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SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair 2008/2009 Outlander™ 400 EFI
Series ATVs as describe in the model list in the
This edition was primarily published to be used by mechanical technicians who are already familiar with
all service procedures relating to BRP products. Mechanical technicians should attend training courses
given by B.R.P.T.I.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This shop manual uses technical terms which may be slightly different from the ones used in the
CATALOG
.
It is understood that this manual may be translated into another language. In the event of any discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-
vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read
and understand these. It does not include dealer modifications, whether authorized or not by BRP, after
manufacturing the product.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any component.
Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those for which it was designed.
Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair
procedures.
This manual emphasizes particular information denoted by the wording and symbols:
Identifies an instruction which, if not followed, could cause serious personal injury including pos-
sibility of death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-
nents.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents.
We strongly recommend that any services be carried out and/or verified by a highly skilled professional
mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing
federal, provincial and state regulations.
VIII
INTRODUCTION
.
WARNING
WARNING
PARTS
vmr2008-113

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Summary of Contents for BRP Outlander 400 EFI 2008

  • Page 1 The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser- vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read and understand these. It does not include dealer modifications, whether authorized or not by BRP, after manufacturing the product.
  • Page 3 EPA Emission Regulations Some ATVs manufactured by BRP are certified to the EPA as conforming to the requirements of the regulations for the control of air pollution from new ATV engines. This certification is con- tingent on certain adjustments being set to factory standards.
  • Page 4 INTRODUCTION TIGHTENING TORQUE In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the Tighten fasteners to torque mentioned in explod- following procedure: ed views and/or text, When they are not specified, Manually screw all screws, bolts and/or nuts. refer to following table.
  • Page 5 INTRODUCTION SELF-LOCKING FASTENERS Apply a few drops of threadlocker at proposed tightened nut engagement area. PROCEDURE Position nut and tighten as required. Blind Holes A00A6LA TYPICAL — SELF-LOCKING FASTENER The following describes the most common appli- cation procedures when working with self-locking fasteners.
  • Page 6 INTRODUCTION NOTE: To avoid a hydro lock situation, do not apply Adjusting Screw too much Loctite. Apply several drops of proper strength Loctite on stud threads. Install stud. Install cover, etc. Apply drops of proper strength Loctite on uncov- ered threads. Tighten nuts as required.
  • Page 7 INTRODUCTION Repair of Small Holes/Fine Threads If holes are sunken, apply proper strength Loc- tite on bolt threads. Option 1: Enlarge damaged hole, then follow STANDARD THREAD REPAIR procedure. Tighten as usual. Option 2: Apply FORM-A-THREAD on the screw Mounting on Shaft and insert in damaged hole.
  • Page 8 INTRODUCTION Spray housing and gasket with Loctite Primer N (P/N 293 800 041). Apply a strip of proper strength Loctite on lead- ing edge of outer metallic gasket diameter. NOTE: Any Loctite product can be used here. A low strength liquid is recommended as normal strength and gap are required.
  • Page 9 INTRODUCTION Typical_iso_2008_en vmr2008-113...
  • Page 10 INTRODUCTION typical_txt_2008_en XVII vmr2008-113...
  • Page 11 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) MAINTENANCE CHART MAINTENANCE CHART The schedule should be adjusted according to operating conditions and use. The initial maintenance is very important and must not be neglected. NOTE: The chart gives an equivalence between number of hours and months/year. Perform the mainte- nance operation to whatever time comes first.
  • Page 12 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) INITIAL INSPECTION 10 H OR 30 DAYS OR 300 km (185 mi) ADJUST 25 H OR 750 km (470 mi) CLEAN INSPECT 50 H OR 1500 km (930 mi) LUBRICATE 100 H OR 1 YEAR OR 3000 km (1865 mi) REPLACE 200 H OR 2 YEARS OR 6000 km (3730 mi) PART/TASK...
  • Page 13 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) INITIAL INSPECTION 10 H OR 30 DAYS OR 300 km (185 mi) ADJUST 25 H OR 750 km (470 mi) CLEAN INSPECT 50 H OR 1500 km (930 mi) LUBRICATE 100 H OR 1 YEAR OR 3000 km (1865 mi) REPLACE 200 H OR 2 YEARS OR 6000 km (3730 mi) PART/TASK...
  • Page 14 Section 01 MAINTENANCE Subsection 02 (PRESEASON PREPARATION) PRESEASON PREPARATION Prior to use vehicle, proper vehicle preparation is required after performing the storage procedure. Any worn, broken or damaged parts found during the storage procedure should have been replaced. If not, proceed with the replacement. Using the maintenance chart, performed items in the column indicated: 100 h or 1 year or 3000 km (1865 mi).
  • Page 15 With the new fuel additives, it is critical to use the body bore to avoid blocking idle bypass valve. BRP fuel stabilizer (P/N 413 408 600) or an equiva- lent to prevent fuel deterioration and fuel system Press start button, 1 or 2 seconds maximum, to gumming.
  • Page 16 To clean the entire vehicle, including metallic parts use BRP heavy duty cleaner (P/N 293 110 001). Inspect the vehicle and repair any damage. Touch up all metal spots where paint has been scratched off.
  • Page 17 Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE PRODUCTS Description Part Number Page XP-S Lube ................293 600 016 ........9–10 NOTE: These procedures give a guideline of Drain air filter housing then clean and dry air filter. things to do if one of these abnormal situations Remove muffler and empty it.
  • Page 18 Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) Start the engine and allow it to run at idle speed until the engine reaches its operating tempera- ture. Stop the engine. Change engine oil and filter. NOTE: Change oil as many times as necessary, until there is no white appearance in engine oil.
  • Page 19 Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES) TECHNICAL GUIDELINES The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. ENGINE Cooling System Symptom: HIGH ENGINE OPERATING TEMPERATURE 1. Check mud/dust in radiator fins. Radiator fin obstructed, hard air cooling.
  • Page 20 Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES) Symptom: (cont’d) HIGH ENGINE OPERATING TEMPERATURE 16. Check cylinder head and/or cylinder base gasket. Worn out gasket(s) is (are) causing water leakage. Replace gasket(s) and refill with coolant and COOLING SYSTEM LUBRICATION SYSTEM oil (refer to 17.
  • Page 21 Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES) Symptom: (cont’d) LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION 9. Check oil pump operation. LUBRICATION SYSTEM Oil pump rotor is out of wear limit. Replace oil pump shaft (refer to LUBRICATION Oil pump seized due to oil leakage and/or air inclusion. Replace oil pump (refer to SYSTEM Gears driving oil pump are broken or damaged.
  • Page 22 Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES) Crankshaft and Balancer Shaft Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATIONS 1. Check if mark on balancer shaft is aligned with crankshaft position mark. Mark on balancer shaft and crankshaft are not aligned. Readjust position of balancer shaft and CRANKCASE/CRANKSHAFT crankshaft (refer to 2.
  • Page 23 Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES) Symptom: (cont’d) GEAR(S) IS (ARE) HARD TO SHIFT 2. Check transmission lever and connecting rod. Ball joint and/or ball joint nut is (are) loose. Retighten or replace the ball joint. Check shifter adjustment. 3.
  • Page 24 Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES) Symptom: (cont’d) THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED 2. Check roller(s) on governor cup and/or lever condition on drive pulley sliding sheave. CONTINUOUSLY VARIABLE TRANSMISSION Roller(s) is (are) worn and/or damaged (refer to (CVT) ).
  • Page 25 Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES) Symptom: (cont’d) DRIVE PULLEY NOISE WHEN ACCELERATING/DECELERATING 2. Check if belt runs in dry conditions. Drive pulley area is wet/contaminated due to water/dirt intrusion. Clean driven pulley area and/or drain water out of CVT cover. 3.
  • Page 26 Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES) Symptom: (cont’d) BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE 2. Check if pulley sheaves are clean. Oil on pulley surfaces. Clean pulley sheaves and replace belt. Water intrusion in CVT area. Find root cause and repair. Drain water and replace belt. Symptom: BELT WORN EXCESSIVELY ON TOP WIDTH 1.
  • Page 27 Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES) Starting System Symptom: STARTER DOES NOT TURN 1. Check that multifunction gauge and taillight turn on when ignition switch is turned on and engine stop switch is set to RUN. Check main fuse and ECM fuse. Replace if faulty. Repair or replace faulty switch(es) or repair wiring harness.
  • Page 28 Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES) Symptom: (cont’d) BATTERY NOT CHARGING OR CHARGING VOLTAGE INADEQUATE 2. Check voltage regulator/rectifier. CHARGING SYSTEM Refer to 3. Check wiring harness for cracks or other damages. Harness shows electrical failure and/or other damages. Replace/repair wiring harness. 4.
  • Page 29 Section 02 TROUBLESHOOTING Subsection 02 (DIAGNOSTIC FLOW CHART) DIAGNOSTIC FLOW CHART FUEL SYSTEM vmr2008-023-100_aen vmr2008-119...
  • Page 30 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL/INSTALLATION) ENGINE REMOVAL/INSTALLATION SERVICE TOOLS Description Part Number Page lifting tool................529 035 619 ........... 28 engine lifting tool ..............529 035 898 ........... 28 SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ........... 29 vmr2008-120...
  • Page 31 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL/INSTALLATION) vmr2008-120-001_a vmr2008-120...
  • Page 32 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL/INSTALLATION) GENERAL WARNING To avoid potential burns, let engine and ex- haust system cool down before performing any servicing. During assembly/installation, use the torque val- ues and service products as in the exploded view. Clean threads before applying a threadlocker.
  • Page 33 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL/INSTALLATION) Detach link rod from shifting plate. vmr2008-120-008_a 1. Coolant hose 2. Throttle body Unplug the cooling temperature sensor (CTS). vmr2008-120-005_a 1. Link rod Unplug the crankshaft position sensor (CPS) con- 2. Shifting plate nector.
  • Page 34 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL/INSTALLATION) vmr2008-120-012_a vmr2008-120-014_a 1. Coupling unit screws 1. Caliper screws Unscrew exhaust pipe nuts. Remove differential bolts. vmr2008-120-013_a vmr2008-120-016_a 1. Exhaust pipe nuts 1. Differential bolts Apply parking brake and remove the four (4) EXHAUST SYS- Remove exhaust pipe.
  • Page 35 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL/INSTALLATION) vmr2008-120-018_a 1. Spark plug cable Remove the intake adaptor from cylinder head. TYPICAL Install the lifting tool (P/N 529 035 619) to tilt en- gine. vmr2008-120-019_a 1. Intake adaptor screws 2. Throttle body Temporarily, attach throttle body, all cables, wires and hoses on the frame.
  • Page 36 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL/INSTALLATION) ENGINE MOUNT NOTE: Use the same procedure for the front and rear engine mounts. Engine Mount Removal Insert a punch in hole of engine mount bushing and push the other bushing out of the housing. vmr2008-120-022_a 1.
  • Page 37 Section 03 ENGINE Subsection 02 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM SERVICE PRODUCTS Description Part Number Page air filter cleaning solution............219 700 341 ........... 32 vmr2008-121-001_a vmr2008-121...
  • Page 38 Section 03 ENGINE Subsection 02 (AIR INTAKE SYSTEM) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded views. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to APPLICATION at the beginning of this manual for complete procedure.
  • Page 39 Section 03 ENGINE Subsection 02 (AIR INTAKE SYSTEM) AIR FILTER HOUSING Remove air filter housing cover. Detach inlet tube. Air Filter Housing Draining Remove retaining screws of air filter housing. Periodically inspect air filter housing drain tube for Cut locking tie. liquid or deposits.
  • Page 40 Section 03 ENGINE Subsection 03 (EXHAUST SYSTEM) EXHAUST SYSTEM vmr2008-122-001_a vmr2008-122...
  • Page 41 Section 03 ENGINE Subsection 03 (EXHAUST SYSTEM) GENERAL WARNING To avoid potential burns, never touch exhaust system components immediately after the engine has been run because these compo- nents are very hot. Let engine and exhaust system cool down before performing any servicing.
  • Page 42 Section 03 ENGINE Subsection 03 (EXHAUST SYSTEM) Install muffler bolt. Use the following illustration to position parts properly. vmr2008-122-005_a 1. Exhaust pipe 2. Muffler clamp 3. Muffler While supporting muffler, unscrew muffler bolts. vmr2008-122-008_a 1. Spacer (MAX Series only) 2. Flat washer M8 3.
  • Page 43 Section 03 ENGINE Subsection 03 (EXHAUST SYSTEM) Exhaust Pipe Installation Install a NEW exhaust gasket on exhaust pipe end (cylinder head side). Secure exhaust pipe on cylinder head with ex- haust nuts. Do not tighten yet. Install muffler. Align all parts then tighten nuts, clamp and bolts. vmr2008-122...
  • Page 44 Section 03 ENGINE Subsection 04 (REWIND STARTER) REWIND STARTER SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ........43–44 Molykote PG 54..............420 899 763 ........... 41 vmr2008-123...
  • Page 45 Section 03 ENGINE Subsection 04 (REWIND STARTER) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded views. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to APPLICATION at the beginning of this manual for complete procedure.
  • Page 46 Section 03 ENGINE Subsection 04 (REWIND STARTER) Rewind Starter Disassembly At assembly, position spring no. 2 outer end into spring guide notch. Use appropriate ring to push WARNING spring into starter housing as illustrated. Spring tension has to be released prior to WARNING withdraw the rewind starter sheave.
  • Page 47 Section 03 ENGINE Subsection 04 (REWIND STARTER) Install locking spring no. 10. TYPICAL 1. Apply Molykote PG 54 in spring area NOTICE The use of standard multipurpose TYPICAL 1. Locking spring grease could result in rewind starter malfunc- 2. Pawl tion.
  • Page 48 Section 03 ENGINE Subsection 04 (REWIND STARTER) Rewind Starter Installation For installation, reverse the removal procedure. Pay attention to the following details. Prior to reinstalling rewind starter on engine, clean threads from Loctite deposits. NOTE: Before torquing mounting bolts no. 15, apply Loctite 243 (blue) (P/N 293 800 060) on threads.
  • Page 49 Section 03 ENGINE Subsection 04 (REWIND STARTER) STARTING PULLEY Starting Pulley Removal Remove rewind starter. Remove screw no. 13 and starting pulley no. 14 from crankshaft MAG side. Starting Pulley Installation For installation, reverse the removal procedure. Pay attention to the following details. CAUTION: Take care to have the starting pulley well mounted on crankshaft end.
  • Page 50 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number Page adapter hose................. 529 035 652 ........... 50 pressure gauge..............529 035 709 ........... 50 SERVICE PRODUCTS Description Part Number Page XP-S 5W30 4-stroke oil............219 700 706 ........... 47 XP-S 5W40 synthetic oil ............
  • Page 51 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) vmr2008-124-001_a vmr2008-124...
  • Page 52 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) GENERAL Engine Oil Viscosity Chart During assembly/installation, use the torque val- SAE 0W30 ues and service products as in the exploded views. SAE 5W30 (XP-S 5W30 Mineral Oil) Clean threads before applying a threadlocker. Re- SAE 10W30 SELF-LOCKING FASTENERS LOCTITE...
  • Page 53 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) 3. Remove and check oil level. It should be near or equal to the upper mark. vmr2008-124-101_a 1. Dipstick vmr2008-124-100_a 2. O-ring 1. Full 2. Add Unscrew drain plug no. 3. 3. Operating range To add oil, remove the dipstick.
  • Page 54 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) Dispose oil and filter as per your local environmen- tal regulations. OIL FILTER Oil Filter Removal Remove: – Engine cover 1. Inlet bore from the oil pump to the oil filter 2. Outlet bore to the engine oil providing system Oil Filter Installation The installation is the opposite of the removal pro- cedure.
  • Page 55 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) vmr2008-124-103_A vmr2008-124-105_a Install the pressure gauge (P/N 529 035 709) and Start engine and measure oil pressure as per fol- the adapter hose (P/N 529 035 652) to the switch lowing table. hole. The engine oil pressure should be within the fol- lowing values.
  • Page 56 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) Oil Pressure Switch Activation OPS CIRCUIT MEASUREMENT Oil pressure switch is normally closed and it opens RESISTANCE OPS PIN ECM PIN when engine runs and pressure reaches 30 and @ 20°C (68°F) 60 kPa (4.4 and 8.7 PSI). So, when engine runs, Close to 0 switch is open and if pressure goes to low, the switches closes.
  • Page 57 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) Drain engine oil, refer to OIL CHANGE in this sec- Inspect O-ring on the oil collector and rubber ring tion. on the oil strainer cover. Remove screws retaining oil strainer cover. If O-ring and/or rubber ring is (are) brittle, cracked or hard, replace the defective part(s).
  • Page 58 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) Oil Pressure Regulator Inspection Stop engine. Wait a while to allow oil to flow down to crankcase then check oil level. Refill as Inspect valve piston for scoring or other damages. necessary. Check compression spring for free length. ENGINE OIL PRESSURE COMPRESSION SPRING FREE LENGTH REGULATOR...
  • Page 59 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) vmr2006-054-004 1. Dowel pins Remove oil pump gear no. 11. 1. Intermediate gear NOTE: Oil pump gear is snapped on needle pin. 2. Pin This needle pin passes through the oil pump shaft. Use screwdrivers to remove this gear.
  • Page 60 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) 1. Pittings on the teeth Using a feeler gauge, measure the clearance be- tween inner and outer rotor. 1. Oil pump shaft assembly 2. Oil pump housing 1. Outer rotor 2. Inner rotor OUTER AND INNER ROTOR CLEARANCE vmr2008-124-002_a SERVICE LIMIT...
  • Page 61 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) NOTE: After tightening the oil pump housing screws check for smooth operation of the oil pump assembly. Install the O-ring no. 13 on oil pump cover. 1. Oil pump housing surface 2. Dial indicator After engine is completely reassembled, start en- gine and make sure oil pressure is within specifi- ENGINE OIL PRESSURE TEST...
  • Page 62 ECM adapter tool..............529 036 085 ........... 70 SERVICE PRODUCTS Description Part Number Page BRP premixed coolant ............219 700 362 ........... 62 Super Lube grease ............... 293 550 030 ........... 75 Loctite 243................293 800 060 ........... 65 vmr2008-125...
  • Page 63 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) RADIATOR (2008) vmr2008-125-001_a vmr2008-125...
  • Page 64 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) RADIATOR (2009) vmr2008-125-011_a vmr2008-125...
  • Page 65 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) WATER PUMP vmr2007-024-001_b vmr2008-125...
  • Page 66 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) THERMOSTAT vmr2008-125-002_a vmr2008-125...
  • Page 67 Recommended Coolant Use BRP premixed coolant (P/N 219 700 362) or a blend of 50% antifreeze with 50% water. To prevent antifreeze deterioration, always use 1. Cooling system drain plug the same brand.
  • Page 68 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) 1. Hose pincher Remove cooling system bleeder screw from top TYPICAL of thermostat housing. 1. Gasket ring 2. Bleeder screw Remove hose pincher from radiator coolant return hose. Top up radiator coolant and install radiator cap. Refill coolant tank up to the MIN.
  • Page 69 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) INSPECTION COOLING SYSTEM LEAK TEST WARNING To avoid potential burns, do not remove the radiator cap or loosen the cooling system drain plug if the engine is hot. Remove the service compartment cover. Remove the radiator cap.
  • Page 70 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) PROCEDURES THERMOSTAT The thermostat is a single action type, located on the RH rear side of the cylinder head. Thermostat Removal Remove the RH side body panel. Install a hose pincher on both radiator hoses. vmr2008-125-005_a 1.
  • Page 71 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) Remove insects, mud or other obstructions with compressed air or low pressure water. Radiator Removal ENGINE COOLANT Drain cooling system, refer to in this section. Remove front fascia and both inner fenders, refer BODY Remove radiator coolant outlet and return hoses.
  • Page 72 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) Coolant Tank Removal Remove radiator mounting screws. BODY Remove the LH inner fender panel, refer to section. Remove the coolant tank support bolt. TYPICAL — COOLANT TANK 1. Radiator mounting screws Remove the service compartment cover to access Remove radiator from vehicle.
  • Page 73 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) Coolant Tank Installation Remove the cooling fan fuse and test it to be sure that it is good. Installation is the reverse of the removal proce- dure. Remove the cooling fan relay. Torque tank mounting screw as specified in ex- ploded view.
  • Page 74 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) If the fan functioned normally with a jumper in- stalled in place of the relay, remove the cooling fan fuse and the jumper wire. Carry out the following test: – Fan relay input voltage –...
  • Page 75 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) vmr2008-125-008_b FAN RELAY CONTROL CIRCUIT TEST vmr2008-139-008_a If continuity was not measured, repair or replace 1. Press to release connector lock wiring/connector as required. 2. Push to rotate connector lock upwards If cooling fan relay, relay input voltage and relay Install ECM connector onto the ECM adapter tool control circuit continuity tested good, the problem (P/N 529 036 085).
  • Page 76 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) vmr2008-125-009_b vmr2008-125-007_a FAN GROUND CIRCUIT CONTINUITY TEST (BKACK WIRE) 1. Radiator cooling fan connector If continuity was not measured, repair or replace On 2009 models, remove the cooling fan vent wiring/connector as required. tube.
  • Page 77 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) vmr2008-125-003_b 1. Coolant temperature sensor vmr2008-125-012_b 2. Valve cover TYPICAL — LEFT SIDE ILLUSTRATED, RIGHT SIDE SIMILAR 3. Thermostat housing 1. Radiator mounting screws 2. Mounting bracket for inner fender panel ELECTRONIC FUEL INJECTION Refer to section for testing and replacement procedures of the...
  • Page 78 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) Water Pump Cover Inspection Unscrew impeller from water pump shaft. Check if gasket is brittle, hard or damaged. Replace as required. 1. Impeller NOTE: Water pump shaft and impeller have right- hand threads. Remove by turning counterclock- wise and install by turning clockwise.
  • Page 79 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) 1. Water pump shaft with rotary seal Extract oil seal no. 3 from inside magneto cover using an appropriate pusher. 1. Retaining ring (circlip) 2. Water pump gear Remove water pump gear, needle pin and thrust washer.
  • Page 80 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) Water Pump Shaft and Gear Inspection Inspect water pump gear no. 4 for wear, cracks or broken teeth. Also inspect the gear snap (lock- ing) mechanism to the needle pin. Replace if dam- aged.
  • Page 81 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) TYPICAL 1. Water pump shaft with rotary seal 2. Water pump ceramic seal installer Always use torque values specified in the explod- ed view. Torque water pump cover screws as per sequence specified in following illustration. vmr2008-125...
  • Page 82 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) MAGNETO/STARTER SERVICE TOOLS Description Part Number Page crankshaft protector ............. 420 876 557 ........... 86 handle ................... 420 877 650 ........... 82 magneto puller..............529 035 748 ........... 86 oil seal installer ..............529 035 759 ........... 82 Fluke 111 multimeter ............
  • Page 83 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) vmr2008-126-001_a vmr2008-126...
  • Page 84 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) GENERAL The engine removal is necessary to work on mag- neto components except for the CPS (Crankshaft Position Sensor), vehicle speed sensor and oil seal. Always perform the electric tests before removing or installing whatever component. During assembly/installation, use the torque val- ues and service products as in the exploded views.
  • Page 85 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) NOTE: It is recommended to apply this specific sealant as described here to get an uniform appli- cation without lumps. If you do not use the roller method, you may use your finger to uniformly dis- tribute the sealant (using a finger will not affect the adhesion).
  • Page 86 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) Install the magneto cover. vmr2008-126-004_a 1. Gasket ring Tightening sequence for screws on magneto cov- vmr2008-126-003_a er is as per following illustration. 1. Oil seal protector 2. Oil seal on magneto cover 3. Crankshaft MAG side Refer to the following illustration for proper instal- lation of screws.
  • Page 87 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) Install the oil seal protector (P/N 529 035 935) on crankshaft end to avoid damaging oil seal during installation. 529035935 With Magneto Cover Removed Using the oil seal installer (P/N 529 035 759) and the handle (P/N 420 877 650), install the oil seal in its location.
  • Page 88 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) vmr2008-138-007_a vmr2008-138-005_b STATOR CONNECTOR PIN-OUT STATOR CONTINUITY TEST NOTE: Pin 2 is not used. Read resistance as per following table. If resistance readings are as specified, repair or re- YELLOW WIRES RESISTANCE @ place connector or wiring between the front stator (EACH PAIR) 20°C (69°F) connector and the voltage regulator input connec-...
  • Page 89 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) If there is a resistance or continuity, repeat test at stator connector. Test at Stator Connector To access the stator connector, remove the RH BODY inner fender panel, refer to section. vmr2008-138-005_a 1. Disconnect the voltage regulator input connector Set Fluke 111 multimeter (P/N 529 035 868) to Vac scale.
  • Page 90 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) vmr2008-138-006_a STATOR CONNECTOR, RH INNER FENDER PANEL REMOVED vmr2008-126-006_a 1. Stator Disconnect the stator connector and repeat stator 2. Stator screws output voltage test as per previous table. 3. Holding strip 4. Holding strip screw Stator Inspection Check stator condition.
  • Page 91 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) Remove: Measure trigger wheel teeth diameter at different locations. Maximum allowed diameter is 134 mm – Magneto cover (5.28 in). Otherwise, check for bent teeth. – Nut retaining rotor – Serrated washer. vmr2008-014-011_a 1. Rotor 2.
  • Page 92 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) vmr2008-139-004_c vmr2008-136-026_A FUSE F3 Remove conduit clips and corrugated tube from NOTE: Check engine will be displayed in multi- sensor and stator cables. function gauge, starter will crank engine but with Unscrew the CPS screw and pull CPS to remove an initial delay of approximately 4 seconds.
  • Page 93 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) Starter Removal Make sure the ignition switch is in the OFF posi- tion. Disconnect the BLACK (-) battery cable from the battery. vmr2008-139-009_b STARTER VOLTAGE TEST If you do not obtain close to battery voltage at the starter terminal, carry out a continuity test of the wire between the starter and the solenoid.
  • Page 94 Section 03 ENGINE Subsection 07 (MAGNETO/STARTER) vmr2008-139-014_a Torque starter screws to 10 N•m (89 lbf•in). Connect the RED (+) cable to the starter and torque nut to 6 N•m (53 lbf•in). vmr2008-139-009_d Apply dielectric grease (P/N 293 550 004) on starter terminal and nut.
  • Page 95 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) CONTINUOUSLY VARIABLE TRANSMISSION (CVT) SERVICE TOOLS Description Part Number Page pulley holding tool..............529 006 400 ........95, 104 drive pulley puller..............529 035 746 ........... 96 driven pulley expander............529 035 747 ........... 94 pulley holding tool..............
  • Page 96 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2008-127-001_a vmr2008-127...
  • Page 97 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) GENERAL PROCEDURES NOTE: For a better understanding, the following DRIVE BELT illustrations are taken with engine out of vehicle. To perform the following instructions, it is not nec- Drive Belt Removal essary to remove engine from vehicle.
  • Page 98 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2008-127-002_b 1. Remove last 1. Screw in of driven pulley expander 2. Removal direction for belt Open driven pulley with the driven pulley expander (P/N 529 035 747). Drive Belt Inspection Inspect belt for cracks, fraying or abnormal wear.
  • Page 99 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) DRIVE PULLEY vmr2008-127-003_a 1. Arrow towards the back of the vehicle 2. Drive pulley (front) 3. Driven pulley (rear) 1. Belt 2. Drive pulley NOTE: To ease installation of CVT cover with gas- 3.
  • Page 100 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) 1. Pulley holding tool 2. Drive pulley sliding sheave 1. Unscrew drive pulley screw 3. Area to place holding tool hook 2. Spring washer 3. Thrust washer Removal Procedure Continuation when 4.
  • Page 101 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) 1. Drive pulley puller 2. Fixed sheave 1. Slider shoe Drive Pulley Disassembly Put governor cup on a vise. Use protection plates Governor Cup on the vise jaws to avoid marks and/or damages to the governor cup.
  • Page 102 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2008-127-004_a 1. Bearing sleeve 2. Roller 3. Thrust washers Sliding Sheave Unscrew lock nut and remove centrifugal lever piv- ot bolt. 1. One-way clutch Remove centrifugal lever and both thrust wash- 2.
  • Page 103 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Remove all hardened oil deposits that have baked Measure the roller diameter. If one roller is out of on crankshaft and pulley tapered surfaces with specification, replace all rollers. coarse or medium steel wool and/or sand paper no.
  • Page 104 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2006-021-019_b 1. Lock nut 2. Centrifugal lever pivot bolt 3. Centrifugal lever A. Centrifugal lever pivot bolt bore diameter 4. Thrust washers 5. Contact surface to the roller CENTRIFUGAL LEVER PIVOT BORE DIAMETER CAUTION: Whenever replacing centrifugal 6.113 to 6.171 mm levers, always replace all levers at the same...
  • Page 105 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Check for any marks on fixed sheave plate. Re- place if necessary. Check ring gear teeth for excessive wear or other damage. Replace fixed sheave if necessary. WARNING Fixed sheave and ring gear are balanced to- gether.
  • Page 106 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) One-Way Clutch Apply Isoflex grease Topas NB 52 (P/N 293 550 021) on spring sleeves no. 8 and their springs then between one-way clutch bearings. Sliding Sheave Install centrifugal lever and both thrust washers. vmr2008-127-053_a A.
  • Page 107 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2006-021-017 CAUTION: Rollers must move easily after in- stallation. Insert slider shoes no. 3 into governor cup to prop- erly slide in guides. vmr2006-021-029_a Align governor cup with sliding sheave using the 1.
  • Page 108 WARNING 2. Sliding sheave of driven pulley 3. Spring Never substitute spring washer and/or screw with jobber ones. Always use BRP genuine NOTE: Two methods can be carried out to remove parts for this particular case. driven pulley. First Method...
  • Page 109 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Second Method Block driven pulley with pulley holding tool (P/N 529 006 400) then unscrew the driven pulley screw. Do not remove screw completely. vmr2008-127-005_a 1. Driven pulley screw 2. Thrust washer 3.
  • Page 110 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Clean the CVT crankcase area from contamination. Using a paper towel with cleaning solvent to clean main shaft end and the inside of the shaft no. 12. CAUTION: To avoid damage, make sure cleaner does not contact the countershaft seal.
  • Page 111 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) BUSHINGS BORE DIAMETER 30.060 to 30.100 mm NOMINAL (1.183 to 1.185 in) SERVICE LIMIT 30.200 mm (1.189 in) Fixed Sheave Check ball bearing no. 11 for free play and smooth operation. Replace if necessary. Check shaft no.
  • Page 112 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2008-127-055_a A. Free length 1. Ball bearing CLUTCH SPRING SQUARENESS CAUTION: Do not use a hammer, use a press SERVICE LIMIT 3.8 mm (.150 in) only. vmr2008-127-056_a A. Squareness 1. Shaft 2.
  • Page 113 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) 1. Retaining ring 2. Torque gear 1. Sharp edge of cam retainer to engine side 2. Main shaft spline 3. Printed mark “ENGINE SIDE” Driven Pulley Installation Install sliding sheave no. 15 into fixed sheave For installation, reverse the removal procedure.
  • Page 114 Section 03 ENGINE Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) 1. Washer 2. Driven pulley screw NOTE: Driven pulley end-play is 0 (zero). Torque driven pulley screw. vmr2008-127...
  • Page 115 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) CYLINDER HEAD/CYLINDER SERVICE TOOLS Description Part Number Page dial gauge ................414 104 700 ......... 115 valve spring compressor cup..........529 035 725 ......... 128 valve spring compressor clamp ..........529 035 764 ......... 128 piston ring compressor tool..........
  • Page 116 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) CYLINDER HEAD vmr2008-128-001_a vmr2008-128...
  • Page 117 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) CYLINDER AND PISTON vmr2008-128...
  • Page 118 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) GENERAL CAUTION: In case of piston rings and/or valve replacement, always clean the whole engine To work on cylinder head, cylinder and piston, the and change oil and oil filter. engine removal is not necessary. MAINTENANCE Always place the vehicle on level surface.
  • Page 119 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) INSPECTION Remove valve cover. Refer to CYLINDER HEAD/CYLINDER. LEAK TEST Before performing the cylinder leak test, verify the following: – Clamp(s) tightness – Radiator and hoses. NOTE: For best accuracy, the leak test should be done with the engine at normal operating temper- ature.
  • Page 120 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) NOTE: At TDC of compression stroke, the marks on the camshaft timing gear have to be parallel to cylinder head edge as per following illustration. TYPICAL 1. Leak tester 2. Air supply hose vmr2008-128-100_a Set needle of measuring gauge to zero.
  • Page 121 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) Valve Cover Inspection NOTE: For all the checkpoints mentioned above see the appropriate engine section to diagnose Check the gasket no. 1 on the valve cover no. 2 and repair the engine. if it is brittle, cracked or hard. If so, replace the gasket.
  • Page 122 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) 1. Decompressor shaft 2. Groove for centrifugal weight A. Measure here the bearing seat to cylinder head B. Measure top end (contact to camshaft lobe exhaust) C. 7 mm (.276 in) DECOMPRESSOR SHAFT MEASUREMENT A 5.578 to 5.590 mm (.219 to .220 in) 5.450 mm (.215 in)
  • Page 123 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) TIMING CHAIN TENSIONER Tensioner Removal WARNING Chain tensioner is spring loaded. Never per- form this operation immediately after the en- gine has been run because the exhaust sys- tem can be very hot. Wait until exhaust sys- tem is warm or cold.
  • Page 124 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) 529035926 vmr2007-036-004_a TYPICAL — MOVE GEAR BACK AND FORTH Apply engine oil on the plunger before installing. NOTE: Slightly screw in the plunger until the ten- sioned chain allows no more back and forth move- ment of the camshaft timing gear.
  • Page 125 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) vmr2008-128-102_a vmr2008-128-103_a 1. Camshaft locking tool 1. Mating surface on camshaft 2. Camshaft timing gear screw 2. Threads for camshaft timing gear screw 3. Camshaft timing gear Camshaft timing gear must be at TDC compres- When the camshaft timing gear and the timing sion before installing the timing chain.
  • Page 126 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) If protrusion exceeds service limit, replace tim- – Magneto cover and rotor (refer to MAGNE- ing chain, camshaft timing gear and timing chain TO/STARTER guides at the same time. – Bearing screw at the bottom of chain tensioner guide.
  • Page 127 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) 1. 2 thrust washers 2. Rocker arm (exhaust side) 3. Cylinder head — spark plug side 4. Big taper to PTO side vmr2008-128-105_a 1. Cylinder head Rocker Arm Inspection 2. Camshaft retaining plate screw 3.
  • Page 128 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) 1. Free movement of adjustment screw top Rocker Arm Shaft Check for scored friction surfaces; if so, replace parts. 1. Rocker arm shaft Measure rocker arm shaft diameter. 2. Thrust washer (MAG side) 3.
  • Page 129 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) A. Camshaft lobe (exhaust valves) B. Camshaft lobe (intake valves) C. Camshaft journal MAG side D. Camshaft journal PTO side vmr2008-128-105_a CAMSHAFT LOBE — EXHAUST VALVES 1. Cylinder head 2. Camshaft retaining plate screw 3.
  • Page 130 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) A. Cylinder head camshaft bearing MAG side B. Cylinder head camshaft bearing PTO side vmr2008_128-106_b 1. Camshaft retaining plate position CYLINDER HEAD CAMSHAFT BEARING — 2. Slot retaining camshaft MAG SIDE 3. Direction of movement 35.000 to 35.025 mm For other parts, refer to proper installation proce- (1.3780 to 1.3789 in)
  • Page 131 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) – Cylinder head screws M10 retaining cylinder head no. 24 and cylinder no. 25 to crankcase housings. vmr2008_128-107_a 1. Oil port to lubricate camshaft lobes intake/exhaust 2. Oil supply to camshaft bearing journal MAG side 3.
  • Page 132 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) vmr2008_128-108_a 1. Chain guide (fixed between cylinder and cylinder head) 2. Chain guide on tensioner side (mounted in crankcase) 1. Valve spring compressor clamp 2. Valve spring compressor cup Remove crankshaft locking bolt then reinstall all 3.
  • Page 133 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) Push valve stem then pull valves out of valve guide no. 32. A. Valve spring length VALVE SPRING FREE LENGTH 40.81 mm (1.607 in) SERVICE LIMIT 39.00 mm (1.535 in) vmr2006-043-021_a Replace valve springs if not within specifications. 1.
  • Page 134 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) Valve Valve Face and Seat Inspect valve surface, check for abnormal stem wear and bending. If out of specification, replace by a new one. VALVE OUT OF ROUND (intake and exhaust valves) 0.005 mm (.0002 in) SERVICE LIMIT 0.06 mm (.0024 in) Valve Stem and Valve Guide Clearance...
  • Page 135 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) VALVE GUIDE Valve Guide Removal Remove: – Cylinder head – Valve spring – Valves. NOTE: Clean valve guide area from contamination before removal. Using the valve guide remover (P/N 529 035 924) and a hammer, remove valve guide. A.
  • Page 136 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) vmr2006-043-025 1. Valve seat 2. Valve face (contact surface to valve seat) 3. Turn valve while pushing against cylinder head A. Valve seat angle 45° NOTE: Ensure to seat valves properly. Apply marking paste to ease checking contact pattern. Repeat procedure until valve seat/valve face fits together.
  • Page 137 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) Cylinder Out of Round Measure cylinder diameter in piston axis direction from top of cylinder. Take another measurement 90° from first one and compare. NOTE: Take the same measuring points like de- CYLINDER TAPER scribed in above.
  • Page 138 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) 1. Piston circlip NOTE: The removal of both piston circlips is not 1. Timing chain 2. Piston ring compressor tool necessary to remove piston pin. 3. Piston 4. Cylinder Push piston pin out of piston. NOTE: Put timing chain through the chain pit then put the cylinder in place.
  • Page 139 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) The measured dimension should be as described in the following table. If not, replace piston. PISTON MEASUREMENT 90.950 to 90.966 mm (3.5807 to 3.5813 in) SERVICE LIMIT 90.850 mm (3.577 in) Piston/Cylinder Clearance Adjust and lock a micrometer to the piston dimen- sion.
  • Page 140 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) Place piston no. 37 over connecting rod. Position the piston with the punched arrow towards the exhaust side. Insert piston pin no. 38 into piston and connecting rod. A. Piston pin diameter PISTON PIN DIAMETER 19.996 to 20.000 mm (.7872 to .7874 in) SERVICE LIMIT...
  • Page 141 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) Align sleeve with piston pin axis and push assem- RING/PISTON GROOVE CLEARANCE bly jig until circlip engages in piston. UPPER COMPRESSION RING 0.030 to 0.070 mm (.0012 to .0028 in) SERVICE LIMIT 0.150 mm (.0059 in) LOWER COMPRESSION RING 0.020 to 0.060 mm (.0008 to .0024 in)
  • Page 142 Section 03 ENGINE Subsection 09 (CYLINDER HEAD/CYLINDER) NOTE: First install spring and then rings of oil scraper ring. Install the oil scraper ring first, then the lower com- pression ring with the word “N and TOP “ fac- ing up, then the upper compression ring with the word “N and TOP“...
  • Page 143 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) CRANKCASE/CRANKSHAFT SERVICE TOOLS Description Part Number Page dial gauge ................414 104 700 ......... 153 insertion handle ..............420 877 650 ..143–144, 147, 150–151 crankshaft locking bolt............529 035 617 ......... 154, 158 crankcase support PTO ............
  • Page 144 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) CRANKCASE vmr2008-129-001_a vmr2008-129...
  • Page 145 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) CRANKSHAFT/BALANCER SHAFT vmr2008-129...
  • Page 146 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) GENERAL This section includes the procedures pertaining to the crankcase, crankshaft and balancer shaft. For the gearbox, follow the procedure for the CRANKCASE then refer to GEARBOX/OUTPUT SHAFT section. During assembly/installation, use the torque val- ues and service products as in the exploded views.
  • Page 147 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) Starter Drive Installation For installation, reverse the removal procedure. However, pay attention to the following. Apply multi-purpose grease inside starter drive pinion cover. OUTPUT SHAFT OIL SEAL Output Shaft Oil Seal Removal NOTE: The output shaft oil seal no. 5 can be re- moved and installed without removing the engine from vehicle.
  • Page 148 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) Shift Shaft Oil Seal Installation Using a suitable tube, with the proper diameter, install the seal. Align the previous scribing marks and install the shifting plate. Torque shifting plate bolt to 10 N•m (89 lbf•in). CRANKSHAFT OIL SEAL Crankshaft Oil Seal Removal NOTE: The crankshaft oil seal no.
  • Page 149 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) 1. Feeler gauge CRANKSHAFT AXIAL CLEARANCE 1. Oil seal (crankcase PTO side) 2. Oil seal installer 0.1 to 0.4 mm 3. Installer handle (.0039 to .0157 in) If measurement is out of specification, in- CRANKCASE spect butting faces of crankshaft and crankcase (MAG/PTO side) for excessive wear.
  • Page 150 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) Crankcase mating surfaces are best cleaned us- ing a combination of the chisel gasket remover (P/N 413 708 500) and a brass brush. Brush a first pass in one direction then make the final brushing perpendicularly (90°) to the first pass cross (hatch).
  • Page 151 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) Use the oil seal installer (P/N 529 035 933) and the insertion handle (P/N 420 877 650) to install oil seal. 529036069 1. PTO plain bearing without groove 2. Oil bore 3. Split of the plain bearing halves 4.
  • Page 152 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) vmr2006-044-026 NOTE: Use crankcase support MAG (P/N 529 035 916) and crankcase support PTO (P/N 529 035 754) when removing plain bearings. PUSH PLAIN BEARINGS OUTSIDE 1. Plain bearing remover/installer 2. Plain bearing 3. Crankcase PTO Crankshaft Plain Bearing Installation To install the plain bearing turn the plain bearing remover/installer up side down.
  • Page 153 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) 1. Crankcase support PTO 2. Crankcase PTO side 1. Mark on crankcase and oil bore position NOTE: Mark oil bore position on crankcase to align 2. Split between bearing halves 3. Perpendicular axle to cylinder base new plain bearing with crankcase thrust surface.
  • Page 154 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) Counter Shaft Needle Bearing Removal To remove counter shaft needle bearing no. 19, use a punch as follows. 1. Bevel gear needle bearing 2. Punch Bevel Gear Needle Bearing Installation Install needle bearing no. 18 with the needle bear- 1.
  • Page 155 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) vmr2008-126-010_a 1. Needle bearing installer 2. Handle COUNTER SHAFT 1. Counter shaft needle bearing 2. Needle bearing installer 3. Installer handle Starter Drive Needle Bearing Removal Use needle bearing remover (P/N 529 035 756) to remove needle bearing no.
  • Page 156 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) Balancer Shaft (MAG side) Ball Bearing NOTE: It is recommended to apply this specific Installation sealant as described here to get a uniform appli- cation without lumps. If you do not use the roller Use a suitable installer for installing ball bearing method, you may use your finger to uniformly dis- no.
  • Page 157 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) CRANKSHAFT Crankshaft Locking Procedure Unplug spark plug cable then remove the spark plug. Install the dial gauge (P/N 414 104 700). 1. Crankshaft 2. Balancer shaft 3. Connecting rod 4. Rotate crankshaft for balancer shaft removal vmr2007-019-001_a 5.
  • Page 158 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) 1. Screw 2. Sealing ring 1. Crankshaft locking bolt 3. Output shaft on front side of vehicle 2. Front output shaft area Use a screwdriver to check if groove in crankshaft is aligned with the hole. Crankshaft Removal Remove: BALANCER SHAFT...
  • Page 159 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) 1. Bore gauge 2. Connecting rod 1. Balancer gear 2. Crankshaft timing gear Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between butting face of connecting rod and crankshaft counterweight. If the distance exceeds specified A.
  • Page 160 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) 1. Connecting rod screw Measure crankpin. Compare to inside diameter of connecting rod big end. A. Connecting rod big end plain bearing CRANKSHAFT PIN DIAMETER 40.009 to 40.025 mm (1.575 to 1.576 in) SERVICE LIMIT 39.980 mm (1.574 in) CONNECTING ROD BIG END DIAMETER SERVICE LIMIT...
  • Page 161 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) CAUTION: Always use NEW connecting rod screws for the final assembly of the crankshaft. Torque NEW connecting rod screws no. 7 as per following procedure: – Install screws with half of recommended torque in the exploded view. Do not apply any thread locker product.
  • Page 162 Section 03 ENGINE Subsection 10 (CRANKCASE/CRANKSHAFT) 1. Crankshaft locking bolt 2. Engagement groove for TDC position of the piston 1. Installer of balancer shaft Using pulley flange cleaner (P/N 413 711 809), Align the marks of crankshaft and balancer shaft. clean both crankshaft tapers before installing the rotor or the drive pulley.
  • Page 163 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) GEARBOX/OUTPUT SHAFT vmr2006-058-001_aen vmr2008-130...
  • Page 164 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) GENERAL Remove: – Output shaft bearing cover During assembly/installation, use the torque val- – Magneto cover rotor (refer ues and service products as in the exploded view. MAGNETO/STARTER WARNING Use a soft hammer to remove output shaft no. 6 from housing.
  • Page 165 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) 1. Thrust washer 1. Soft hammer 2. Output shaft ring gear Push output shaft as per following illustration. Output Shaft Inspection Check output shaft for bending, cracks and other visible damages. CAUTION: Always replace output shaft and bevel gear shaft at the same time.
  • Page 166 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) Use the measured thickness to choose the re- quired thrust washer as per the following table. MEASURED THRUST WASHER THICKNESS THICKNESS 0.79 to 0.88 mm 0.70 mm (.0276 in) (.0311 to .0346 in) 0.89 to 0.98 mm 0.80 mm (.0315 in) (.0350 to .0386 in)
  • Page 167 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) 1. Shift fork shaft Remove shift fork. 1. Shift fork engagement pin 2. Shift drum Insert a flat screwdriver in the slot of index lever. Turn screwdriver counterclockwise and remove shift drum. 1. Shift fork (engaged in main shaft gear) Disengage shift fork from shift drum.
  • Page 168 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) – Distance sleeve no. 24, thrust washer no. 25, intermediate gear no. 26, needle bearing no. 27 and intermediate gear shaft no. 28. NOTE: It is not necessary to remove index lever no. 29. Check index lever for visible damage and if it moves freely.
  • Page 169 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) SHIFT FORK CLAW THICKNESS 4.800 to 4.860 mm (.189 to .191 in) SERVICE LIMIT 4.750 mm (.187 in) 1. PTO side Shift Drum Check tracks of shift drum no. 32 for scoring or heavy wear like rounded engagement slots.
  • Page 170 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) The bevel gear adjustment includes: The bevel gear axial clearance is adjusted by find- ing the proper thrust washer thickness J as per – Bevel gear backlash on MAG side crankcase following illustration. –...
  • Page 171 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) Bevel Gear Backlash Procedure (MAG Side Crankcase) Use the following course of calculation to deter- mine the theoretical thickness D of thrust washer no. 35 on MAG side crankcase: D = B - C - A B = Distance between the thrust surface of bevel gear and the theoretical center of its taper.
  • Page 172 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) Measure the distance C with a depth gauge, between the washer thrust surface in the MAG side and the mating surface of crankcase MAG/ magneto cover. C = 34.040 mm (1.340 in) The nominal thickness A of needle bearing is al- ways 2 mm (.0787 in).
  • Page 173 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) Gearbox Assembly THEORETICAL THRUST WASHER THRUST WASHER For assembly, reverse the disassembly procedure. NUMBER J THICKNESS I Pay attention to the following details. 1.22 mm to 1.31 mm Install: (.0480 to .0516 in) –...
  • Page 174 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) 1. Parking stop location 2. Reverse stop location 3. Neutral stop location 4. High gear stop location 5. Low gear stop location 6. Contact to stop location for neutral/park position 7. Contact to reverse stop location 1.
  • Page 175 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) Measure the resistance of the pertaining switch using the following table. SHIFTER WIRE LOCATION RESISTANCE POSITION PARK 1 (BLUE) REVERSE Battery (BROWN) Close to 0 ground NEUTRAL (YELLOW/ GREEN) vmr2008-129-055_a 1. Selected shifter position of vehicle 2.
  • Page 176 Section 03 ENGINE Subsection 11 (GEARBOX/OUTPUT SHAFT) NOTE: Clean area from dirt and belt dust before removing gearbox position switch(es). Disconnect terminal. vmr2008-129-054_a Unscrew the gearbox position switch. Gearbox Position Switch Installation For installation, reverse the removal procedure. Pay attention to the following details. Take care not to damage gearbox position switch- es threads during installation.
  • Page 177 Section 03 ENGINE Subsection 12 (SHIFTER) SHIFTER SERVICE PRODUCTS Description Part Number Page XP-S synthetic grease............293 550 010 ......... 175 Loctite 243 (blue)..............293 800 060 ......... 174 vmr2006-046-001_b vmr2008-131...
  • Page 178 Section 03 ENGINE Subsection 12 (SHIFTER) GENERAL SHIFT LEVER Before performing any servicing on the shifter link- Shift Lever Removal age system, be sure the shift lever is in NEUTRAL BODY Remove RH side panel (refer to position and the parking brake is applied. Remove the shift lever handle.
  • Page 179 Section 03 ENGINE Subsection 12 (SHIFTER) Shift Lever Inspection Check both O-rings on threaded fitting and apply XP-S synthetic grease (P/N 293 550 010) on the Check the shift lever for bending or cracks. bushing inside threaded fitting. Replace O-rings if Check the tie-rod at the end of lever.
  • Page 180 Section 03 ENGINE Subsection 12 (SHIFTER) Mark the location of shifting plate before removing it from shift shaft. vmr2007-040-008_a 1. Threaded fitting 2. Jam nut vmr2007-040-009_b 3. Link rod 1. Mark aligned with slot Verify if the shift lever moves into the PARK and Remove the shifting plate.
  • Page 181 Section 03 ENGINE Subsection 12 (SHIFTER) vmr2007-040-009_b 1. Mark aligned with slot Install the shifting plate bolt. LINK ROD Install link rod and adjust it (refer to above). Install side panel and check if the shifting system works well. vmr2008-131...
  • Page 182 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 01 (OVERVIEW) OVERVIEW Engine Management System (EMS) vmr2008-132-004_aen vmr2008-132...
  • Page 183 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 01 (OVERVIEW) Power Distribution vmr2008-132-002_aen vmr2008-132...
  • Page 184 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 01 (OVERVIEW) ECM and VFB Interaction with the Electrical System vmr2008-132-003_aen ECM Inputs/Outputs vmr2008-132-001_aen vmr2008-132...
  • Page 185 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 01 (OVERVIEW) SYSTEM DESCRIPTION ENGINE CONTROL MODULE (ECM) A highly advanced engine management system (EMS) has been used to ensure a high power out- put with cleaner combustion. There are 4 main systems that are controlled by the engine management system (EMS): 1.
  • Page 186 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 01 (OVERVIEW) Vehicle Speed Limiter – Fuel pump relay – Accessory relay The ECM will limit the maximum vehicle speed both in 2WD and in 4WD. For this purpose, the – Cooling fan relay. ECM uses the VSS (vehicle speed sensor) and the The ECM provides the trigger signal to activate GBPS (gearbox position sensor).
  • Page 187 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 02 (COMMUNICATION TOOLS/B.U.D.S. SOFTWARE) COMMUNICATION TOOLS/B.U.D.S. SOFTWARE SERVICE TOOLS Description Part Number Page Optional extension cable ............529 035 697 ......... 185 MPI-2 ..................529 036 018 ......... 185 Diagnostic cable ..............710 000 851 ......... 185 MULTI-PURPOSE INTERFACE-2 MPI-2 Power Supply (MPI-2)
  • Page 188 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 02 (COMMUNICATION TOOLS/B.U.D.S. SOFTWARE) mmr2006-079-200 vmr2008-133-005_a Use B.U.D.S. software as described further in Connect diagnostic cable to vehicle connector. B.U.D.S. SOFTWARE B.U.D.S. SOFTWARE B.U.D.S. (Bombardier Utility and Diagnostic Soft- ware) is designed to allow electrical component inspection, to diagnose and monitor components and to carry out settings such as the closed throt- tle and idle actuator.
  • Page 189 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 02 (COMMUNICATION TOOLS/B.U.D.S. SOFTWARE) Communication Problems NOTE: Number 2 means that 2 “ECU” are con- nected (ECM and multifunction gauge). If an “X” is shown, this means there is no com- munication between the MPI and the ECM or the multifunction gauge.
  • Page 190 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) MONITORING SYSTEM/FAULT CODES MONITORING SYSTEM COMPONENT EMS (TPS, CPS, MAPTS, CTS, OPS, IACV, The EMS features a monitoring system that self- GBPS, ignition coil and fuel injector) diagnose its electronic components (control mod- ules, sensors and actuators) to ascertain they are Battery voltage not faulty or defective.
  • Page 191 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) How to Read Fault Codes on the Multifunction Gauge Fault codes starting with the letter “P” followed by 4 digits (P-1234) can be displayed in the multifunction gauge for troubleshooting. NOTE: The multifunction gauge can display only fault codes that are active.
  • Page 192 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) NOTE: A minimum of 3 HI - LO toggles must be completed within 2 seconds. If there is no fault code, the NO ACTIVE P_CODE will be displayed. If there is any fault code, it will be displayed. vmr2008-134-003_d NOTE: To quickly exit the on-board diagnostic mode, press and HOLD the mode button.
  • Page 193 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) POSSIBLE CAUSES ACTION POSSIBLE CAUSES ACTION Check if connector is Fix. Sensor has been replaced Reset Closed Throttle and Idle Actuator. disconnected from TPS and TPS closed position not reset Check if sensor is loose Tighten and reset Closed Throttle and Idle...
  • Page 194 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) FAULT CODE TABLE FAULT DESCRIPTION POSSIBLE FAULT ACTION CODE Manifold absolute Make sure sensor's connector is fully Faulty MAPTS - disconnected pressure sensor signal connector - faulty terminals inserted. Check for approximately 5 volts shorted to GND or Open between sensor connector pins 1 and 2.
  • Page 195 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) FAULT DESCRIPTION POSSIBLE FAULT ACTION CODE Coolant temperature Faulty CTS - partially Check for disconnected engine sensor intermittent fault disconnected connector - temperature sensor. Check sensor faulty terminals - cut wires resistor value between 1800 ohm and - shorted wire - change in 2200 at 22°C.
  • Page 196 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) FAULT DESCRIPTION POSSIBLE FAULT ACTION CODE Starter solenoid shorted Faulty solenoid - faulty Check for damaged or disconnected terminal at solenoid or at to battery 12 V starter solenoid, damaged circuit wires, engine connector - Dirt stuck damaged connectors or damaged ECM on solenoid blades and/or...
  • Page 197 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) FAULT DESCRIPTION POSSIBLE FAULT ACTION CODE Idle air control valve Faulty IACV - disconnected Make sure IACV connector is fully pin(s) disconnected or connector - faulty terminals - inserted. Check circuits between idle shorted to GND cut wires - shorted wire valve motor pins and ECM pins D3-1,...
  • Page 198 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) FAULT DESCRIPTION POSSIBLE FAULT ACTION CODE Gearbox position sensor Not plaussible GBPS Check for disconnected transmission fault combination - shorted to connector. Check switch continuity GND wire - faulty sensor - worn separately in all position (PR &...
  • Page 199 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) FAULT DESCRIPTION POSSIBLE FAULT ACTION CODE Battery voltage under Battery voltage too low - Check battery voltage for 12 to 13 volts 8 V at key switch voltage disconnected connector - faulty with engine stopped.
  • Page 200 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) ELECTRONIC FUEL INJECTION SERVICE TOOLS Description Part Number Page tachometer ................529 014 500 ......... 201 cable luber ................529 035 738 ......... 202 Fluke 115 multimeter ............529 035 868 ....205–206, 211–213, 215, 217–219, 223–225 ECM adapter.................
  • Page 201 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) Intake Manifold Slowly disconnect the fuel hose to minimize spilling. Cover the fuel line connection with an The intake manifold is connected to the engine absorbent shop rag. Wipe off any fuel spillage. cylinder head.
  • Page 202 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) Check related-circuit fuse solidity and condition Also remember this validates the operation of the with an ohmmeter. Visual inspection could lead sensor at room temperature. It does not validate to false results. the over temperature functionality.
  • Page 203 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) – Throttle body is replaced. Start engine and make sure it operates normally through its full engine RPM range. If fault codes – IACV is replaced. appear, refer to MONITORING SYSTEM/FAULT –...
  • Page 204 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) Spray the cable lubricant (P/N 293 600 041) into the cable until the lubricant runs out at throttle body end of the throttle cable. NOTE: If the recommended lubricant is not avail- able, an equivalent silicone lubricant can be used.
  • Page 205 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) FUEL INJECTOR vmo2008-019-005_c 1. Throttle lever A. 2 to 4 mm (5/64 to 5/32 in) vmr2008-136-008_a Tighten lock nut and reinstall the rubber protector. Injector Leakage Test Turn handlebar from lock to lock and ensure and ensure there is still free-play in each position.
  • Page 206 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) vmr2008-139-004_h Use the Fluke 115 multimeter (P/N 529 035 868) vmr2006-014-001_a and select NOTE: It is not necessary to activate the injector Read resistance. since it is continuously powered. Use the Fluke 115 multimeter (P/N 529 035 868) INJECTOR CIRCUIT and select Vdc.
  • Page 207 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) vmr2008-136-009_b If resistance value is correct, injector coil is in good vmr2006-014-075_c condition. If control circuit is faulty, repair/replace wiring/ If resistance value is incorrect, repeat test at injec- connectors. tor connector. If control circuit and all tests applicable to the in- jector are good, try a new ECM.
  • Page 208 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) vmr2006-014-072_a Firmly push injector until it bottoms. Reinstall fuel rail. See above. vmr2006-014-079_a FUEL RAIL ASS’Y FUEL RAIL 1. Fuel rail 2. Fuel injector 3. Injector top O-ring Fuel Rail Removal 4.
  • Page 209 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) vmr2008-136-019_a vmr2008-136-019_a NOTE: To reach the screws, a 1/4 inch drive, 8 mm Secure inlet hose to injector. hexagonal socket works well. WARNING Gently pull rail up by hand. Perform a fuel pressure test and ensure that there is no leak.
  • Page 210 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) vmr2008-136-021_a vmr2006-014-064_c Turn throttle lever and pull out cable barrel. Throttle Body Removal To remove the throttle body from engine, proceed as follows: BODY Remove side panels. Refer to Remove air filter housing. Refer to AIR INTAKE SYSTEM Unplug TPS and IACV connectors.
  • Page 211 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) vmr2006-014-65_a vmr2006-014-063_a When the throttle body has been replaced, ensure Hook cable to throttle lever. – Check throttle cable adjustment. Refer to THROTTLE CABLE in this section. – Reset the Closed Throttle and Idle Actuator. BASIC ADJUSTMENTS Refer to in this section.
  • Page 212 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) The EMS may generate several fault codes THROTTLE WIDE OPEN pertaining to the TPS. Refer to MONITORING ECM CONNECTOR IDLE THROTTLE SYSTEM/FAULT CODES section for more infor- POSITION POSITION mation. RESISTANCE @ 20°C (68°F) TPS Wear Test 990 - 1190...
  • Page 213 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) Turn ignition key ON and set engine stop switch to RUN. Use the Fluke 115 multimeter (P/N 529 035 868) and select Vdc. Check the voltage readings from harness connec- tor as follows. CONNECTOR VOLTAGE 5.0 Vdc...
  • Page 214 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) IDLE AIR CONTROL VALVE MEASUREMENT RESISTANCE @ 20°C (68°F) 45 - 55 vmr2008-022-005 Use the Fluke 115 multimeter (P/N 529 035 868) and select Check the resistance of both windings. ECM CONNECTOR MEASUREMENT RESISTANCE @ 20°C (68°F)
  • Page 215 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) vmr2006-014-085_a 1. Clean bore from contamination vmr2008-136-025_b Clean all remaining parts and install the idle air con- If resistance test failed, repair/replace wiring/con- trol valve on the throttle body. nectors. Proceed with the Closed Throttle and Idle Actu- BASICS ADJUST- ator Reset.
  • Page 216 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) vmr2008-136-026_A vmr2008-136-027_b Use the Fluke 115 multimeter (P/N 529 035 868) If resistance is not within specifications, replace and select Vac. the CPS. Probe terminals as shown. If resistance tests good at component, reconnect the CPS connector and repeat the test at the ECM Crank engine and read voltage.
  • Page 217 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) Ensure sensor is correctly installed on intake manifold. Otherwise, the MAPTS could gener- ate a fault code for an unexpected sensor range at idle when it reads the absolute pressure. Remove sensor and check for oil or dirt on its end and if problem persists, check throttle plate condition/position and the wiring harness.
  • Page 218 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) Use the Fluke 115 multimeter (P/N 529 035 868) and select Vdc. Read voltage. MAPTS CONNECTOR MEASUREMENT VOLTAGE 5 Vdc vmr2008-136-029_a If continuity is good, replace MAPTS. If continuity is not good, repair/replace wiring/ connectors between the ECM and the MAPTS.
  • Page 219 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) Sensor Temperature Function MAPTS Resistance Test (AT ECM Connector) The sensor also monitors the temperature at in- Disconnect the ECM connector. take manifold. Install ECM adapter (P/N 529 036 085) on ECM connector.
  • Page 220 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) COOLANT TEMPERATURE MAPTS CIRCUIT MEASUREMENT SENSOR (CTS) MAPTS RESISTANCE ECM PIN @ 20°C (68°F) Close to 0 If continuity is not good, repair/replace wiring/ connectors between the ECM and the MAPTS. If continuity and all tests applicable to the MAPTS are good, try a new ECM.
  • Page 221 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) Disconnect CTS connector. Remove CTS. vmr2008-136-032_a If resistance is out of specification, replace the CTS. vmr2008-136-032 If resistance tests good, reconnect the CTS con- nector and repeat test at ECM connector. CTS Installation Install the new CTS.
  • Page 222 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) vmr2008-136-013_a FRONT RH SIDE vmr2008-022-014_a TYPICAL Pull out connector. vmr2008-136-014_a 1. ECM 2. ECM connector vmr2008-022-015_a Push and hold the locking tab. TYPICAL ECM Connector Installation Fully open connector lock. vmr2008-022-013_a TYPICAL Rotate connector lock until it stops.
  • Page 223 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) 529036085 Disconnect the ECM connector and reconnect on the tool connector. Probe required terminals di- rectly in the tool holes. vmr2008-022-015_b TYPICAL Install connector to ECM. Rotate connector lock until it snaps locked. vmr2008-139-016_a 1.
  • Page 224 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) When engine stop switch is set to STOP or igni- tion key is turned OFF, ECM will turn off after ap- proximately 30 seconds. All the electrical system will then be cut-off. ECM Quick Troubleshooting Tips Turn ignition key to ON AND set engine stop switch to RUN.
  • Page 225 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) CONNECTOR BATTERY MEASUREMENT Battery ground Close to 0 post (continuity) vmr2008-136-003_A ENGINE GROUND vmr2008-022-005_d If test succeeded, ECM grounds are adequate. If test failed, ensure wiring/connectors are good and repair/replace as necessary. If wiring/connec- tors are good, check the following grounds.
  • Page 226 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) vmr2008-022-005_b If voltage is out of specification, check wiring/ connectors from ECM fuse to ECM through igni- IGNITION tion and engine stop switches. Refer to 529035868_a SYSTEM. Check voltage as follows. If voltage is as per specification, carry out the MAIN RELAY CIRCUIT TEST ECM CONNECTOR PIN...
  • Page 227 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) ECM Removal NOTE: If ECM is removed for replacement, refer ECM REPLACEMENT. first to Disconnect battery cables. WARNING Battery BLACK negative cable must always be disconnected first and connected last. vmr2006-012-100_aen ECM CON- Disconnect ECM connector.
  • Page 228 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) There are 2 possible methods to collect the re- NOTE: You may have to go to another AutoSave quired information. folder from a previous version of B.U.D.S. – Use B.U.D.S. software and get the data from a Choose the latest file saved for this specific vehi- saved .mpem file on your PC computer.
  • Page 229 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION) Enter data into ECM as detailed in ENTERING THE COLLECTED INFORMATION INTO THE ECM low. Collecting Method: Collect the Information from the Vehicle Remove the faulty ECM. Install and connect the new ECM. vmr2006-020-058_a Record vehicle serial number and model number.
  • Page 230 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) FUEL TANK/FUEL PUMP SERVICE TOOLS Description Part Number Page Oetiker pliers ................ 295 000 070 ......... 237 small hose pincher..............295 000 076 ......... 234 vacuum/pressure pump............529 021 800 ......... 234 pressure gauge..............
  • Page 231 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) 2008 MODELS vmr2008-135-100_a vmr2008-135...
  • Page 232 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) 2009 MODELS vmr2008-135-200_a vmr2008-135...
  • Page 233 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) GENERAL Never use a hose pincher on injection system high pressure hoses. WARNING Replace any damaged or deteriorated fuel lines. Fuel is flammable and explosive under cer- When the repair is complete, ensure that all hoses tain conditions.
  • Page 234 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-135-201_a vmr2008-135-201_b 2009 MODELS 2009 MODELS 1. Vent inlet check valve 1. Inlet check valve blocks fuel 2. Outlet pressure relief valve allows pressure to go out If the pressure in the fuel tank builds up and ex- ceeds 2.5 - 7.6 kPa (.36 - 1.1 PSI), then the pres- INSPECTION sure relief valve opens and lets the excess pres-...
  • Page 235 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-135-001_a vmr2008-135-202_a TYPICAL 2009 MODELS 1. Seat reinforcement plate 1. Vent system outlet 2. Exhaust heat shield 2. Small hose pincher 3. Retaining screws (5) 3. Vent pressure relief valve All Models Using the vacuum/pressure pump (P/N 529 021 800), pressurize fuel tank through vent line (INLET Install a small hose pincher (P/N 295 000 076) on...
  • Page 236 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-135-005_a Step 1: Block vent outlet with finger vmr2008-135-203_a Step 2: Remove hose pincher 2009 MODELS 1. Fuel tank vent Alternately touch and release end of pressure re- 2. Vent inlet line lief valve.
  • Page 237 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) WARNING If engine has been recently running, always allow engine and exhaust system time to cool before disconnecting any fuel component. Ensure there is enough gas in fuel tank. Remove the seat and the RH side body panel, re- BODY fer to the section.
  • Page 238 FUEL HOSE AND OETIKER CLAMPS Fuel Hose Replacement When replacing fuel hoses, be sure to use hoses and clamps as available from BRP parts depart- ment. This will ensure continued proper and safe operation. WARNING Use of fuel lines other than those recom-...
  • Page 239 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) IN-LINE FUEL FILTER Filter Installation (2008 MODELS) Insert new Oetiker clamps on fuel hoses prior to installing hoses on filter. Replace fuel filter as per maintenance chart sched- Use arrow on filter to position filter according to MAINTENANCE ule.
  • Page 240 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) Fuel Tank Draining WARNING Never perform this operation when the en- gine and/or the exhaust system is/are hot. Never use a hose pincher on injection system high pressure hoses. Remove fuel tank cap and siphon gas into an ap- proved fuel container.
  • Page 241 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) Disconnect fuel line at fuel rail quick disconnect fitting. vmr2008-135-009_a 2008 MODELS 1. Fuel pump connector vmr2008-135-010_a 2. Fuel tank 1. Fuel rail quick disconnect 3. Rear drive shaft 2. From fuel filter Remove screw securing in-line fuel filter to vehicle frame.
  • Page 242 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-135-201_g vmr2008-135-903_a 1. Pull out vent outlet TYPICAL – 2009 MODEL SHOWN 2. Fuel pump fitting All Models All Models except MAX Remove the upper and the lower fuel tank retain- Remove 2 fuel tank retaining screws on right side ing screws on the left side of the tank.
  • Page 243 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-135-207_a TYPICAL – 2009 MODEL SHOWN Pull fuel tank out from the RH side of vehicle. vmr2006-015-002_a 1. Tank protector 2. Protector retaining tab Complete removal of protector from fuel tank. For installation, reverse the removal procedure.
  • Page 244 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) Inspect tank and protector attachment points for damages. Inspect protector for damages. If cracks, gouges or other damages which may lead to a fuel leak, or damages to attachment points that could prevent the tank from being secure are found, replace fuel tank.
  • Page 245 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) In B.U.D.S., select Read Data. Select the Activation page tab. On the RH side of the page in the Activate field, select Fuel Pump. This will turn on the fuel pump for 5 seconds.
  • Page 246 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) Fuel Pump Relay Input Voltage Test Remove front compartment cover and fuse box cover. Remove fuel pump relay. vmr2006-015-009_c TYPICAL OBSERVATION SIGNIFICATION Battery voltage is – Validates fuel pump relay R2 read for approx supplies power to fuel pump.
  • Page 247 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) Fuel Pump Relay Continuity (Ground Circuit) BODY Remove RH inner fender panel, refer to the section. Disconnect ECM connector. vmr2008-135-012_a If ground circuit continuity is good, check ECM. ENGINE MANAGEMENT SYSTEM Refer to sec- tion.
  • Page 248 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-135-012_b FUEL PUMP WINDING CONTINUITY TEST If fuel pump motor winding resistance is not as per table, replace the fuel pump. vmr2006-015-012_a GASKET AND FLANGE NOT SHOWN FOR CLARITY OF Fuel Pump Removal ILLUSTRATION 1.
  • Page 249 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) – Substitute fuel pump relay with a known working relay in fuse box. vmr2008-135-015_a Pull strainer off fuel pump. vmr2008-139-004_o Insert new strainer on fuel pump making sure that – Check in B.U.D.S. for applicable fault it pressed in tightly against pump face.
  • Page 250 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) From the RH side of the vehicle, ldisconnect the FUEL PUMP INPUT VOLTAGE TEST fuel pump connector. FUEL PUMP BATTERY VOLTAGE READING NOTE: It may be necessary to remove seat re- CONNECTOR inforcement plate and/or LH side panel to make Pin 3...
  • Page 251 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) FUEL PUMP RELAY INPUT VOLTAGE TEST TEST PROBES READING Fuse box contact 1A Battery ground Battery voltage Fuse box contact 3A vmr2008-139-008_a 1. Press to release connector lock 2. Push to rotate connector lock upwards Install ECM adapter tool (P/N 529 036 085) onto ECM connector.
  • Page 252 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-135-012_a vmr2008-135-012_c ENGINE If continuity is good, check ECM. Refer to If resistance test failed, disconnect fuel pump con- MANAGEMENT SYSTEM section. nector and measure winding again directly to fuel pump connector. If continuity is not good, repair/replace wiring/con- nectors between ECM and fuse box.
  • Page 253 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-135-001_a vmr2008-135-214_a TYPICAL Carefully pull out fuel pump. 1. Seat reinforcement plate 2. Exhaust heat shield 3. Retaining screws (x5) Disconnect electric connector, vent line and fuel hose from fuel pump. NOTE: Wrap shop rags around the fuel hose prior to removal.
  • Page 254 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) While maintaining pump seated, rotate pump to align its mark with the mark on the fuel tank as per the following specification. vmr2008-135-216_a 1. Gasket flange here vmr2008-135-300_a Pay attention to pump orientation as in following ANGLE PURPOSELY EXAGGERATED IN ILLUSTRATION FOR CLARITY illustration.
  • Page 255 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-135-220_a Remove rubber pad. vmr2008-135-217_a ANGLE PURPOSELY EXAGGERATED IN ILLUSTRATION FOR CLARITY To apply the proper torque to the pump nut, use a torque wrench and install it perpendicularly (90°) to the tool handle. vmr2008-135-221_a Remove push nut securing strainer to fuel pump.
  • Page 256 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) Fuel Level Sensor Resistance Test Remove and disconnect multifunction gauge, LIGHTS/GAUGE/ACCESSORIES refer to the sec- tion. vmr2008-135-223_a NOTE: A non serviceable filter is located in fuel pump. If it is clogged, replace fuel pump. Insert the new strainer on fuel pump making sure topressit in tightly against pump face.
  • Page 257 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) If readings are as per specification, test sensor If continuity was not obtained, repair/replace input voltage from multifunction gauge. wiring. Connect and install multifunction gauge. Fuel Level Sensor Replacement Fuel Level Sensor Input Voltage Test Replace fuel pump.
  • Page 258 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page Fluke 111 multimeter ............529 035 868 ......259, 261–263 ECM adapter tool..............529 036 085 ......... 262 SERVICE PRODUCTS Description Part Number Page Super lube ................
  • Page 259 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Some intermittent problems may be attributable to loose, dirty or corroded connections, or wa- ter infiltration, and may be resolved by cleaning the contacts and applying a dielectric grease for protection. Always check for these problems be- fore replacing expensive components and apply the protective grease as specified in the proce- dures.
  • Page 260 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) The ignition switch receives 12 Vdc directly from If you do not obtain battery voltage, test the fol- the ECM fuse (F1). When the ignition switch is lowing: set to ON (with or without headlights), it sends a –...
  • Page 261 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) vmo2006-016-001_e 1. Engine stop switch button 2. STOP position TYPICAL 3. RUN position 1. Disconnect ignition switch connector When the engine stop switch is set to RUN, it While holding switch with one hand, unscrew the completes a circuit between the ignition switch ignition switch retaining nut with the other.
  • Page 262 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) IGNITION COIL The ignition coil is mounted under the top RH side of the frame, along the steering column, in front of the engine. vmr2008-139-002_b MULTIFUNCTION SWITCH CONNECTORS 1. Disconnect MG1 2. Disconnect MG2 Set the Fluke 111 multimeter (P/N 529 035 868) vmr2008-138-006_b IGNITION COIL LOCATION...
  • Page 263 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Ignition Coil Ground Circuit Continuity Test Disconnect ignition coil input connector. Disconnect ECM connector. vmr2008-137-005_a 1. Remove plastic pin lock Set the Fluke 111 multimeter (P/N 529 035 868) to Vdc. Measure battery voltage between the battery ter- vmr2008-139-008_a minal on the starter solenoid and battery ground.
  • Page 264 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) If it tests good, test the secondary winding resis- tance. Secondary Winding Resistance Test A resistance test of the ignition coil secondary winding is not possible due to internal circuitry. Spark Plug Cable Resistance Test Disconnect the spark plug cable from the spark plug and the ignition coil.
  • Page 265 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) If nothing happens when the start button is pressed, refer to the STARTING SYSTEM section. If the starter rotates the engine and there is no spark indicated by the tester, follow the ignition system troubleshooting sequence as indicated.
  • Page 266 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Spark Plug Analysis TYPICAL 1. Overheated (light grey, white) 2. Normal (light brown, brown) 3. Fouled (black, wet or dry, dark deposits, grey, melted coating) The plug face reveals the condition of the engine, operating condition, method of driving and fuel mixture.
  • Page 267 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS Description Part Number Page Fluke 111 multimeter ............529 035 868 ......... 269, 271 SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page Extech inductive ammeter............ 380941 ......... 270 Electro Specialties battery load tester ........
  • Page 268 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Remove the diagnostic connector from its storage MODEL VOLTAGE Vdc cap. 400 EFI 14.8 vmr2007-042-001_a vmr2006-017-002 DIAGNOSTIC CONNECTOR TYPICAL Connect to the latest B.U.D.S. software, refer to NOTE: If the battery will not stay charged, the COMMUNICATION TOOLS/B.U.D.S.
  • Page 269 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) vmr2008-138-004_a vmr2008-138-010_a CHARGING SYSTEM VOLTAGE TEST TYPICAL 1. Solenoid battery terminal 1. Voltage indication 2. Negative battery post 2. RPM indication Start engine. If voltage is below specification, test the follow- Read voltage as follows. ing: –...
  • Page 270 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) NOTE: If battery is in poor condition or is not at a full state of charge, current reading will be above specification. Refer to BATTERY in this section for battery testing. DC Current Test with a Multimeter WARNING Be careful not to touch chassis with tool used when disconnecting or connecting battery...
  • Page 271 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Connect multimeter probes between voltage reg- ulator wire and the disconnected solenoid battery terminal. vmr2008-138-003_a DC CURRENT TEST WITH MULTIMETER vmr2006-017-002_a 1. Multimeter probes 2. Starter solenoid battery terminal 1. Battery cable installed 3.
  • Page 272 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) – Loose or bad engine and chassis ground con- Follow battery load tester instructions. nections Apply a load of 3 times the ampere-hour rating of – Faulty system wiring or connections the battery. At 14 seconds into the test, check –...
  • Page 273 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Inspect condition of battery posts, battery sup- port, holding strap and strap attachment points and wire terminal lugs. Battery Storage It is not necessary to remove the battery during vehicle storage but it is recommended for long term storage.
  • Page 274 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) When using a constant current charger, charge With the left hand, lift the BLACK battery cable battery according to the chart below. and holding strap as you insert the battery in the battery support.
  • Page 275 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) vmr2008-061-001_a STARTER SOLENOID COVER REMOVAL Ensure main ground connection is clean and tight. vdd2007-001-086_a ELECTRICAL SYSTEM MAIN GROUND Reinstall starter solenoid cover. vmr2008-138...
  • Page 276 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page Fluke 111 multimeter ............529 035 868 ......279, 281–283 ECM adapter tool..............529 036 085 ......... 281 GENERAL If the engine can be started (pull start), check the following in this order: STARTING SYSTEM OPERATION –...
  • Page 277 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) vmr2008-139-002_a vmr2008-139-004_b MULTIFUNCTION SWITCH CONNECTOR (MG2) FUSE F4 Test start button switch continuity as follows. Test continuity of the following main vehicle har- ness wires: MULTI-FUNCTION START SWITCH – YL/RD wire from multifunction switch connec- RESISTANCE BUTTON CONNECTOR...
  • Page 278 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) vmr2008-139-001_a vmr2008-139-004_a 1. Starter solenoid 2. Voltage regulator/rectifier FUSE BOX PIN-OUT 3. Battery Repair or replace wiring/connections. Power Signal to Solenoid Coil Test STARTER SOLENOID Set transmission to Park, or Neutral. The starter solenoid is located to the right of the Set Fluke 111 multimeter (P/N 529 035 868) to battery, forward of the voltage regulator/rectifier.
  • Page 279 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) vmr2008-139-005_a vmr2008-139-005_e DISCONNECT SOLENOID COIL WIRES If voltage is as specified, test continuity of sole- 1. Small solenoid coil wires noid ground control circuit. 2. Small solenoid coil terminals Solenoid Ground Control Circuit Test Set engine stop switch to RUN.
  • Page 280 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) vmr2008-139-006_a SOLENOID GROUND CONTROL CIRCUIT TEST vmr2008-139-008_a 1. Press to release connector lock If resistance is not as specified, repair or replace 2. Push to rotate connector lock upwards wiring/connections. Install the ECM connector onto the ECM adapter If solenoid input circuits and ground control cir- tool (P/N 529 036 085).
  • Page 281 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) NOTE: Diode is located in main wiring harness near solenoid. It is approximately 22 cm (8-3/4 in) from the main fuse holder as shown in following picture. vmr2006-020-005 vmr2008-139-018_a Probe wires while paying attention to the diode 1.
  • Page 282 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) NOTE: Torque the large solenoid cable terminals to 4 N•m (35 lbf•in). Solenoid Dynamic Test Remove fuse F3 to prevent engine from starting. NOTE: Check engine will be displayed in multi- function gauge, starter will crank engine but with an initial delay of approximately 4 seconds.
  • Page 283 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) If voltage is above specification, replace solenoid. vmr2008-139...
  • Page 284 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) LIGHTS, GAUGE AND ACCESSORIES SERVICE TOOLS Description Part Number Page Fluke 115 multimeter ............529 035 868 ..287, 293, 295, 297–300, 303–304, 307, 310, 313, 315 SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page...
  • Page 285 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Isolate the circuit by disconnecting its connectors. Let’s suppose that the circuit to be checked is composed of a RED and a BLACK wire. Using an ohmmeter, measure the resistance between the RED and the BLACK wire.
  • Page 286 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Rear Fuse Holder (PF2) The easiest way to check a relay is to remove it and temporarily replace it with another relay not essential for immediate engine operation (e.g. ac- cessory relay or cooling fan relay).
  • Page 287 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) MULTIFUNCTION GAUGE Display 2 (mode) Gauge Operation vmo2008-001-020_e DISPLAY 2 1. Display 2 (mode) vmo2008-001-020_q 2. Display 3 (mode/message) 3. Selector button 1. Display 1 (speedometer) 2. Display 2 (mode) 3.
  • Page 288 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Display 3 (mode/message) This display will show either an abbreviation of the mode selected for viewing in display 2 or will com- municate important messages to the operator if an anomaly occurs.
  • Page 289 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Display Selector Button Button used to navigate between modes or to re- set data depending on the feature selected. vmo2008-001-020_p 1. Transmission position DISPLAY FUNCTION Park vmo2008-001-020_i 1. Selector button Reverse Tachometer Neutral...
  • Page 290 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Indicator Lights To change the unit of measurement, carry out the following procedure. Indicator lights (LEDs) are incorporated within the LCD display. These LEDs backlight an LCD dis- Connect vehicle to the latest applicable B.U.D.S. COMMUNICATION play symbol which represents an operating condi- software,...
  • Page 291 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Connect vehicle to the latest applicable B.U.D.S. Connect vehicle to the latest applicable B.U.D.S. software, refer to the COMMUNICATION software, refer to the COMMUNICATION TOOLS/B.U.D.S. SOFTWARE section. TOOLS/B.U.D.S. SOFTWARE section. Select the Read Data button.
  • Page 292 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) If the speedometer always reads 144 km/h, or Disconnect the LH multifunction switch connec- 89 MPH, connect the vehicle to B.U.D.S. and fol- tor (MG2). low the CLUSTER COUNTRY SELECTION proce- dure in this section.
  • Page 293 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Fuel Level Indication and Low Fuel Level Indicator Light The multifunction gauge receives a signal from the fuel level sensor which it uses to produce an in- dication of fuel level in the gauge, as well as for activating the low fuel level indicator light.
  • Page 294 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) As you gently lift up on the tongue suppressor to release ring locking tab, rotate gauge clockwise to unlock and remove it from steering cover. vmr2006-020-058_a IMPORTANT: If a multifunction gauge from anoth- er vehicle model is installed and is not registered in the ECM through B.U.D.S., engine starting will not be allowed until gauge is registered with...
  • Page 295 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) vmr2008-129-051_c If you read battery voltage, test the signal circuit. If you do not read battery voltage, test for voltage as follows. mmr2009-023-027_a SPEED SENSOR CONNECTOR Back-probe connector and read voltage as you VOLTAGE (HARNESS SIDE) slowly rotate the rear wheels with your hands.
  • Page 296 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Headlight Switch Test Pull out sensor. Remove front steering cover. VSS Installation Disconnect multifunction switch connector Apply some Super Lube (P/N 293 550 030) grease (MG2). on sensor O-ring. Install sensor. Torque retaining screw to 10 N•m (89 lbf•in).
  • Page 297 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Replace multifunction switch if the headlight switch is defective. Refer to STEERING SYSTEM section. OVERRIDE SWITCH All Models except 2009 CE HEADLIGHT SWITCH above to locate the re- verse override button (switch) on the multifunc- tion switch.
  • Page 298 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) 12-Volt Auxiliary Power Connector Test If battery voltage is not read for both tests, check to see if headlights function. NOTE: When the auxiliary power connector is to be used on an accessory, be sure to apply a small If headlights do not function, test the following: amount of dielectric grease (P/N 293 550 004) to –...
  • Page 299 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) vmr2006-020-062_aen If battery voltage is not read for both test, check to see if headlights function. If headlights do not function, test the following: vmo2008-001-020_m – Accessories fuse (F6) INDICATOR LIGHTS 1.
  • Page 300 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) HEADLIGHT INPUT VOLTAGE TEST SWITCH WIRE COLOR VOLTAGE POSITION BLACK LO beam GREEN Battery voltage Chassis ground BLACK HI beam BLUE Battery voltage Chassis ground If battery voltage is read as specified in table, re- vmo2006-005-040_a place headlight bulb.
  • Page 301 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Lift and hold the spindle then remove the bulb. vmr2006-020-002_a 1. Light beam center A. 5 m (17 ft) B. 131 mm (5 in) Headlight Beam Adjustment Turn adjustment screws to adjust beam height and side orientation as described below.
  • Page 302 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) The brake light comes on when either the brake lever or brake pedal is depressed. NOTE: When testing the brake light, always test it using both controls to make ensure both switches can turn on the brake light.
  • Page 303 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) vmr2008-140-006_a vmr2008-140-006_b TAILLIGHT/BRAKE LIGHT INPUT VOLTAGE TEST CONTINUITY TEST OF TAILLIGHT/BRAKE LIGHT WIRING If battery voltage is not read, repair or replace If you do not obtain close to 0 through the tail- wiring/connectors from light assembly to re- light circuit, repair or replace wiring.
  • Page 304 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) vmr2008-140-004_a 1. Lens retaining pin (x2) 2. Retaining grommet (x2) vmo2007-005-001_b TYPICAL – 2008 CE MODEL 1. Turn signal lights switch vmo2008-001-006 Push bulb in and hold while turning counterclock- wise to release from bulb holder.
  • Page 305 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) 2009 CE Models The flasher diodes (D2 and D3) are integrated in the vehicle harness near the electronic flasher unit located in the steering cover. Diode D2 is approximately 48 cm (19 in) from the flasher module connector (3-MC1).
  • Page 306 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) vmr2008-140-010_a REAR VIEW – BOTH STEERING COVERS REMOVED vmr2008-140-501_a 1. Turn signal switch connector 1. Connector 3-MG1 2. Flasher module 2. Connector 3-MG2 3. Multifunction gauge connector 3. Connector 3-MG3 (green) 4.
  • Page 307 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) 2009 CE Models The flasher diodes are integrated in the wiring har- ness. To test them, you must first isolate them from the rest of the circuits by disconnecting the following connectors.
  • Page 308 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) The switch has a mechanical detent which, locks The hazard warning lights button on 2009 models the switch in the activation position. Press the is not internally lit. However, a red indicator light hazard warning lights button once to activate, on top of the LH multifunction switch will flash press once again to deactivate.
  • Page 309 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) HAZARD WARNING SWITCH TESTING HAZARD WARNING SWITCH INPUT VOLTAGE WITCH WITCH RESISTANCE @ SWITCH VOLTAGE CONTACTS CONTACTS POSITION FUNCTION 20°C (68°F) FUNCTION READING Light (dim) Pin 31 Pin 58 Turn signal Chassis Pin 49 Close to 0...
  • Page 310 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Test for 12 Vdc at connector 3-MC1 pin 6 (RED/BLACK wire), battery power to flasher unit. Test for 12 Vdc at connector 3-MG3 pin 3 (RED/BLACK wire), accessories power to haz- ard lights control switch.
  • Page 311 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) WINCH Press the horn button, you should obtain close to 0 (continuity). XT Models Only If you do not obtain continuity through the switch Test winch using the control switch on the LH han- from the horn terminal, carry out the following.
  • Page 312 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) Winch Control Switch Input Voltage Test BODY Remove the front steering cover. Refer to Disconnect the winch control switch connector. vmo2008-019-045_a FRONT SERVICE COMPARTMENT 1. Winch remote control connector Winch Test vmr2008-140-014_a TYPICAL Winch Motor...
  • Page 313 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) vmr2006-020-071_b vmr2006-020-074_b SWITCH WIRE TERMINAL VOLTAGE VOLTAGE POSITION AT RELAY POSITION RELAY TERMINAL DROP Switch pressed BLUE/ Chassis Battery Battery OUT cable GREEN voltage to OUT and held ground Switch pressed 0.2 Vdc post (RED to winch...
  • Page 314 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) vmr2007-043-011_b vmr2007-043-010_a REVERSE POLARITY (MUST BE OPEN CIRCUIT) Use the Fluke 115 multimeter (P/N 529 035 868) and set it to the diode symbol as shown. vmr2007-043-011_a vmr2006-020-005 FORWARD POLARITY (MUST BE AROUND 0.5 V) Probe wires while paying attention to the diode If a diode fails the test, replace the diode.
  • Page 315 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) vmr2007-043-012_a DIODE LOCATION 1. Cotter pin 2. Hook retaining pin Properly reinstall removed parts. Remove the winch retaining screws, and winch. Winch Removal Disconnect, the BLACK (-) battery cable, then the RED (+) cable.
  • Page 316 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES) vmr2008-140-014_a TYPICAL 1. Winch control switch connector Set multimeter to and test switch as per fol- lowing table. WINCH CONTROL SWITCH CONTINUITY TEST SWITCH SWITCH CONNECTOR PINS POSITION Pin A Pin B Pin A Pin C...
  • Page 317 Section 07 DRIVE SYSTEM Subsection 01 (4X4 COUPLING UNIT) 4X4 COUPLING UNIT SERVICE TOOLS Description Part Number Page Fluke 115 multimeter ............529 035 868 ......... 321, 323 blind hole bearing puller set..........529 036 117 ......... 326 SERVICE PRODUCTS Description Part Number Page...
  • Page 318 Section 07 DRIVE SYSTEM Subsection 01 (4X4 COUPLING UNIT) vmr2008-141-001_a vmr2008-141...
  • Page 319 Section 07 DRIVE SYSTEM Subsection 01 (4X4 COUPLING UNIT) GENERAL During assembly/installation, use the torque val- ues and services products as in the exploded view. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to APPLICATION at the beginning of this manual for complete procedure.
  • Page 320 Section 07 DRIVE SYSTEM Subsection 01 (4X4 COUPLING UNIT) If voltage is not as specified, check wires and con- nectors. If good, replace the 2WD/4WD selector at handlebar. 2WD/4WD Selector Replacement To replace the 2WD/4WD selector, refer to THROTTLE LEVER STEERING SYSTEM sec- tion.
  • Page 321 Section 07 DRIVE SYSTEM Subsection 01 (4X4 COUPLING UNIT) Verify if sliding sleeve is in 2WD position. The slid- Apply Loctite 243 (blue) (P/N 293 800 060) on ing sleeve should be pointed toward the front of threads of actuator screws. vehicle.
  • Page 322 Section 07 DRIVE SYSTEM Subsection 01 (4X4 COUPLING UNIT) COUPLING UNIT Coupling Unit Removal FRONT Remove front propeller shaft. Refer to DRIVE section. Unplug coupling unit connector and 2WD/4WD switch connector. Remove screws retaining the coupling unit hous- ing to the engine. vmr2008-141-012 Using an alligator clip, place the BLACK probe on the external pin.
  • Page 323 Section 07 DRIVE SYSTEM Subsection 01 (4X4 COUPLING UNIT) vmr2008-141-015_a 1. Oil seal vmr2008-141-018_a 1. Sliding sleeve Remove the Allen set screw. Remove the shifter fork. vmr2008-141-016_a vmr2008-141-019_a 1. Allen set screw 1. Shifter fork Pull out the sliding sleeve pin. Pull out the coupling sleeve.
  • Page 324 Section 07 DRIVE SYSTEM Subsection 01 (4X4 COUPLING UNIT) vmr2008-141-021_a 1. Inner circlilp Turn the coupling unit housing and remove the out- 529036117 er circlip. NOTE: Remove the ball bearing only if it does not turn freely and smoothly. Coupling Unit Inspection Check disconnect unit housing and actuator for cracks or other damages.
  • Page 325 Section 07 DRIVE SYSTEM Subsection 01 (4X4 COUPLING UNIT) SHIFTER FORK CLAWS THICKNESS 2.93 mm (.115 in) SERVICE LIMIT A. Shifter fork claw thickness Check inner and outer shaft splines for wear or A. Groove width other damages. Replace shaft if necessary. Check sliding sleeve dog for bend and measure it.
  • Page 326 Section 07 DRIVE SYSTEM Subsection 01 (4X4 COUPLING UNIT) Insert pin and install Allen set screw. Apply Loctite 243 (blue) (P/N 293 800 060) on Move the sliding sleeve on right side and check if threads of Allen set screw. the coupling sleeve is flush with the end of shaft.
  • Page 327 Section 07 DRIVE SYSTEM Subsection 01 (4X4 COUPLING UNIT) Coupling Unit Installation The installation is the reverse of removal proce- dure. However, pay attention to the following. Apply XP-S synthetic grease (P/N 293 550 010) on coupling unit housing O-ring. Apply Loctite 243 (blue) (P/N 293 800 060) on threads of coupling unit screws.
  • Page 328 SERVICE PRODUCTS Description Part Number Page XP-S synthetic grease............293 550 010 ......... 335, 339 BRP differential oil ..............293 600 043 ......... 333 Loctite 277................293 800 073 ......... 339 pulley flange cleaner............. 413 711 809 ......... 333 vmr2008-142...
  • Page 329 Section 07 DRIVE SYSTEM Subsection 02 (FRONT DRIVE) vmr2008-142-001_a vmr2008-142...
  • Page 330 MAINTENANCE DIFFERENTIAL OIL Recommended Oil The BRP differential oil (P/N 293 600 043) is highly recommended. 1. Drain plug If the BRP differential oil is not available, use a 2. Filler plug 75W90 synthetic oil (API GL-5).
  • Page 331 Section 07 DRIVE SYSTEM Subsection 02 (FRONT DRIVE) PROCEDURES Extract CV joint from the knuckle. Move the knuckle and the tie-rod aside to make DRIVE SHAFT room. BRAKES Remove caliper. Refer to section. Pull drive shaft out of differential. NOTE: Pull drive shaft strongly. Drive Shaft Inspection Inspect the condition of drive shaft boots.
  • Page 332 Section 07 DRIVE SYSTEM Subsection 02 (FRONT DRIVE) Without the Joint Extractor Tool Pack bearing area with the grease included in the new boot kit. Clamp joint housing in a vise. NOTE: Do not use or add other grease. Align shaft with joint. Pull hard on shaft to remove from joint.
  • Page 333 Section 07 DRIVE SYSTEM Subsection 02 (FRONT DRIVE) DIFFERENTIAL Differential Inspection DIFFERENTIAL Check backlash and preload, see Differential Removal ADJUSTMENT further in this section. DIFFERENTIAL OIL Drain the differential. See Check if oil seals are brittle, hard or damaged. Re- the beginning of this section.
  • Page 334 Section 07 DRIVE SYSTEM Subsection 02 (FRONT DRIVE) vmr2008-142-007_a vmr2008-142-009_a 1. Oil seal 1. Pinion gear 2. Bearing Unscrew the pinion nut. Use the differential span- NOTE: The pinion gear and bearing can be easily ner socket (P/N 529 035 649). removed using the following suggested tool: –...
  • Page 335 Section 07 DRIVE SYSTEM Subsection 02 (FRONT DRIVE) If the old pinion shim stack measurement is under 1.00 mm (.039 in), install a 0.5 mm (.02 in) shim on the differential components as per CHART B CHART A CHART B 1.85 mm PINION PINION...
  • Page 336 Section 07 DRIVE SYSTEM Subsection 02 (FRONT DRIVE) vmr2008-142-011_a vmr2006-023-011_a 1. Half housing seal TYPICAL Check all bearings and all oil seals. Change them Using a needle torque wrench, measure the drag if necessary. torque. Pinion Gear To install, reverse the removal procedure. Pay at- tention to the following details.
  • Page 337 Section 07 DRIVE SYSTEM Subsection 02 (FRONT DRIVE) 1. Remove these clamps Remove the differential mounting bolts. 1. Differential mounting bolts Move differential forward to separate propeller shaft from differential and disconnect unit. Propeller Shaft Inspection Check propeller shaft splines for wear or other damages.
  • Page 338 SERVICE PRODUCTS Description Part Number Page XP-S synthetic grease............293 550 010 ......347–348, 351 BRP differential oil ..............293 600 043 ......... 343 Loctite 243 (blue)..............293 800 060 ......... 347 Loctite 277................293 800 073 ......... 351 smr2008-143...
  • Page 339 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) vmr2008-143_001_a smr2008-143...
  • Page 340 DIFFERENTIAL OIL Remove filler plug to help oil flowing out of differ- ential. Recommended Oil The BRP differential oil (P/N 293 600 043) is highly recommended. If the BRP differential oil is not available, use a 75W90 synthetic oil (API GL-5).
  • Page 341 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) PROCEDURES Drive Shaft Inspection Inspect the condition of drive shaft boots. If there DIFFERENTIAL PROTECTOR is any damage or evidence of leaking lubricant, re- DRIVE SHAFT DISASSEM- place them. Refer to Differential Protector Removal further in this section.
  • Page 342 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) vmr2008-143-013 CV JOINT PROPERLY SEATED vmr2008-143-011_a 1. Aluminum tube 2. Inner race NOTE: In some case, you may have to hit one side, then move the drive shaft 180 degrees in the vise and hit the other side until joint is off.
  • Page 343 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) Support the vehicle securely using jack stands. Remove rear wheels. Remove caliper screws then suspend the caliper aside. 529036120 CV BOOT CLAMP PLIERS vmr2007-054-004_a CAUTION: Do not let caliper hang by the hose and do not stretch or twist hose.
  • Page 344 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) Apply XP-S synthetic grease (P/N 293 550 010) on splines of engine drive shaft and differential pinion. Apply Loctite 243 (blue) (P/N 293 800 060) on the threads of both propeller shaft screws. Install screws and washers.
  • Page 345 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) Support U-joint in vice and drive inner yoke down to remove remaining bearing caps. Remove U-joint cross. U-joint Installation Install new U-joint cross in inner yoke. Install new bearing cap by hand. NOTE: Carefully install U-joint cross with grease fitting properly positioned.
  • Page 346 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) Check backlash and drag torque, see DIFFEREN- Remove and discard the O-ring retaining the bear- TIAL ADJUSTMENT further in this section. ing. Check if oil seals are brittle, hard or damaged. Re- place if necessary.
  • Page 347 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) vmr2006-023-016 Rotate pinion gear 1/2 turn and check backlash vmr2006-024-010_a again. Note the result. 1. Backlash side 2. Preload side Rotate pinion gear 1 turn and check backlash again. Assemble the differential. If backlash is below 0.05 mm (.002 in), increase Backlash backlash shim by 0.05 mm (.002 in) and check the...
  • Page 348 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) Apply XP-S synthetic grease (P/N 293 550 010) in the lips of the NEW oil seal and install it. Differential Installation The installation is the reverse of the removal pro- cedure. vmr2006-023-012 TYPICAL —...
  • Page 349 Section 08 CHASSIS Subsection 01 (WHEELS/TIRES) WHEELS/TIRES SERVICE PRODUCTS Description Part Number Page Loctite 767 (antiseize lubricant) ..........293 800 070 ......... 355 vmr2008-144-001_a vmr2008-144...
  • Page 350 Section 08 CHASSIS Subsection 01 (WHEELS/TIRES) GENERAL TIRE PRESSURE WARNING OUTLANDER 400 EFI and OUTLANDER MAX 400 EFI Severe injury or death can result if these in- FRONT REAR structions are not followed. – When the tires are replaced, never install a 34.5 kPa 34.5 kPa MAX.
  • Page 351 Section 08 CHASSIS Subsection 01 (WHEELS/TIRES) – Inside edge. It is normal to see uneven wear on tires depending on how the vehicle is driven and road conditions. The front tires external or internal edges tread will wear unevenly depending on if the vehicle is driv- en smoothly or aggressively.
  • Page 352 Section 08 CHASSIS Subsection 01 (WHEELS/TIRES) Check wear ring. If damage is apparent, replace the wear ring. vmr2008-144-002_a 1. Cotter pin vmr2008-144-005_a Unscrew the castellated nut. 1. Wheel hub 2. Wheel hub splines 3. Wear ring Wheel Hub Installation The installation is the reverse of removal proce- dure.
  • Page 353 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) STEERING SYSTEM SERVICE TOOLS Description Part Number Page steering alignment tool............529 036 059 ......... 359 SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page Smoothflow™ tapered tip ............ 16 ga #511 ......... 360 rtt-b SERVICE PRODUCTS Description...
  • Page 354 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) vmr2008-145-001_a vmr2008-145...
  • Page 355 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded view. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to APPLICATION at the beginning of this manual for complete procedure.
  • Page 356 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) PROCEDURES HANDLEBAR GRIP Handlebar Grip Removal Loosen (2–3 turns only) the screw at the end of handlebar grip. NOTE: If the screw is removed completely, the threaded insert will stay inside handlebar and its vmr2007-055-013_a removal could be difficult.
  • Page 357 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) Lift a part of the grip using a small screwdriver and inject glue (about 4 spots per side). NOTE: The glue dries quickly. Do not apply it be- fore installing grip. Apply pressure on the grip for approximately 30 seconds to set the glue.
  • Page 358 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) Slide rubber protector back to expose throttle ca- ble adjuster. vmr2008-145-013_a 1. Multifunction switch connectors Remove screws securing multifunction switch. 1. Cable protector 2. Throttle cable adjuster 3. Lock nut 4. Throttle lever housing Loosen lock nut and fully tighten the throttle cable adjuster.
  • Page 359 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) – Multifunction switch (see procedure in this sec- tion) – Brake lever (see procedure in BRAKES section). HANDLEBAR COVERS Remove both , see proce- dure above in this section. Unscrew 4 bolts securing handlebar to steering column.
  • Page 360 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) Remove the handlebar. Handlebar Inspection Check handlebar for: – Wear – Cracks – Bending. Replace handlebar if any of these problems is de- tected. WARNING vmr2008-145-021_a Never try to weld or modify the handlebar. 1.
  • Page 361 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) vmr2008-145-025_a vmr2008-145-024_a 1. Bearing flange bolts 1. Elastic nut 2. Upper bearing flange 2. Washer Remove bearing. Separate steering column and tie-rods. Refer to TIE-ROD , further in this section. Pull out steering column. Steering Column Inspection Check steering column for: –...
  • Page 362 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) Install steering column. Steering Column Installation For the installation, reverse the removal proce- dure. Pay attention to the following. Apply XP-S synthetic grease (P/N 529 550 010) on steering column O-rings and on bushings. Install a NEW steering column nut.
  • Page 363 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) KNUCKLE Knuckle Removal Place vehicle on a level surface. Loosen wheel lug nuts. Lift the front of vehicle. Remove wheel. WHEELS/TIRES Remove wheel hub. Refer to section. Detach tie-rod end from knuckle. vmr2008-145-032_a 1.
  • Page 364 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) When knuckle is cold, install the circlip. Install a NEW seal. Install the other parts in the reverse order of re- moval procedure. Remove the circlip securing the bearing into the knuckle. 1. Circlip Using a press machine, push the bearing out of knuckle.
  • Page 365 Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) FRONT SUSPENSION SERVICE TOOLS Description Part Number Page spring remover ..............529 036 007 ......... 371 SERVICE PRODUCTS Description Part Number Page suspension grease..............293 550 033 ......... 374 Loctite 243 (blue)..............293 800 060 ......... 372 vmr2008-146...
  • Page 366 Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) vmr2008-069-002_a vmr2008-146...
  • Page 367 Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) GENERAL The procedure explained below is the same for the RH and LH sides unless otherwise noted. During assembly/installation, use the torque val- ues and service products as in the exploded view. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to...
  • Page 368 Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) Strut Inspection Inspect the spring for damage. Replace if neces- sary. Inspect strut as following: Examine the strut for leaks. Extend and compress the strut shaft several times over its entire stroke. Check that the strut shaft moves smoothly and with uniform resistance with rod up.
  • Page 369 Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) Check ball joint bellows on suspension arm for cracks or any other damage. Inspect ball joint end for damage. Ensure it's moving freely. Replace ball joints as required, see below for procedure. Suspension Arm Removal Loosen wheel lug nuts of the appropriate wheel.
  • Page 370 Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) Install suspension arm bolts as per following illus- tration. vmr2008-146-008_a Torque suspension arm bolts to 61 N•m (45 lbf•ft). Use suspension grease (P/N 293 550 033) to lubri- cate both suspension arms. There are two grease fitting on each arm.
  • Page 371 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) REAR SUSPENSION SERVICE TOOLS Description Part Number Page Bearing extractor/installer............. 529 035 918 ......... 383 Bearing extractor/installer............. 529 035 920 ......... 383 trailing arm support............... 529 035 922 ......... 382 trailing arm nut socket ............529 035 925 ......... 381, 384 spring remover ..............
  • Page 372 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) vmr2008-147-001_a vmr2008-147...
  • Page 373 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) GENERAL The procedure described below is the same for the RH and LH sides, unless otherwise instructed. During assembly/installation, use the torque val- ues and service products as in the exploded view. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to...
  • Page 374 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) vmr2008-147-004_a vmr2006-026-011 1. Shock absorber upper bolt Remove spring from shock. Shock Absorber Inspection Shock Absorber Disassembly Inspect the spring for damage. Replace if neces- Use the spring remover (P/N 529 036 007). sary.
  • Page 375 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) NOTE: Install cap opening at 180° from spring stopper opening. TORSION BAR Torsion Bar Removal Apply parking brake and lift rear of vehicle until rear shock absorbers are fully extended. Install a jack stand or blocks under the frame to safely support the vehicle.
  • Page 376 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) vmr2008-147-010_a Remove torsion bar nut, washer and torsion bar vmr2008-147-011_a lever. 1. Torsion bar lever tab 2. Trailing arm slot Discard torsion bar nut. 3. Arrow upward Install the flat washer and a NEW elastic nut. Torsion Bar Inspection Tighten first the RH elastic nut of torsion bar lever Check torsion bar for:...
  • Page 377 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) vmr2008-147-009_a vmr2008-147-006_a 1. Torsion bar lever 1. Protective cover Remove the circlip retaining the trailing arm nut. Unscrew and discard a torsion bar nut. CAUTION: Unscrew nut slowly to avoid dam- aging threads and jamming nut on torsion bar. vmr2008-147-012_a vmr2008-147-007_a 1.
  • Page 378 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) vmr2008-147-013_a vmr2008-147-015_a 1. Trailing arm nut WHEEL SIDE 1. Circlip Unscrew lower bolt of shock absorber. Remove trailing arm. Trailing Arm Inspection Verify trailing arm for: – Cracks – Bending – Other damages. Replace trailing arm if necessary.
  • Page 379 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) FRAME SIDE Using a press and the proper bearing extractor/in- staller, remove the bearing. FRAME SIDE LOCATION TOOL Clean the bearing housing. Bearing To install the bearing in its location, use the same Wheel side extractor/installer tool as per removal procedure.
  • Page 380 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) vmr2008-147-012_a 1. Circlip TOR- Finalize the torsion bar installation. Refer to SION BAR in this section. Tighten shock absorber lower bolt. Wheel Side WHEELS/TIRES Install wheel hub. Refer to sec- tion for complete procedure. FRAME SIDE Install the circlip.
  • Page 381 Section 08 CHASSIS Subsection 05 (BRAKES) BRAKES SERVICE TOOLS Description Part Number Page vacuum/pressure pump............529 021 800 ......... 390 SERVICE PRODUCTS Description Part Number Page dielectric grease ..............293 550 004 ......... 393 XP-S synthetic grease............293 550 010 ......... 395, 399 brake fluid GTLMA (DOT 4) ..........
  • Page 382 Section 08 CHASSIS Subsection 05 (BRAKES) FRONT BRAKE CIRCUIT (EXCEPT 2009 CE MODELS) vmr2008-148-001_a vmr2008-148...
  • Page 383 Section 08 CHASSIS Subsection 05 (BRAKES) FRONT BRAKE CIRCUIT (2009 CE MODELS) vmr2008-148-015_a vmr2008-148...
  • Page 384 Section 08 CHASSIS Subsection 05 (BRAKES) REAR BRAKE CIRCUIT vmr2008-148-021_a vmr2008-148...
  • Page 385 Section 08 CHASSIS Subsection 05 (BRAKES) GENERAL WARNING Periodically check the brake hoses for dam- During assembly/installation, use the torque val- ages or leaks. Repair any damage before op- ues and service products as in the exploded erating the vehicle. views.
  • Page 386 Section 08 CHASSIS Subsection 05 (BRAKES) Brake Fluid Replacement NOTE: A low level may indicate leaks or worn brake pads. To replace brake fluid, follow the brake bleeding procedure and replenish system with new brake Brake Lever Fluid Reservoir fluid. Turn steering in the straight-ahead position to en- sure reservoir is level.
  • Page 387 Section 08 CHASSIS Subsection 05 (BRAKES) Pump vacuum pump then loosen bleeder. Pump until no more air bubbles appear in clear hose. Close bleeder. Operate brake lever or brake pedal (except for CE models, continue bleeding procedure. Refer to BRAKE BLEEDING (ADDITIONAL STEPS FOR CE MODELS) ).
  • Page 388 Section 08 CHASSIS Subsection 05 (BRAKES) PROCEDURES BRAKE LIGHT SWITCH Brake Light Switch Test NOTE: First, ensure brake light is good. BODY Remove the LH inner fender. Refer to sec- tion. Disconnect brake light switch connector. vmr2008-071-006_a 1. Brake light switch BODY Remove LH and RH footwells.
  • Page 389 Section 08 CHASSIS Subsection 05 (BRAKES) PARKING BRAKE MECHANISM Parking Brake Mechanism Removal Unscrew the nut underneath the brake lever. Remove the parking lever lock pivot and the spring. Remove the parking lever lock. vmr2008-148-002_a 1. Brake lever 2. Brake lever pivot 3.
  • Page 390 Section 08 CHASSIS Subsection 05 (BRAKES) vmr2008-148-009_a vmr2008-071-007_a 1. Banjo fitting 2. Sealing washers 1. Brake light switch 3. Brake hose 2. Brake pedal fluid reservoir hose 4. Front master cylinder reservoir 3. Rear brake hose BRAKE LEVER Remove from master cylinder, see Unscrew the front brake hose.
  • Page 391 Section 08 CHASSIS Subsection 05 (BRAKES) With the handlebar in straight ahead position, position master cylinder reservoir parallel to the ground. Tighten upper screw first. vmr2008-033-035_a 1. Hook 2. Locking nut 3. Master cylinder rod Remove boot, snap ring and push rod. Master Cylinder Inspection (Front and Rear) Check boot for crack.
  • Page 392 Section 08 CHASSIS Subsection 05 (BRAKES) Caliper Installation (Front and Rear) CAUTION: Do not let caliper hangs by the hose and do not stretch or twist the hose. Simply For the installation, reverse the removal proce- hang it with a piece of wire to take the weight dure, pay attention to the following details.
  • Page 393 Section 08 CHASSIS Subsection 05 (BRAKES) Brake Pad Inspection CAUTION: Do not clean brake pads in petrole- um based solvent. Use brake system cleaner only. Soiled brake pads must be replaced with new ones. Measure brake pad lining thickness or look at the hollow places on both sides on the pad lining.
  • Page 394 Section 08 CHASSIS Subsection 05 (BRAKES) Front Brake Disc Installation MAXIMUM DISC WARPAGE The installation is the reverse of removal proce- Front dure. However, pay attention to the following de- 0.2 mm (.01 in) Rear tails. The Belleville washers must be installed with Front Brake Disc Removal theirs concave side toward the brake disc.
  • Page 395 Section 08 CHASSIS Subsection 05 (BRAKES) Drain brake fluid. Refer to BRAKE FLUID DRAIN- at the beginning of this section. Disconnect brake light switch connector. vmr2008-148-013_a 1. Retaining bolt 2. Brake pedal Brake Pedal Inspection vmr2008-148-004_a Check brake pedal for: 1.
  • Page 396 Section 08 CHASSIS Subsection 05 (BRAKES) Connect the brake light switch. Install the inner fender. BRAKE HOSES Brake Hose Inspection Brake hoses should be inspected frequently for leaks and damages. Check if the hoses are crushed or damaged. Any deformation can restrict the proper flow of fluid and cause braking problems.
  • Page 397 Section 08 CHASSIS Subsection 05 (BRAKES) FRONT MASTER CYLINDER SHOWN 1. Banjo fitting 2. Sealing washers Install any retaining clips or brackets. BRAKE Refill and bleed the system. Refer to BLEEDING at the beginning of this section. vmr2008-148...
  • Page 398 Section 08 CHASSIS Subsection 06 (BODY) BODY SERVICE TOOLS Description Part Number Page pliers Oetiker 1099 ............... 295 000 070 ......... 409 vmr2008-149...
  • Page 399 Section 08 CHASSIS Subsection 06 (BODY) BODY PARTS (FRONT) vmr2008-149-001-a vmr2008-149...
  • Page 400 Section 08 CHASSIS Subsection 06 (BODY) BODY PARTS (REAR) vmr2008-149-002_a vmr2008-149...
  • Page 401 Section 08 CHASSIS Subsection 06 (BODY) BODY PARTS (SIDE) vmr2008-149-003_a vmr2008-149...
  • Page 402 Section 08 CHASSIS Subsection 06 (BODY) SEAT vmr2008-149-004_a vmr2008-149...
  • Page 403 Section 08 CHASSIS Subsection 06 (BODY) BUMPERS XT Package vmr2008-149-005_a vmr2008-149...
  • Page 404 Section 08 CHASSIS Subsection 06 (BODY) GENERAL PROCEDURES During assembly/installation, use the torque val- REUSABLE PLASTIC RIVETS ues and service products as in the exploded views. Rivets Removal Clean threads before applying a threadlocker. Re- Reusable plastic rivets are used in the riveting of SELF-LOCKING FASTENERS LOCTITE fer to...
  • Page 405 Section 08 CHASSIS Subsection 06 (BODY) CAUTION: Do not apply isopropyl alcohol or Gently lift the rear of seat. solvent directly on decals. Use these products Pull seat rearwards. in a well ventilated area. Continue lifting movement until you can release the front retaining device then completely remove SEAT passengers seat.
  • Page 406 Section 08 CHASSIS Subsection 06 (BODY) TYPICAL 1. Piece of wood 2. ETN-50 (electric) After cover installation cut all around the excess 1. Insert these tabs in hooks 2. Hooks of material. NOTE: A distinctive snap will be felt. Double CONSOLE check that the seat is secure by giving it a tug to confirm proper latching.
  • Page 407 Section 08 CHASSIS Subsection 06 (BODY) Lift the console. Disconnect the following components: – Ignition switch – 12-volt power outlet – Hazard warning button (2008 CE models). Remove the console. Console Installation The installation is the reverse of removal proce- dure.
  • Page 408 Section 08 CHASSIS Subsection 06 (BODY) vmr2008-149-044_b VEHICLE LOCK MOUNTING SCREWS Remove the lock from its mounting bracket. Outlander/Outlander XT Models Vehicle Lock Installation Remove plastic rivets retaining the front tabs of side panels. For lock installation, reverse the removal proce- dure.
  • Page 409 Section 08 CHASSIS Subsection 06 (BODY) FOOTREST Remove all bolts securing the footrest to front and rear fenders. vmr2008-149-011_a vmr2008-149-009_a FRONT FENDER 1. LH footrest 1. LH fender bolts 2. Operator's footpeg 3. Passenger's footpeg Footrest Removal Remove SIDE PANEL , see procedure above in this section.
  • Page 410 Section 08 CHASSIS Subsection 06 (BODY) INNER FENDER HEAVY DUTY BUMPER Outlander XT Package vmr2008-149-016_a 1. Inner fender Inner Fender Removal vmr2008-149-017_a 1. Front heavy duty bumper Loosen wheel lug nuts from appropriate wheel. Lift the front of vehicle and support it securely. Remove wheel.
  • Page 411 Section 08 CHASSIS Subsection 06 (BODY) Front Fascia Removal Unplug headlamps. On CE models, unplug position lamps. Remove bolts securing front fascia to front skid plate. vmr2006-029-021_a Remove the heavy duty bumper. Rear Bumper Unscrew bolts retaining the rear heavy duty bumper to the rear bumper.
  • Page 412 Section 08 CHASSIS Subsection 06 (BODY) vmr2008-149-021_a vmr2008-149-023_a 1. Plastic rivets 1. Front heavy duty bumper 2. Hook Remove front fascia. 3. Fairlead Disconnect headlights. Front Fascia Installation On CE models, disconnect position lamps. The installation is the reverse of the removal pro- cedure.
  • Page 413 Section 08 CHASSIS Subsection 06 (BODY) vmr2008-149-024_a vmr2008-149-024_b OUTLANDER CE SHOWN 1. Lower mounting bolts on front skid plate 1. Skid plate bolts Remove the two center mounting screws from Remove skid plate and front fascia assembly. lower skid plate, then the two rear mounting Remove bolts retaining skid plate and front fascia.
  • Page 414 Section 08 CHASSIS Subsection 06 (BODY) FRONT BUMPER vmr2008-149-041_a vmr2008-149-040_a 1. RH direction indicator lamp support 2. Bumper 1. Front bumper Remove upper bolts securing front bumper to fender support. Front Bumper Removal Using removal instructions described in this sec- tion, remove the following parts: –...
  • Page 415 Section 08 CHASSIS Subsection 06 (BODY) LUGGAGE RACK Rack Installation The installation is the reverse of removal proce- dure. FENDER vmr2008-149-030_a 1. Front rack 2. Rear rack Rack Removal vmr2008-149-032_a NOTE: On XT models, heavy duty bumpers (front 1. Front fender and rear) must be removed to allow luggage racks 2.
  • Page 416 Section 08 CHASSIS Subsection 06 (BODY) vmr2008-149-035_a vmr2008-149-021_a 1. Winch remote control connection connector 1. Plastic rivets Remove plastic rivets retaining front fender to con- Using removal instructions described in this sec- sole. tion, remove the following parts: – Side panels –...
  • Page 417 Section 08 CHASSIS Subsection 06 (BODY) FENDER SUPPORT vmr2008-149-038_a 1. RH rear fender bolt vmr2008-149-042_a Unplug brake light connector. 1. Front fender support 2. Rear fender support On CE models, unplug direction indicator lamp connectors. Fender Support Removal Front Fender Support FRONT FENDER Remove , see procedure in this...
  • Page 418 Section 08 CHASSIS Subsection 06 (BODY) Rear Fender Support REAR FENDER Remove , see procedure in this section. Remove bolts that attach fender support to frame. Unscrew the exhaust support bolt. vmr2006-029-019_a Fender Support Installation The installation is the reverse of removal proce- dure.
  • Page 419 Section 08 CHASSIS Subsection 07 (FRAME) FRAME Outlander 400 EFI and Outlander 400 EFI XT Models vmr2008-150-001_a vmr2008-150...
  • Page 420 Section 08 CHASSIS Subsection 07 (FRAME) Outlander MAX 400 EFI and Outlander MAX 400 EFI XT Models vmr2008-150-002_a vmr2008-150...
  • Page 421 Section 08 CHASSIS Subsection 07 (FRAME) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded views. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to APPLICATION at the beginning of this manual for complete procedure.
  • Page 422 Section 08 CHASSIS Subsection 07 (FRAME) Battery Support Installation The installation is the reverse of removal proce- dure. HITCH Hitch Removal Remove the differential protector. Unscrew bolts retaining the hitch to frame. Remove lower differential bolts. vmr2008-150-006_a 1. Battery support upper bolts 2.
  • Page 423 Section 08 CHASSIS Subsection 07 (FRAME) Frame Welding CAUTION: Before performing electrical weld- ing anywhere on the vehicle, unplug the multiple connector at the electronic module connector. Also unplug the negative cable and the voltage regulator. This will protect the electronic module and battery against damage caused by flowing current when welding.
  • Page 424 Compression ratio 10.3:1 Decompressor type Automatic Maximum HP RPM 7500 Type Wet sump with replaceable oil filter BRP ROTAX paper type, replaceable Oil filter Engine oil pressure Minimum kPa (PSI) 350 (51) at 6000 RPM Capacity 3 (3.17) Lubrication L (quarts)
  • Page 425 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 400 EFI) OUTLANDER™ 400 EFI MODEL STANDARD MAX XT ENGINE (cont'd) Upper compression ring, rectangular Piston ring type Lower compression ring, taper-face Oil scraper ring, standard Upper compression mm (in) 0.20 to 0.40 (.008 to .016) ring Lower compression mm (in)
  • Page 426 Liquid cooled, single radiator with Type cooling fan Ethyl glycol/water mix (50% coolant, 50% water). Use premixed coolant sold Type by BRP (P/N 219 700 362) or Coolant coolant specifically designed for aluminum engines Capacity L (quarts) 2.9 (3.06) Opening temperature Thermostat °C (°F)
  • Page 427 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 400 EFI) OUTLANDER™ 400 EFI MODEL STANDARD MAX XT ELECTRICAL SYSTEM Magneto generator output 400 W @ 6000 RPM Ignition system type IDI (Inductive Discharge Ignition) Ignition timing Not adjustable Quantity Spark plug Make and type NGK DCPR8E mm (in)
  • Page 428 500 (17) Capacity Rear ml (U.S. oz) 250 (8.5) Differential oil BRP differential oil (P/N 293 600 043) or Recommended synthetic oil 75W90 (API GL5) CV joint grease CV joint grease (P/N 293 550 019) Propeller shaft grease XP-S synthetic grease (P/N 293 550 010)
  • Page 429 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 400 EFI) OUTLANDER™ 400 EFI MODEL STANDARD MAX XT STEERING Turning radius m (ft) 1.83 (6) 2.0 (6 ft – 7 in) Total toe (vehicle on ground) mm (in) 0 ± 4 (0 ± .157) Camber angle 0°...
  • Page 430 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 400 EFI) OUTLANDER™ 400 EFI MODEL STANDARD MAX XT TIRES AND WHEELS TIRES Maximum 34 kPa (5 PSI) 34 kPa (5 PSI) Front Minimum 31 kPa (4.5 PSI) 31 kPa (4.5 PSI) Pressure Maximum 34 kPa (5 PSI) 34 kPa (5 PSI)
  • Page 431 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 400 EFI) OUTLANDER™ 400 EFI MODEL STANDARD MAX XT MATERIAL (cont'd) High density polyethylene Material Front/rear fender Yellow/Laurentian green/Viper red Color High density polyethylene Material Inner fender Color Black High density polyethylene Material Fuel tank Color Black...
  • Page 432 Section 10 WIRING DIAGRAM Subsection 01 (OUTLANDER 400 EFI) OUTLANDER 400 EFI WIRING DIAGRAM INFORMATION NOTE: The wiring diagrams are in the manual back cover pocket. The wiring diagrams use the following codes. 1. Wire colors AREA LOCATION 2. Wire gauge 3.
  • Page 433 2008-2015 OUTLANDER 400 EFI GENERAL SYSTEM vdd2014-001-001...

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