BOMBARDIER 2006 outlander max 400 Operator's Manual
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BOMBARDIER 2006 outlander max 400 Operator's Manual

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  • Page 2 Printed in the E.U. (Outlander Max CE EN 2006.fm) Trademarks of Bombardier Recreational Products Inc. or its affiliates. ® TM 2006 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved. © * Trademark of Bombardier Inc., used under license.

  • Page 3: Foreword

    Bombardier* recreational vehicle. 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. (BRP), however,...

  • Page 4: Table Of Contents

    HANG TAG......................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....................
  • Page 5 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 6 22) Radiator Cap ..................23) Fuses ....................24) Tool Box .................... 25) Rewind Starter Handle ..............100 26) Dipstick ..................... 100 27) Winch ....................100 28) Winch Control Switch ................ 101 29) Fairlead ..................... 101 30) Vehicle Lock..................101 31) Direction Indicator Switch ..............101 32) Horn Button ..................
  • Page 7 TROUBLESHOOTING..................115 SPECIFICATIONS ....................118 MAINTENANCE INFORMATION MAINTENANCE CHART ..................124 GENERAL......................127 ENGINE/TRANSMISSION ................... 128 Oil Change and Oil Filter Replacement ..........128 Oil Strainer Cleaning................129 Coolant Replacement ................129 Radiator ....................131 CARBURETOR....................132 AIR INTAKE SYSTEM ..................133 Air Filter box Draining ................
  • Page 8 WARRANTY BRP INTERNATIONAL LIMITED WARRANTY: 2006 BOMBARDIER ATV PRODUCTS....................150 PRIVACY OBLIGATIONS/DISCLAIMER ............153 CHANGE OF ADDRESS/OWNERSHIP ............. 155...

  • 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 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

    OPERATION WARNINGS 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: The following illustrations are general representations only. Your model may differ. WARNING V00A0AQ POTENTIAL HAZARD Operating this vehicle without proper instruction.
  • Page 17 WARNING V00A1AQ POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle. 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 V00A1EQ POTENTIAL HAZARD Operating this vehicle 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 a road usage is allowed in your area, operate your vehicle on paved surfaces only for short distance and for the only purpose of moving the vehicle from an off-road usage to another.
  • Page 22 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 23 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 24 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 25 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 26 WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the 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 27 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 28 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 29 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 30 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 31 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 32 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 33 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 34 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 35 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 36 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 37 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 38 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 39 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 40 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 41 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 42 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 43 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 44: 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 45: Pre-Operation Check

    Check fuel, oil and coolant levels. Correct any problem you may have found be- • Check for oil leaks on the engine/transmis- fore riding. See an authorized Bombardier sion and drive train components. ATV dealer as necessary. • Ensure fuel valve is in fully open position (ON).

  • Page 46: 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 47: 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 48: 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 49: Design Limitation

    Design Limitation Although the vehicle is exceptionally rugged for its class, it is still a light vehicle by definition and its operation must be restricted to its proper purpose. The addition of weight to any part of the vehicle changes its gravitational stability and modifies its performance.

  • Page 50: Uphill Driving

    Uphill Driving Due to configuration, this vehicle has excellent climbing ability, so much so that tipover is possible before traction is lost. For example, it is common to encounter terrain situations where the top of the hill has eroded to a point that the hill peak rises very sharply. The vehicle can readily negotiate such a condition, however, in doing so, when the front of the vehicle is driven to a point that the vehicle's balance changes rearward tipover can occur.

  • Page 51: Riding Techniques

    Riding Techniques Riding your vehicle too fast for the conditions may result in injury. Apply only enough throttle to proceed safely. Statistics show that high speed turns usually result in mishaps and injury. Always remember that this vehicle is heavy! Its pure weight alone may entrap you should it fall and pin you down.
  • Page 52 If a road usage is allowed in your area, operate your vehicle on paved surfaces only for short distance and for the only purpose of moving the vehicle from an off-road usage to another. Always operate your vehicle at low speed (never exceed 65 km/h (40 MPH)) and reduce the speed before making a turn.
  • Page 53 Mud or marsh lands may be encountered near water. Be prepared for sudden "holes" or changes in depth. Similarly so, be watchful of hazards such as rocks, logs, etc., partially covered by vegetation. If your trip crosses frozen waterways, make sure that the ice is thick enough and sound enough to support the total weight of yourself, your passenger, the vehicle and its load.
  • Page 54 V00A1WL If you do get into a slide or skid, it may help to turn the handlebar into the direction of the skid until you regain control. Never jam the brakes and lock the wheels. Respect and follow all posted trail signs. They are there to help you and others. Obstacles in the "trail"...
  • 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.

  • 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

    OFF ROAD USE ONLY. NEVER operate: • without proper 2-UP ATV training or instructions. BOMBARDIER 2-UP ATV SAFETY • at speeds too fast for your skills or the conditions. • on public roads - a collision can occur with another vehicle.

  • Page 60: Location Of The Important Labels

    The following labels are on your vehicle and they should be considered permanent parts of the vehicle. 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...
  • 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 8 CAUTION WARNING MAXIMUM LOAD: 2.3 kg (5 lb). 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 9 WARNING LABEL 7...
  • Page 64 LABEL 11 LOCATED UNDER SEAT LABEL 12 704 900 400 V01M0PY...

  • 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 ommendation. Worn 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

    It may sometimes become necessary to locate these numbers for warranty purposes or to trace your vehicle in the event of loss. These numbers are required by the authorized Bombardier ATV dealer to complete warranty claims properly. No warranty will be allowed by BRP if the engine identification number (EIN) or vehicle identification number (VIN) is removed or mutilated in any way.

  • Page 83: Compliance Label

    Compliance Label This label indicates vehicle’s compliance in many countries. Label Location Outlander MAX Under seat, on the upper bar of frame V00M0FY EUROPEAN COMMUNITY COUNTRIES...

  • 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 Located on the left side of handlebar. When details of how to operate one control in con- the brake lever is compressed, the front and junction with some others, refer to OPERAT- rear brakes are applied.

  • Page 87: Brake Lever Lock

    To release mechanism: Squeeze brake lever. Lever lock should automatically return to its original position. Brake lever should return to rest position. Always release brake lever lock before riding. 5) Transmission Lever Located on the right side of vehicle. A 5-posi- tion lever: P, R, N, H and L.

  • Page 88: Multi-Function Switch

    Headlamp Switch Located on the top of multi-function switch. Place headlamp switch to LO for the low beam and brake lamp. Place headlamp switch to HI for the high beam and brake lamp. V07I02Y TYPICAL 1. Multi-function switch The controls located on this multi-function switch are: V07I03Y TYPICAL...

  • Page 89: Engine Stop Switch

    Engine Stop Switch Start Button Located at the middle of multi-function switch. Located above engine stop switch. The engine will turn over but will not start if the engine stop switch is turned to OFF position. V07I06Y TYPICAL 1. Start button 2.

  • Page 90: Override Button

    Override Button Choke Lever Located below engine stop switch. Located at bottom of multi-function switch. This device features a variable lever to ease cold start. Position OFF is for normal use with a warm engine. V07I08Y V07I07Y CHOKE LEVER IN THE OFF POSITION TYPICAL 1.

  • Page 91: Speedometer

    Speedometer Change from One Unit to the Other This vehicle is equipped with an electronic The speedometer is factory preset in miles speedometer. It indicates the speed of vehicle but it is possible to change it to kilometer read- either in MPH or km/h. ing.
  • Page 92 18 volts in the electrical sys- tem, caused by a disconnected or defective voltage regulator. 1. Selector button Check voltage regulator connection or con- tact an authorized Bombardier ATV dealer for voltage regulator replacement.
  • Page 93 Hourmeter after engine starting, stop engine. Check en- gine oil level. Refill if necessary. If the oil level is good, see an authorized Bombardier ATV dealer. Do not use the vehicle until repaired. Engine Temperature (RED) The hourmeter records engine running time in hours and minutes.

  • Page 94: 12-Volt Power Outlet

    An auxiliary supply is available to connect ad- ditional accessories. Two wires are hidden in WARNING the wiring harness at the rear of vehicle. See an authorized Bombardier ATV dealer for Always stop engine before refueling. Open more details. cap slowly. If a differential pressure condi-...

  • Page 95: Fuel Gauge

    11) Fuel Gauge Stops fuel supply to carburetor. Located on the left side of the rear fender near fuel tank cap, the gauge shows an approxi- CAUTION: Turn valve to OFF position when mate amount of the fuel in tank. vehicle is not being operated or when trans- porting.

  • Page 96: Brake Pedal

    13) Brake Pedal 15) 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/Storage Box

    16) Passenger’s Seat/Storage Box Passenger’s Seat Installation – Insert passenger's seat positioning tubes into rear fender provided holes. WARNING Never operate the vehicle without passen- ger’s seat or storage box properly installed. The passenger’s seat is designed specially to allow a secure and pleasant ride at ONE (1) passenger.

  • Page 98: Operator's Seat

    Storage Box Removal 17) 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 18) 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

    19) Rear Storage Compartment 20) 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, gently lift then remove cover.

  • Page 101: Radiator Cap

    22) Radiator Cap 23) Fuses Located in service compartment, under ac- The electrical system is protected with fuses. cess panel. Refer to MAINTENANCE for details. The fuse holders are located in the service WARNING compartment. In order to avoid getting burned, do not re- move the radiator cap when the engine is hot.

  • Page 102: Rewind Starter Handle

    25) Rewind Starter Handle 27) Winch The rewind starter handle is provided as an XT Models emergency starting device. Located behind front skid plate. Follow the usual starting procedure; but use the rewind starter instead of the electric starter. Located on right side of vehicle. Auto-rewind type.

  • Page 103: 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 104: Hazard Warning Button

    33) 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 105: 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. Fuel Level NOTE: This section specifies the recom- mended liquids and procedures to check their levels. Refer to MAINTENANCE for proce- WARNING dures to replace the liquids.

  • Page 106: Oil Level

    °C °F V07C24Y RH SIDE OF ENGINE 1. Dipstick With vehicle on a level surface and engine cold, not running, check the oil level as fol- lows: 1. Unscrew dipstick then remove it and wipe clean. 2. Reinstall dipstick, screw in it completely. 3.

  • Page 107: Engine Coolant

    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 In order to avoid getting burned, do not re- Bombardier premixed coolant (P/N 219 700 move the radiator cap if the engine is hot.

  • Page 108: 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 109: Break-In Period

    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

    Check tire pressure and condition. Correct any problem you may have found be- • Check wheels and bearings for wear and fore riding. See an authorized Bombardier damage. ATV dealer as necessary. • Check location of controls and ensure they work properly.

  • Page 111: Initial Cold Starting

    Initial Cold Starting Insert key in ignition switch and turn to ON. Place the engine stop switch to RUN. In cold weather, under 0°C (32°F), place the choke lever in full position. V07I08Z TYPICAL 1. OFF position Warm Engine Starting Start the engine as explained above but with- out the choke.

  • Page 112: Emergency Manual Starting

    Emergency Manual Starting Shifting the Transmission Let engine idle to warm up. WARNING Apply brakes and select the desired gear range H or L. Always place transmission lever on PARK NOTE: The brake must be applied when the or NEUTRAL before starting engine manu- transmission lever is engaged in the park po- ally.

  • Page 113: Special Procedures

    Never refill cooling system when engine is Clean the spark plug cap area then remove it. hot. Remove the spark plug (tools are supplied in tool box). See an authorized Bombardier ATV dealer as soon as possible. WARNING Post-Operation Care Always wear eye protector and gloves When vehicle is used in salt-water environ- when cleaning the spark plug hole.

  • Page 114: Turn Over

    MAINTENANCE CHART. When a vehicle is not in use for more than one month, proper storage is a necessity. See an authorized Bombardier ATV dealer for proper procedures. When using your ATV after storage, a prepa- ratio n is required. Se e an authorized Bombardier ATV dealer for proper proce- dures.

  • 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 Rear 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 V07A0FY TYPICAL V00A174 WARNING Never tip this vehicle on end for transport- ing. We recommend that you carry the ve- Do not tow this vehicle behind a car or other hicle in its normal operating position (on all vehicle.

  • Page 117: Troubleshooting

    – Start engine with spark plug grounded to the engine away from spark plug hole. If no spark appears, replace spark plug. – If trouble persists, contact an authorized Bombardier ATV dealer. 6. Engine compression. – As the engine is pulled over with the rewind starter, “cycles” of resistance should be felt as piston goes past top dead center.
  • Page 118 – Contact an authorized Bombardier ATV dealer. 4. Engine is overheating. – Check ENGINE OVERHEATING in SPECIAL PROCEDURES. – If overheating persists, contact an authorized Bombardier ATV dealer. 5. Air filter/box plugged or dirty. – Check air filter and clean if necessary.
  • Page 119 – Check the position of the air intake tube. 4. CVT dirty or worn-out. – 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 400 H.O. VEHICLE MODEL MAX XT ENGINE BOMBARDIER-ROTAX 4-TEC, 4-stroke. ® Type Over Head Camshaft (OHC) Number of cylinder Single cylinder Number of valves 4 valves with mechanical lifters (adjustable) Displacement 400 cc (24.4 cu. in) Bore Standard 91 mm (3.58 in)
  • Page 121 OUTLANDER 400 H.O. VEHICLE MODEL MAX XT ELECTRICAL Make Denso Magneto generator Type 400 W @ 6000 RPM Ignition type CDI (Capacitor Discharge Ignition) Ignition timing Not adjustable Engine RPM limiter 8000 RPM (any gear in forward) Vehicle speed limiter 15 km/h (9 MPH) in reverse Make Spark plug...
  • Page 122 OUTLANDER 400 H.O. VEHICLE MODEL MAX XT SUSPENSION Type Independent suspension — McPherson type Front Travel 178 mm (7 in) Type TTI independent Rear Travel 203 mm (8 in) TIRES Make Othsu Carlisle ACT Type Bias Radial 34 kPa (5 PSI) maximum, Front Up to 31 kPa (4.5 PSI) minimum...
  • Page 123 Bombardier synthetic oil 5W40. Refer to OIL VISCOSITY CHART for other grade Ethylene-glycol/water mix (50% coolant, 50% distilled water). Coolant Use Bombardier premixed coolant or a coolant specifically designed for aluminum engines Type Regular unleaded gasoline Fuel Octane...
  • Page 124 OUTLANDER 400 H.O. VEHICLE MODEL MAX XT CAPACITIES 16 L (4.2 U.S. gal) including an approximate reserve Fuel tank of 2 L (0.5 U.S. gal) Engine/transmission oil Oil change with filter: 3 L (3.17 U.S. quarts). Coolant 2.2 L (2.32 U.S. quarts) Front 500 ml (17 U.S.

  • 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.

  • Page 130: Engine/Transmission

    ENGINE/TRANSMISSION Oil Change and Oil Filter Replacement Oil and filter are to be replaced at the same time. Oil change should be done with a warm engine. WARNING The engine oil can be very hot. In order to avoid getting burned, do not remove the en- gine drain plug or the filter cover if the en- gine is hot.

  • Page 131: Oil Strainer Cleaning

    Unscrew the coolant drain plug and drain the 200 hours or every 2 years or every 6000 km coolant into a suitable container. (3730 m). Contact an authorized Bombardier ATV dealer. Coolant Replacement WARNING In order to avoid potential burns, do not re- move the radiator cap or loosen the coolant 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 V07C09Y See an authorized Bombardier ATV dealer to 1. Bleeding screw check the width and the condition of drive belt. 2. Engine temperature sensor...

  • Page 133: Radiator

    WHEN HOSING, USE LOW PRESSURE Stop engine and allow muffler to cool. ONLY, NEVER USE A HIGH PRESSURE Reinstall the clean-out plug. WASHER. See an authorized Bombardier ATV dealer to check the performance of the cooling system.

  • Page 134: Carburetor

    CARBURETOR See an authorized Bombardier ATV dealer each year to verify and clean the fuel system.

  • Page 135: Air Intake System

    AIR INTAKE SYSTEM Air Filter box Draining If liquids/deposits are found, squeeze and re- move the clamp. Pull drain tube out and emp- Periodically inspect air filter box drain tube for ty it. liquids water or deposits. CAUTION: Do not start engine when liq- uids/deposits are found in the drain tube.

  • Page 136: Air Filter Cleaning

    V07C0HY 1. Clamp 2. Air filter Air Filter cleaning Pour cleaning solution (P/N 219 700 341) or an equivalent into a bucket. Put the filter in to soak. While filter soaks, clean inside the air box. Rinse the filter with warm water until all clean- ing solution disappears.

  • Page 137: Electrical

    ELECTRICAL Battery WARNING WARNING Unless otherwise indicated, always turn ig- nition switch to the OFF position before per- Never charge a battery while installed in the forming any maintenance or repair on elec- vehicle. trical system. Removal Spark Plug Disconnect BLACK (-) cable first then RED (+) cable.
  • Page 138 Cleaning Clean battery, battery casing and battery posts using a solution of baking soda and wa- ter. Remove corrosion from battery cable termi- nals and battery posts using a firm wire brush. Battery casing should be cleaned by soft brush and baking soda solution. Installation Reinstall battery in vehicle.

  • Page 139: Bulb Replacement

    Bulb Replacement WARNING Always turn the ignition switch OFF before replacing a defective bulb. Always check light operation after replace- ment. Headlamps Each headlamp has two bulbs, one headlamp bulb and one position lamp bulb. CAUTION: Never touch glass portion of an TYPICAL halogen bulb with bare fingers, it shortens its 1.
  • Page 140 Adjust beam aiming as follows: Turn adjust- ment screws to adjust beam height and side orientation to your convenience. Adjust both headlamps evenly. V06G0RY TYPICAL TYPICAL 1. Headlamp cover Lift and hold the spindle then remove the bulb. 2. Adjustment screws Front Position Lamp To replace the front position lamp bulb located in the headlamp housing, proceed as follows.
  • Page 141 Reinstall the lens. 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. The LEDs are not available separately.

  • Page 142: 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 143: 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 a Check tire for damage and wear.

  • Page 144: 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 ca- ble lubricant (P/N 293 600 041) or an equiva- lent. WARNING Always use a silicone-based lubricant. Us- ing another lubricant (like a water-based lu- bricant) could cause the throttle lever/cable sticking or stiffness.

  • Page 145: Throttle Lever Adjustment

    NOTE: Slide cable in clip slot and remove the end of cable from clip. V07I0JY 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 carburetor side cover.
  • Page 146 Tighten lock nut and reinstall protector. V07I010 1. Throttle lever A. 3 to 6 mm (1/8 to 7/32 in) With the transmission lever on PARK position, start the engine. Check if the throttle cable is adjusted correctly by turning handlebar fully right then fully left.

  • Page 147: 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 148: 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 149: Body/Frame

    Ensure all hose clamps are properly check latch mechanisms and pins for wear. secured and no hose is cracked, kinked or See an authorized Bombardier ATV dealer for otherwise damaged. parts replacement if damaged. Inspect muffler, battery and reservoir fasten- Vehicle Cleaning and Protection ing devices.
  • Page 151 WARRANTY...

  • Page 152: 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 153 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 154 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 155: Privacy Obligations/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 157: 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 158 AFFIX PROPER POSTAGE Bombardier Recreational Products Europe N.V. Customer Service Guldensporenpark 83, building I B-9820 Merelbeke, Belgium...
  • Page 159 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 160 AFFIX PROPER POSTAGE Bombardier Recreational Products Europe N.V. Customer Service Guldensporenpark 83, building I B-9820 Merelbeke, Belgium...
  • Page 161 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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