lb). • Maximum tongue weight: 14 kg (30 lb). Label 7 WARNING INTERNATIONAL MODELS ONLY • NEVER carry a passenger on this carrier •...
  • Page 58 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 Label 11 WARNING This warning applies only in European Countries where on road usage is allowed.

  • Page 59: Vehicle Information

    VEHICLE INFORMATION...

  • Page 60: 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 Under seat, on the will be allowed by BRP Inc.

  • Page 61: Controls/Instruments/Equipment

    CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment are optional. TYPICAL...
  • Page 62 TYPICAL...

  • Page 63: Throttle Lever

    While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death. 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.

  • Page 64: 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 65: 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 66: 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 67: 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 This button is used to override the reverse TYPICAL speed limiter system and while power backing 1.
  • Page 68 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 69 LOW GEAR NOTE: If the letter “E” is displayed in the transmission position display, it means that there is a electrical transmission position er- ror. Contact an authorized Bombardier ATV dealer. Multi-Function Display NOTE: Use the selector button to change dis- play to the desired mode.
  • Page 70 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 71: Indicator Lamps

    Fuel Level Display Bar gauge continuously indicates the amount of fuel in the fuel tank while riding. When the low fuel indicator lamp is ON, it in- When this indicator is ON, it indicates the dicates that there is only 30% of fuel left in fuel 4WD system is activated.

  • Page 72: 12-Volt Power Outlet

    You can buy an additional ignition key and the wiring harness at the rear of vehicle. See have them programmed for your vehicle. an authorized Bombardier ATV dealer for To have additional ignition key, refer to an au- more details.

  • Page 73: Brake Pedal

    11) Brake Pedal 13) Access Panel Located on the right footrest. When pressed The access panel is located on the front fend- down, the rear brake is applied. When re- er, between front racks. To open the panel, leased, the brake pedal should return to its unlatch, lift then remove it completely.

  • Page 74: Rear Storage Compartment

    14) Rear Storage Compartment 15) Seat Latch Located in rear of vehicle. Convenient loca- Located underneath the rear end of seat. It tion to carry personal articles such as a spare allows the removal of seat to give access to spark plugs, first aid kit, etc.

  • Page 75: Cargo Racks

    Seat Installation 17) Trailer Hitch Located near rear axle. Convenient hitch to Insert front tabs of seat into frame hook. install a ball to tow a trailer or other equip- When seat rests in its position, firmly push ment. Install the proper ball size as per trailer seat down to latch.

  • Page 76: Radiator Cap

    18) 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 77: Tool Kit

    20) Tool Kit 22) Winch The tool kit is located in the rear storage com- XT Models partment. It contains tools for basic mainte- nance, this Operator’s Guide and the ATV Located at the front of vehicle, behind front Winch Operator's Manual with the XT models. skid plate.

  • Page 78: Winch Control Switch

    P l e a s e , c h e c k w i t h y o u r a u t h o r i z e d Located on the left side of the handlebar, over Bombardier ATV distributor/dealer to know direction indicator switch.

  • Page 79: Hazard Warning Button

    28) Hazard Warning Button This button is located on the left side of con- sole. V07G24Y TYPICAL 1. Hazard warning button Device fitted to the vehicle that operates a si- multaneous flashing of all the direction indica- tor lamps, used when the vehicle is stationary to indicate that the vehicle is temporarily ob- structing traffic.

  • Page 80: 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 81: 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 82: 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 83: Brake Fluid

    CAUTION: Use only DOT 4 brake fluid from TYPICAL a sealed container. 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.

  • Page 84: 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 85: 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 86: Operating Instructions

    Correct any problem you may have found b e f o r e r i d i n g . S e e a n a u t h o r i z e d Bombardier ATV dealer as necessary. •...

  • Page 87: Shifting The Transmission

    NOTE: The brake must be applied when the nents. Metallic parts lubrication is highly rec- transmission lever is engaged in the park po- ommended. Use BOMBARDIER LUBE sition. (P/N 293 600 016) or an equivalent. This Release brakes.

  • Page 88: Special Procedures

    Start engine as explained above. If engine continues to flood, see an authorized See an authorized Bombardier ATV dealer as Bombardier ATV dealer. soon as possible. Turn Over When vehicle is turned over or stays tilted on...

  • Page 89: Atv Immersion

    ATV Immersion Should the ATV become immersed, it will be necessary to take it to an auth orized 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 90: 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 91: 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 92: 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 93 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 94 – 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 95: Specifications

    SPECIFICATIONS OUTLANDER ™ 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 10.3:1...
  • Page 96 OUTLANDER ™ 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 20 A...
  • Page 97 Engine oil type XP-S 5W40 synthetic 4-stroke oil. Refer to OIL VISCOSITY CHART for other grade. Gearbox oil type XP-S 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 98 VEHICLE MODEL STANDARD Type Regular unleaded gasoline Fuel Octane 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 Suspension synthetic grease (P/N 293 550 033)

  • Page 99: Maintenance Information

    MAINTENANCE INFORMATION...

  • Page 100: 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 101: 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 102 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 103: 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 104: Engine/Gearbox

    ENGINE/GEARBOX 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 105: 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 106: 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 107: 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 108: 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 109: 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 110: Fuses

    Fuses Remove the holding strap then pull the bat- tery out of frame. If a fuse is damaged, replace it by one of the same rating. CAUTION: Do not use a higher rated fuse as this can cause severe damage. Fuses are located in the front service com- partment, and at the rear near battery.

  • Page 111: Bulb Replacement

    To remove fuse from holder, remove the fuse Remove rubber holder screws. holder cover then pull fuse out. Check if fila- ment is melted. TYPICAL 1. Screws 2. Rubber holder A15E0KY Remove rubber protector over headlamp TYPICAL housing. 1. Fuse 2.
  • Page 112 Unplug connector from headlamp. Lift and hold the spindle then remove the bulb. NOTE: Use small locking tab to unlock con- nector then pull on connector. PUSH ON LOCKING TAB TO UNLOCK V06G0SY CONNECTOR TYPICAL NOTE: Concerning the following illustrations, the front fascia has been removed from the Properly reinstall removed parts in the re- vehicle for a better comprehension.
  • Page 113 Brake Light and Rear Position Lamp Unscrew lens screws to expose bulb. Indicator Light If one LED is burnt in the cluster, see an au- thorized Bombardier ATV distributor/dealer for the cluster replacement. Speedometer The speedometer is lighted with LEDs. If one LED burnt, replace the speedometer.

  • Page 114: 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 FRONT OF VEHICLE 1.

  • Page 115: 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 116: 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 117 – the cable from the throttle lever housing. Insert the needle of lubricant can in the end of throttle cable adjuster. NOTE: Slide cable in clip slot and remove the end of cable from clip. WARNING Always wear eye protection and gloves when you lubricate a cable.

  • Page 118: 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 119: 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 120: 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 121: 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 123: Warranty

    WARRANTY...

  • Page 124: 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 125 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 126 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 127: 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 129: 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 130 AFFIX PROPER POSTAGE Bombardier Recreational Products Europe N.V. Customer Service Guldensporenpark 83, building I B-9820 Merelbeke, Belgium...
  • Page 131 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 132 AFFIX PROPER POSTAGE Bombardier Recreational Products Europe N.V. Customer Service Guldensporenpark 83, building I B-9820 Merelbeke, Belgium...
  • Page 133 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.

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