BRP Cam-am Outlander 6x6 DPS 2015 Manual
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BRP Cam-am Outlander 6x6 DPS 2015 Manual

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2015 Can-Am Outlander 650 6x6 ATV Series
Some models may need supplemental manuals which have blue titles.

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Summary of Contents for BRP Cam-am Outlander 6x6 DPS 2015

  • Page 1 2015 Can-Am Outlander 650 6x6 ATV Series Some models may need supplemental manuals which have blue titles.

  • Page 2: Safety Notice

    We strongly recommend that any services be car- act replicas of the parts. ried out and/or verified by a highly skilled profes- The use of BRP parts is most strongly recom- sional mechanic. mended when considering replacement of any It is understood that this manual may be trans- component.

  • Page 3: Vehicle Information

    Due to late changes, there may be some differences between the manufactured product and the de- scription and/or specifications in this document. BRP reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation.
  • Page 4 EPA EMISSION REGULATIONS Vehicles manufactured by BRP are certified to the EPA standards as conforming to the requirements of the regulations for the control of air pollution emitted from new vehicle engines. This certifica-...

  • Page 5: Manual Layout

    INTRODUCTION A number of procedures throughout the book re- quire the use of special tools. Before starting any procedure, be sure that you have on hand all re- quired tools, or their approved equivalents. The use of RIGHT and LEFT indications in the text are always referenced to the driving position (sit- ting on the vehicle).
  • Page 6 INTRODUCTION TYPICAL PAGE Page heading Section 06 ENGINE indicates section Subsection 01 (MAGNETO) and subsection. MAGNETO Subsection title Indicates applicable Models models. Drop represents a Loctite 243 service product Exploded view assists to be applied. Model you in identifying parts and their related Dotted box contains positions.
  • Page 7 INTRODUCTION TYPICAL PAGE Section 03 ENGINE Section 03 ENGINE Subsection 09 (MAGNETO SYSTEM) Subsection 09 (MAGNETO SYSTEM) Tittle in bold indicates category GENERAL GENERAL of information to be carried out. NOTE: The following procedures can be done NOTE: The following procedures can be done without removing the engine.
  • Page 8 INTRODUCTION TIGHTENING TORQUE Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When a torque is not specified, refer to the following table. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices must be replaced when removed (e.g.: locking tabs, elastic stop nuts, self-lock- ing fasteners, cotter pins, etc.).

  • Page 9: Fastener Information

    INTRODUCTION FASTENER INFORMATION Threadlocker Application for Uncovered Holes (Bolts and Nuts) NOTICE Most components in the vehicles are built with parts dimensioned in the metric system. Most fasteners are metric and must not be replaced by customary fasteners or vice-versa. Mismatched or incorrect fasteners could cause damage to the vehicle or possible personal injury.
  • Page 10 INTRODUCTION Threadlocker Application for 4. Apply several drops along the threaded hole Pre-Assembled Parts and at the bottom of the hole. 5. Apply several drops on bolt threads. 6. Tighten as required. Threadlocker Application for Stud Installation in Blind Holes A00A3OA 1.
  • Page 11 INTRODUCTION Gasket Compound Application NOTE: If it is difficult to readjust, heat screw with a soldering iron (232°C (450°F)). Application for Stripped Thread Repair A00A3QA 1. Release agent 2. Stripped threads 3. Form-A-Thread lmr2007-040-006_a 4. Tape 5. Cleaned bolt 1. Proper strength Loctite 6.
  • Page 12 INTRODUCTION Threadlocker Application for Mounting 2. Spray housing and gasket with LOCTITE 7649 on a Shaft (PRIMER) (P/N 293 800 041) 3. Apply a strip of proper strength Loctite on lead- Mounting with a Press ing edge of outer metallic gasket diameter. NOTE: Any Loctite product can be used here.
  • Page 13 XXII vmr2013-002...
  • Page 14 SERVICE TOOLS INDEX ADAPTER HOSE BLIND HOLE PULLER KIT COUNTERSHAFT OIL SEAL PUSHER (P/N 529 035 652) (P/N 529 036 056) (P/N 529 036 222) Page: 90 Page: 325 BACKLASH MEASUREMENT TOOL (P/N 529 035 665) Page: 112, 132 CRANKCASE SUPPORT MAG/PTO (P/N 529 036 031) CAMSHAFT TIMING TOOL (P/N 529 036 268)
  • Page 15 SERVICE TOOLS INDEX CRIMPING TOOL (HEAVY GAUGE ECM ADAPTER TOOL (ONE ENGINE LEAK DOWN TEST KIT WIRE) CONNECTOR) (P/N 529 035 661) (P/N 529 035 730) (P/N 529 036 085) Page: 426 CV BOOT CLAMP PLIER (P/N 529 036 120) Page: 443 Page: 158, 182 ECM ADAPTER TOOL...
  • Page 16 SERVICE TOOLS INDEX HANDLE OIL SEAL INSTALLER (GEARBOX) PISTON RING COMPRESSOR (P/N 420 877 650) (P/N 529 035 758) (P/N 529 035 977) Page: 113, 133, 325 Page: 325 MAGNETO PULLER (P/N 529 035 748) OIL SEAL INSTALLER (P/N 529 036 204) Page: 171 PITMAN ARM JIG Page: 144...
  • Page 17 SERVICE TOOLS INDEX PLAIN BEARING ROTARY SEAL PUSHER PLATE STEERING ALIGNMENT TOOL REMOVER/INSTALLER (P/N 529 036 130) (P/N 529 036 059) (P/N 529 036 032) Page: 501 Page: 234, 258 TDC DIAL INDICATOR Page: 111, 131 POSITIONING ADAPTOR (P/N 414 104 700) (P/N 529 036 230) SEAL PUSHER (P/N 529 035 766)
  • Page 18 SERVICE TOOLS INDEX VALVE GUIDE REMOVER 5 MM (P/N 529 035 924) Page: 170, 194 VALVE SPRING COMPRESSOR CUP (P/N 529 035 764) Page: 166, 190 VALVE SPRING COMPRESSOR (P/N 529 035 724) Page: 166, 190...

  • Page 19: Section 01 Maintenance

    Section 01 MAINTENANCE Subsection 01 (BREAK-IN INSPECTION) BREAK-IN INSPECTION This vehicle should be serviced by an authorized Can-Am dealer after the first 10 hours or 300 km (200 mi) of operation, whichever comes first. The break-in inspection is very important and must not be neglected. The following message will appear in the cluster as a reminder of when the break-in inspection is due: MAINTENANCE SOON.

  • Page 20: Periodic Maintenance Schedule

    Section 01 MAINTENANCE Subsection 02 (PERIODIC MAINTENANCE SCHEDULE) PERIODIC MAINTENANCE SCHEDULE GENERAL Maintenance is very important for keeping the ve- hicle in a safe operating condition. Proper main- tenance is the owner's responsibility. This vehicle should be serviced as per the maintenance sched- ule.

  • Page 21: Maintenance Schedule

    Section 01 MAINTENANCE Subsection 02 (PERIODIC MAINTENANCE SCHEDULE) MAINTENANCE SCHEDULE EVERY 1 500 KM (1,000 MI) OR 50 HOURS OF OPERATION IN TRAIL RIDING CONDITIONS (WHICHEVER COMES FIRST) EVERY 750 KM (500 MI) OR 25 HOURS OF OPERATION IN SEVERE RIDING CONDITIONS (DUSTY OR MUDDY) OR CARRYING HEAVY LOADS CONDITION (WHICHEVER COMES FIRST) Inspect and clean engine air filter.
  • Page 22 Section 01 MAINTENANCE Subsection 02 (PERIODIC MAINTENANCE SCHEDULE) EVERY 6 000 KM (4,000 MI) OR 200 HOURS OF OPERATION IN TRAIL RIDING CONDITIONS (WHICHEVER COMES FIRST) EVERY 3 000 KM (2,000 MI) OR 100 HOURS OF OPERATION IN SEVERE RIDING CONDITIONS (DUSTY OR MUDDY) OR CARRYING HEAVY LOADS CONDITION (WHICHEVER COMES FIRST) Check cooling system and perform a pressure test on pressure cap and cooling system Check engine coolant strength...

  • Page 23: Periodic Maintenance Procedures

    Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) PERIODIC MAINTENANCE PROCEDURES (650) SERVICE TOOLS Description Part Number Page 529 035 991 ........... 21 TEST CAP ..................529 021 800 ........21, 34 VACUUM/PRESSURE PUMP ............SERVICE PRODUCTS Description Part Number Page 219 700 341 ...........
  • Page 24 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) vmr2012-010-017_a vmo2012-012-039_a TYPICAL - SOME PARTS REMOVED FOR CLARITY 1. Air filter housing inlet drain tube 1. Air filter cover 3. Check air filter dirty chamber for cleanliness. 4. Remove air filter. –...
  • Page 25 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) NOTICE It is not recommended to blow com- NOTE: A second application may be necessary pressed air on the paper filter; this could dam- for heavily soiled elements. age the paper fibers and reduce its filtration Foam Filter Oiling ability when used in dusty environments.
  • Page 26 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) vmr2012-005-001_a 1. Cover position arrow 2. Locked tmo2011-001-041_a 3. Unlocked 1. Spark arrester 2. Gasket 3. Exhaust tail pipe EXHAUST SYSTEM 3. Remove carbon deposits from the spark ar- Muffler Spark Arrester Cleaning and rester using a brush.
  • Page 27 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) LUBRICATION SYSTEM Recommended Engine Oil RECOMMENDED ENGINE OIL SEASON TYPE XPS 4-STROKE SYNTH. Summer BLEND OIL (SUMMER) (P/N 293 600 121) XPS 4-STROKE SYNTHETIC OIL Winter (ALL CLIMATE) (P/N 293 600 112) If recommended XPS oil is not available, use a 4-stroke SAE 5W 40 engine oil that meets or ex- vmr2015-063-001_a...

  • Page 28: Engine Oil Filter

    Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) Engine Oil Filter Replacement Engine Oil Filter Access To reach oil filter, refer to BODY subsection and remove the following parts: – Seat – Console – RH side panel – RH footrest panel. Engine Oil Filter Removal 1.
  • Page 29 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) Engine Coolant Level Verification 2. Install a NEW O-ring on oil filter cover. 3. Install the filter into the cover. WARNING 4. Apply engine oil on O-ring and on end of filter. Check coolant level with engine cold.

  • Page 30: Water Pump

    Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) WARNING To avoid potential burns, do not remove the pressure cap if the engine is hot. 3. Using an antifreeze tester, test coolant strength. MINIMUM RECOMMENDED COOLANT STRENGTH -30°C (-22°F) Engine Cooling System Inspection 1.
  • Page 31 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) REQUIRED TOOLS VACUUM/PRESSURE TEST CAP (P/N 529 PUMP 035 991) (P/N 529 021 800) COOLING SYSTEM LEAK TEST 110 kPa (16 PSI) vmr2015-107-005_a If there is no pressure drop after 10 minutes, there SOME PARTS REMOVED FOR CLARITY is no leak in the cooling system.
  • Page 32 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) vmr2015-107-007_a LH SIDE OF VEHICLE vmr2015-029-202_a 1. Rear cylinder bleed screw 1. Outer exhaust heat shield 6. Fill cooling system until coolant comes out of 4. Remove CVT duct outlet. bleed screws. 7.

  • Page 33: Timing Gear

    Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) CYLINDER HEAD 5. Repeat the procedure for each valve. 6. Before installing valve covers, recheck valve Engine Valve Clearance Inspection and clearance. Adjustment NOTE: Check and adjust valve clearance only GEARBOX when engine is cold.
  • Page 34 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) NOTE: Running engine at idle is not sufficient, ve- 8. Reinstall magnetic drain plug with a NEW seal- hicle transmission must be operated. ing ring. 2. Position vehicle on a level surface. DRAIN PLUG 3.
  • Page 35 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) Drive Pulley, Driven Pulley and One-Way Bearing Maintenance CONTINUOUSLY VARIABLE TRANSMIS- Refer to SION (CVT) subsection. FUEL SYSTEM Throttle Body Inspection and Cleaning AIR INTAKE SYSTEM 1. Refer to subsection and remove the air filter housing.
  • Page 36 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) V07I0GA 1. Cable protector 2. Throttle cable adjuster 3. Lock nut 4. Throttle lever housing V07I0IA Screw in the throttle cable adjuster. Remove the throttle body side cover. Remove inner housing protector. vmo2006-007-032_a V07I0HA 1.

  • Page 37: Fuel Pump Removal

    Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) FUEL TANK LEAK TEST 3. Carry out a , refer to FUEL TANK AND FUEL PUMP subsection. WARNING All fuel system leaks must be repaired. Dam- aged, worn or leaking fuel system com- ponents should be replaced to ensure fuel system tightness.
  • Page 38 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) Spark Plug Replacement 2. With vehicle on a level surface, check oil level by removing filler plug. Oil level must reach the Spark Plug Access lower edge. For access to the LH spark plug, remove the aft 3.

  • Page 39: Oil Level

    Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) CAPACITY RECOMMENDED OIL XPS SYNTHETIC GEAR OIL (75W 90) 500 ml (17 U.S. oz) (P/N 293 600 043) or a 75W 90 (API GL-5) gear oil 9. Reinstall filler plug with a NEW sealing ring. 10.
  • Page 40 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) RECOMMENDED OIL QUANTITY XPS SYNTHETIC GEAR OIL (75W 140) Middle 400 ml (P/N 293 600 140) Drive (14 U.S. oz) or a 75W 140 (API GL-5) gear oil XPS SYNTHETIC Rear GEAR OIL (75W 140) 300 ml Final...
  • Page 41 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) – Pitting – Abnormal play. Replace if necessary. Steering Column Half Bushing Cleaning and Lubrication Clean, inspect and lubricate upper and lower steering column half bushings and O rings. Refer STEERING SYSTEM subsection.
  • Page 42 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) 4. Check ball joint for: – Damage – Pitting – Play. 5. Check ball joint bellows for: – Damage – Cracks. Rear Anti-Sway Bar Bushing Inspection and Lubrication Rear Anti-Sway Bar Bushing Inspection Inspect bushings for: vmr2012-040-013_a TYPICAL...

  • Page 43: Brake Disc Inspection

    Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) 2. Clean brake disc using the following recom- BRAKE PAD MINIMUM THICKNESS mended service product. 1 mm (1/32 in) RECOMMENDED SERVICE PRODUCT NOTE: The brake pad grooves are wear indica- XPS BRAKES AND PARTS CLEANER tors.
  • Page 44 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) tmr2011-037-101_a TYPICAL 1. Caliper bleeder vmo2012-012-035_a TYPICAL - UNDER THE SEAT 1. Brake fluid reservoir 3. Loosen bleeder. 4. Pump brake lever(s) and/or brake pedal until no NOTE: If applicable, ensure filler cap diaphragm is more fluid flows out.
  • Page 45 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (650)) BODY 6. Continue to pump until no more air bubbles ap- pear in clear hose. Seat Latch Inspection and Operation 7. Close then tighten bleeder. Ensure seat latch functions properly and that seat BLEEDER is properly secured when latched.

  • Page 46: Preseason Preparation

    Section 01 MAINTENANCE Subsection 06 (PRESEASON PREPARATION) PRESEASON PREPARATION Proper vehicle preparation is required after a storage period. Any worn, broken or damaged parts found must be replaced. Remove rags that were installed for storage: engine air inlet hose, CVT outlet hose and muffler. Clean drive and driven pulleys to remove storage protective lubricant, then reinstall drive belt.

  • Page 47: Special Procedures

    Section 01 MAINTENANCE Subsection 07 (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE PRODUCTS Description Part Number Page 293 600 016 ........... 68 XPS LUBE..................GENERAL WHAT TO DO IF WATER IS IN THE AIR FILTER HOUSING NOTE: Component failures resulting from these events are not warrantable.

  • Page 48: What To Do If Vehicle Is Immersed In Water

    Section 01 MAINTENANCE Subsection 07 (SPECIAL PROCEDURES) – Check rear final drive oil level and refill if neces- Inspect fuel tank vent system for water intrusion. sary. Clean as required. Replace breather filter. Carry out a fuel pump pressure test. –...

  • Page 49: Engine Removal And Installation

    Section 02 ENGINE, CVT AND GEARBOX Subsection 01 (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number Page 529 036 022 ........... 73 ENGINE LIFTING TOOL ..............8 ± 1 N•m 13 ± 2 N•m (70 ± 9 lbf•in) (115 ±...
  • Page 50 Section 02 ENGINE, CVT AND GEARBOX Subsection 01 (ENGINE REMOVAL AND INSTALLATION) PROCEDURES ENGINE REMOVAL 1. Place vehicle on a workstation equipped with an engine-lifting hoist. 2. Set transmission to park "P" and engage parking brake. 3. Carry out the following operations. Refer to ta- ble.
  • Page 51 Section 02 ENGINE, CVT AND GEARBOX Subsection 01 (ENGINE REMOVAL AND INSTALLATION) vmr2012-009-002 TYPICAL - MASTER CYLINDER SECURED TO REAR FENDER vmr2015-025-003_a TYPICAL - FROM LH SIDE 7. Move crankcase vent hose as illustrated. 1. Ignition coil connector 2. Locking ties to cut 10.
  • Page 52 Section 02 ENGINE, CVT AND GEARBOX Subsection 01 (ENGINE REMOVAL AND INSTALLATION) 11. On RH side of engine, remove oil pressure switch cover. vmr2012-043-013_b TYPICAL 1. Magneto connector 14. Remove magneto harness from its location vmr2012-009-009_a TYPICAL - RH SIDE OF ENGINE along vehicle and gather it in a bundle near 1.
  • Page 53 Section 02 ENGINE, CVT AND GEARBOX Subsection 01 (ENGINE REMOVAL AND INSTALLATION) Engine Lifting 1. Install the ENGINE LIFTING TOOL (P/N 529 036 on engine. 022) 529036022 vmr2012-009-025_a SOME PARTS REMOVED FOR CLARITY 1. Disconnect the following coolant hoses 17. Remove main ground wire from engine. vmr2012-009-015 TYPICAL 2.
  • Page 54 Section 02 ENGINE, CVT AND GEARBOX Subsection 01 (ENGINE REMOVAL AND INSTALLATION) vmr2012-009-019_a vmr2012-009-017_a RH SIDE TYPICAL - LH SIDE 1. Engine support plate screws 1. Rear engine mount retaining bolt 7. Remove the following Oetiker clamps from 5. Remove retaining bolt from front engine mount. front propeller shaft.

  • Page 55: Engine Installation

    Section 02 ENGINE, CVT AND GEARBOX Subsection 01 (ENGINE REMOVAL AND INSTALLATION) vmr2012-009-022_a TYPICAL - RH SIDE vmr2012-009-024 1. Rear propeller shaft screw TYPICAL 10. Slightly lift engine and move it forward to dis- ENGINE INSTALLATION connect rear propeller shaft from engine. 11.
  • Page 56 Section 02 ENGINE, CVT AND GEARBOX Subsection 01 (ENGINE REMOVAL AND INSTALLATION) Engine Mount Removal Insert a punch into one engine mount bushing and push the opposite bushing out. tmr2011-007-011 TYPICAL Engine Mount Installation Push in each mount bushing until it bottoms out. vmr2015-025...

  • Page 57: Air Intake System

    Section 02 ENGINE, CVT AND GEARBOX Subsection 02 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM AIR FILTER HOUSING 1.6 ± 0.4 N•m (14 ± 4 lbf•in) Loctite 5150 (silicone sealant) 6 ± 1 N•m (53 ± 9 lbf•in) Suspension grease 6 ± 1 N•m (53 ±...
  • Page 58 Section 02 ENGINE, CVT AND GEARBOX Subsection 02 (AIR INTAKE SYSTEM) GENERAL NOTICE Never modify the air intake system. Otherwise, engine performance degradation or damage can occur. The engine is calibrated to operate specifically with these components. PROCEDURES AIR FILTER For air filter servicing, refer to PERIODIC MAIN- TENANCE PROCEDURES...
  • Page 59 Section 02 ENGINE, CVT AND GEARBOX Subsection 02 (AIR INTAKE SYSTEM) 7. Remove air intake tube retaining screw. 10. Remove link rod from shift lever. vmr2012-010-003_a vmr2012-010-006_a 1. Air intake tube retaining screw 1. Link rod retaining bolt 8. Move air intake tube forward for access to 11.
  • Page 60 Section 02 ENGINE, CVT AND GEARBOX Subsection 02 (AIR INTAKE SYSTEM) vmr2012-010-009_a vmr2012-010-012_a 1. Locking ties to remove FASTENERS LOCATED NEAR FORWARD SEAT ANCHORAGE 1. Nuts and washers (2x) 13. Remove crankcase vent hose from air filter housing. vmr2012-010-013_a SCREW LOCATED UNDER COOLANT TANK 1.
  • Page 61 Section 02 ENGINE, CVT AND GEARBOX Subsection 02 (AIR INTAKE SYSTEM) 17. Move throttle body aside to make room. vmr2012-010-015_a 1. Throttle body 18. Remove air filter housing by pulling it towards rear. vmr2012-010-016_a AIR FILTER HOUSING REMOVAL 19. Remove remaining components from air filter housing.

  • Page 62: Exhaust System

    Section 02 ENGINE, CVT AND GEARBOX Subsection 03 (EXHAUST SYSTEM) EXHAUST SYSTEM 9 ± 1 N•m (80 ± 9 lbf•in) 13 ± 1 N•m (155 ± 9 lbf•in) 21 ± 1 N•m (15 ± 1 lbf•ft) 13 ± 1 N•m (155 ±...

  • Page 63: Heat Shield

    Section 02 ENGINE, CVT AND GEARBOX Subsection 03 (EXHAUST SYSTEM) GENERAL Muffler Inspection Check muffler and cover for cracks or other dam- WARNING ages. Replace if necessary. Never touch exhaust system components im- Check if the rubber support is brittle, hard or oth- mediately after the engine has run.

  • Page 64: Tightening Torque

    Section 02 ENGINE, CVT AND GEARBOX Subsection 03 (EXHAUST SYSTEM) vmr2012-011-010_a vmr2012-011-012_a LH SIDE — PARTS REMOVED FOR CLARITY 1. Remove 1. "Y" exhaust pipe 2. Springs 3. Remove front head pipe from vehicle. "Y" Exhaust Pipe Inspection Check "Y" exhaust pipe for cracks, bending or other damages.

  • Page 65: Lubrication System

    Section 02 ENGINE, CVT AND GEARBOX Subsection 04 (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number Page 529 035 652 ........... 90 ADAPTER HOSE ................529 035 714 ........... 90 DISCONNECT TOOL ..............529 035 709 ........... 90 PRESSURE GAUGE............... SERVICE PRODUCTS Description Part Number...
  • Page 66 Section 02 ENGINE, CVT AND GEARBOX Subsection 04 (LUBRICATION SYSTEM) COMPONENTS 20 ± 2 N•m (15 ± 1.5 lbf•ft) Loctite 243 12 ± 1 N•m (106 ± 9 lbf•in) 10 ± 1 N•m (89 ± 9 lbf•in) Engine oil 30 ± 2 N•m (22 ±...

  • Page 67: Engine Lubrication Circuit

    Section 02 ENGINE, CVT AND GEARBOX Subsection 04 (LUBRICATION SYSTEM) ENGINE LUBRICATION CIRCUIT vmr2007-033-001_a 1. Camshaft bearings 2. Oil pressure switch 3. Oil filter 4. Oil pressure regulator valve 5. Oil strainer 6. Oil pump 7. Crankshaft main bearings 8. Crankshaft support bearing 9.

  • Page 68: Pressure Switch

    Section 02 ENGINE, CVT AND GEARBOX Subsection 04 (LUBRICATION SYSTEM) INSPECTION NOTE: To remove adapter hose from oil pressure gauge, use the disconnect tool. ENGINE OIL PRESSURE REQUIRED TOOL NOTE: The engine oil pressure test should be DISCONNECT TOOL done with a warm engine 100°C (212°F) and the (P/N 529 035 714) recommended oil.

  • Page 69: High Oil Consumption

    Section 02 ENGINE, CVT AND GEARBOX Subsection 04 (LUBRICATION SYSTEM) 2. Cylinder head or cylinder base gasket leak. - Retighten cylinder head to specified torque, refer to TOP END subsection. Replace gasket if tight- ening does not solve the problem. 3.

  • Page 70: Engine Oil Pressure

    Section 02 ENGINE, CVT AND GEARBOX Subsection 04 (LUBRICATION SYSTEM) OIL PRESSURE SWITCH (OPS) Oil Pressure Switch Resistance Test Disconnect the connector from the oil pressure switch. Check resistance as per following tables. ENGINE NOT ENGINE CONNECTOR RUNNING RESISTANCE ( ) Close to 0 Engine (normally closed...

  • Page 71: Engine Oil Pressure Regulator

    Section 02 ENGINE, CVT AND GEARBOX Subsection 04 (LUBRICATION SYSTEM) Oil Pressure Switch Installation Oil Pressure Regulator Access To reach the pressure regulator (Outlander series), refer to BODY and remove: – RH side panel – RH footboard panel. Oil Pressure Regulator Removal Remove plug screw and pull oil pressure regulator out.
  • Page 72 Section 02 ENGINE, CVT AND GEARBOX Subsection 04 (LUBRICATION SYSTEM) vmr2006-042-011_a 1. Retaining screws 2. Oil pump cover vmr2006-042-009_a 1. Oil pump 3. Remove oil pump shaft with needle pin and in- ner rotor. Oil Pump Removal 4. Remove outer rotor. PTO COVER Remove the PTO cover.

  • Page 73: Service Limit

    Section 02 ENGINE, CVT AND GEARBOX Subsection 04 (LUBRICATION SYSTEM) vmr2006-042-014_a 1. Outer rotor 2. Inner rotor A. 0.25 mm (.0098 in) vmr2006-042-012_a If clearance of inner and outer rotors exceeds the 1. Oil pump bore tolerance, replace oil pump rotors. Ensure to also 2.

  • Page 74: Engine Oil Strainer

    Section 02 ENGINE, CVT AND GEARBOX Subsection 04 (LUBRICATION SYSTEM) ENGINE OIL STRAINER Oil Strainer Location The engine oil strainer is located between both crankcase halves. Oil Strainer Removal Remove engine from vehicle. BOTTOM Separate crankcase halves. Refer to subsection. Remove screws and retaining plate.

  • Page 75: Reed Valve

    Section 02 ENGINE, CVT AND GEARBOX Subsection 04 (LUBRICATION SYSTEM) REED VALVE The engine is equipped with a reed valve which prevents accumulation of larger oil quantities in the crankcase. The reed valve is fitted into the crankcase. vmr2006-042-018_a 1. Reed valve 2.

  • Page 76: Cooling System

    Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) COOLING SYSTEM (650) SERVICE TOOLS Description Part Number Page 529 036 056 ......... 112 BLIND HOLE PULLER KIT ............529 035 868 ......... 104 FLUKE 115 MULTIMETER ............420 877 650 ......... 113 HANDLE ..................
  • Page 77 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) RADIATOR 2.5 ± 0.3 N•m (22 ± 3 lbf•in) 10 ± 1 N•m (89 ± 9 lbf•ft) 10 ± 1 N•m (89 ± 9 lbf•ft) Engine = Component must be replaced when removed. vmr2015-115-100 vmr2015-114...
  • Page 78 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) WATER PUMP AND THERMOSTAT 6 ± 0.7 N•m 5 ± 0.6 N•m 5 ± 0.6 N•m (53 ± 6 lbf•in) (44 ± 5 lbf•in) (44 ± 5 lbf•in) Loctite 6 ±...
  • Page 79 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) GENERAL 3. Pull thermostat and gasket from thermostat housing. NOTICE Never start engine without coolant. Some engine parts such as the rotary seal on the water pump shaft can be damaged. PROCEDURES THERMOSTAT Thermostat Location...

  • Page 80: Maintenance Procedures

    Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) Radiator Removal 1. Drain engine coolant. Refer to PERIODIC MAINTENANCE PROCEDURES subsection. BODY 2. Remove front body module. Refer to subsection. 3. Disconnect both radiator hoses. vmr2012-013-006_a TYPICAL 1. Upper retaining bolts 6.

  • Page 81: Coolant Temperature Sensor (Cts)

    Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) Tighten radiator upper retaining bolts to specifica- REQUIRED TOOL tion. FLUKE 115 MULTIMETER (P/N 529 035 868) RADIATOR UPPER RETAINING BOLTS 3. Probe relay as follows. 10 N•m ± 2 N•m Tightening torque (89 lbf•in ±...
  • Page 82 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) AIR INTAKE COOLING FAN TEMPERATURE 88°C (190°F) Turns ON 85°C (185°F) Turns OFF CHECK ENGINE COOLING GAUGE ENGINE TEMP. MESSAGE LIGHT 95°C – – Turns ON (203°F) 93°C – –...

  • Page 83: Radiator Removal

    Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) Radiator Cooling Fan Troubleshooting Chart COOLING FAN TROUBLESHOOTING CHART  Is fan working? Everything is OK  Check ECM fuse (F6)  Replace fuse Check FAN fuse (F9) Is fan working? Is fuse burnt? ...

  • Page 84: Water Pump Impeller

    Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) WATER PUMP IMPELLER Water Pump Impeller Removal WATER PUMP HOUSING RE- 1. Proceed with MOVAL . See procedure in this subsection. 2. Remove impeller by unscrewing it counter- clockwise. vmr2015-115-001_a 1.
  • Page 85 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) DEFECTIVE PART ACTION Replace: - Rotary seal Rotary seal - Oil seal (assembled engine) Replace: - Rotary seal Oil seal - Oil seal (assembled engine) Replace: - Water pump shaft assembly Water pump shaft vbs2008-011-005...
  • Page 86 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) tmr2011-011-054_a 1. Wooden screws 2. Oil seal 7. Remove oil seal from crankcase by pulling screws with pliers. tmr2011-011-052_a 1. Screwdrivers NOTICE Be careful not to damage the crankcase while removing outer part of the rotary seal.

  • Page 87: Required Tool

    Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) vbs2008-011-035_a TYPICAL 1. Oil seal properly seated tmr2011-011-056_a 6. Apply engine oil on water pump shaft. Seals Installation 7. Place rotary seal onto water pump shaft and pull 1. Apply engine oil on water pump shaft. out water pump shaft by hand.
  • Page 88 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) 12. Install rotary seal installation tools REQUIRED TOOLS crankcase as follows. ROTARY SEAL PUSHER PLATE (P/N 529 036 130) NOTE: Make sure pusher bolt has a plane 4x M6 x 85 screws (P/N 420 440 347) surface.
  • Page 89 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) 14. Ensure that the rotary seal is going straight 19. Refill and bleed cooling system. Refer to RIODIC MAINTENANCE PROCEDURES into crankcase. sub- section. 15. Remove rotary seal installation tools from crankcase.
  • Page 90 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) tmr2011-011-012_a OIL SEAL REMOVAL - VIEW FROM INSIDE CRANKCASE MAG vmr2007-034-105_a SIDE 1. Orifices for oil seal removal 5. Remove oil seal from inside of crankcase MAG Water Pump Shaft and Seals Installation side using a pusher tool.
  • Page 91 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) mmr2009-112-028_a WATER PUMP SHAFT ASSEMBLY 1. Surface where rotary seal is pushed by tool NOTICE Never use a hammer for rotary seal installation. Only use a press to avoid damag- tmr2011-011-014_a ing the ceramic component.
  • Page 92 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) WATER PUMP GEARS Water Pump Gears Identification tmr2011-011-013_a CRANKCASE PTO SIDE vmr2012-013-009_a 1. Water pump intermediate drive gear 2. Circlip 1. Water pump shaft 3. Water pump intermediate shaft 2.
  • Page 93 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) – Needle pin – Water pump gear. NOTICE A missing thrust washer will cause a leaking rotary seal. tmr2011-011-009_a CRANKCASE MAG SIDE 1. Water pump gear 2. Needle pin 3.
  • Page 94 Section 02 ENGINE, CVT AND GEARBOX Subsection 05 (COOLING SYSTEM (650)) Install NEW circlip to retain water pump interme- diate drive gear. NOTICE Never use the circlip a second time. Always install a NEW one. Water Pump Drive Gear BOTTOM END subsection.

  • Page 95: Magneto And Starter

    Section 02 ENGINE, CVT AND GEARBOX Subsection 07 (MAGNETO AND STARTER) MAGNETO AND STARTER SERVICE TOOLS Description Part Number Page 529 035 617 ......... 144 CRANKSHAFT LOCKING BOLT............. 529 036 034 ......... 144 CRANKSHAFT PROTECTOR ............529 035 868 ......... 141 FLUKE 115 MULTIMETER ............
  • Page 96 Section 02 ENGINE, CVT AND GEARBOX Subsection 07 (MAGNETO AND STARTER) 6 ± 0,7 N•m (53 ± 6 lbf•in) See ELECTRONIC FUEL Engine oil INJECTION (EFI) 10 ± 1 N•m (89 ± 9 lbf•in) 5 ± 0,6 N•m (44 ± 5 lbf•in) Drei Bond sealing compound Loctite 243 Loctite 243...
  • Page 97 Section 02 ENGINE, CVT AND GEARBOX Subsection 07 (MAGNETO AND STARTER) GENERAL All electrical test have been performed using the FLUKE 115 MULTIMETER (P/N 529 035 868) vmr2015-030-002_a 529035868 1. Dipstick 2. O-ring Results may vary when another multimeter is 3.
  • Page 98 Section 02 ENGINE, CVT AND GEARBOX Subsection 07 (MAGNETO AND STARTER) Magneto Cover Installation For installation, reverse the removal procedure. However, pay attention to the following. Install a NEW magneto cover gasket. Apply DREI BOND SEALING COMPOUND (P/N 420 on stator cable grommet as shown in next 297 906) illustration.

  • Page 99: Magneto Cover

    Section 02 ENGINE, CVT AND GEARBOX Subsection 07 (MAGNETO AND STARTER) Stator Inspection RESISTANCE @ TEST PROBES 20°C (68°F) Check stator windings and insulation for cracks or other damages. If damaged replace it. Any YELLOW wire and Infinite (open circuit) engine ground Check if stator wires are brittle, hard or otherwise damaged.

  • Page 100: Magneto Puller

    Section 02 ENGINE, CVT AND GEARBOX Subsection 07 (MAGNETO AND STARTER) Rotor Inspection REQUIRED TOOL Check inner side of rotor for scratches or other CRANKSHAFT LOCKING BOLT damage. (P/N 529 035 617) Blow pressurized air in the rotor oil bore and make Heat screw in order to break the Loctite.

  • Page 101: Sprag Clutch

    Section 02 ENGINE, CVT AND GEARBOX Subsection 07 (MAGNETO AND STARTER) tmr2011-012-008_a 1. Crankshaft (MAG side) 2. Oil passage vmr2006-041-012_b 3. Threads 1. Starter double gear 2. Sprag clutch gear Oil sprag clutch and install sprag clutch gear. 3. Intermediate gear ROTOR RETAINING SCREW LOCTITE 648 (GREEN) Service product...

  • Page 102: Sprag Clutch Gear

    Section 02 ENGINE, CVT AND GEARBOX Subsection 07 (MAGNETO AND STARTER) vmr2006-041-013_a 1. Sprag clutch housing screws 2. Rotor vmr2006-041-015_b 3. Sprag clutch 1. Sprag clutch 4. Sprag clutch housing 2. Sprag clutch housing 3. Sprag clutch gear Sprag Clutch Inspection 4.

  • Page 103: Starter Drive Gears

    Section 02 ENGINE, CVT AND GEARBOX Subsection 07 (MAGNETO AND STARTER) Check needle bearing condition. Replace sprag clutch gear if necessary. vmr2006-041-017_a 1. Intermediate gear 2. Starter double gear 3. Starter gear 4. Location pins vmr2006-041-016_a Starter Drive Gear Inspection INSPECT 1.

  • Page 104: Intake Manifold

    Section 02 ENGINE, CVT AND GEARBOX Subsection 08 (INTAKE MANIFOLD) INTAKE MANIFOLD 0.7 ± 0.1 N•m (6 ± 1 lbf•in) 10 ± 1 N•m (89 ± 9 lbf•in) 6 ± 0.7 N•m (53 ± 6 lbf•in) 10 ± 1 N•m (89 ±...
  • Page 105 Section 02 ENGINE, CVT AND GEARBOX Subsection 08 (INTAKE MANIFOLD) PROCEDURES 6. Pull off throttle body from intake manifold and ELECTRONIC FUEL air intake silencer. Refer to INJECTION (EFI) INTAKE MANIFOLD NOTE: Do not disconnect throttle cable need- Intake Manifold Access lessly.
  • Page 106 Section 02 ENGINE, CVT AND GEARBOX Subsection 08 (INTAKE MANIFOLD) INTAKE MANIFOLD RETAINING SCREWS 20 N•m ± 2 N•m Tightening torque (15 lbf•ft ± 1 lbf•ft) Reinstall the fuel pump relay fuse (F15). vmr2015-117...
  • Page 107 Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) TOP END (650) SERVICE TOOLS Description Part Number Page 529 035 617 ......... 172 CRANKSHAFT LOCKING BOLT............. 529 035 661 ......... 158 ENGINE LEAK DOWN TEST KIT ........... 529 035 921 ......... 175 PISTON CIRCLIP INSTALLER............
  • Page 108 Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) CYLINDER HEAD NO. 1 7 ± 0.8 N•m (62 ± 7 lbf•in) 12 ± 1 N•m (106 ± 9 lbf•in) Engine oil See tightening Engine oil procedure 20 ± 2 N•m 10 ±...
  • Page 109 Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) CYLINDER HEAD NO. 2 Engine oil 7 ± 0.8 N•m (62 ± 7 lbf•in) 12 ± 1 N•m (106 ± 9 lbf•in) See tightening procedure 20 ± 2 N•m (5 ±...

  • Page 110: Cylinders And Pistons

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) CYLINDERS AND PISTONS Engine oil Engine oil Engine oil Engine oil Engine oil Engine = Component must be replaced when removed. vmr2015-118-001_a vmr2015-117...

  • Page 111: Valve Cover

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) GENERAL WARNING Always respect this order for disassembly; Special reference are made in the text for proce- disconnect BLACK (-) cable first. dures which are different for cylinder no. 1 and cylinder no.
  • Page 112 Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) NOTE: All testers have specific instructions on REQUIRED TOOL gauge operation and required pressure. TDC DIAL INDICATOR Install gauge adapter into previously cleaned spark (P/N 414 104 700) plug hole. Supply combustion chamber with air pressure.

  • Page 113: Rocker Arm

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) – Air escaping into crankcase area means exces- sively worn cylinder and/or broken piston rings. – Air/oil escaping from crankcase means dam- aged gasket and/or loosened screws (refer to BOTTOM END subsection).

  • Page 114: Timing Chain

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) TIMING CHAIN Refer to subsection and remove following parts: – Timing chain tensioner – Camshaft timing gear. Remove pan head screw and camshaft retaining plate. tmr2011-013-010_a 1. Rocker arm (exhaust side) 2.
  • Page 115 Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) ROCKER ARM SHAFT DIAMETER 12.00 mm to 12.018 mm (.4724 in to .4731 in) SERVICE LIMIT 11.990 mm (.472 in) Any area worn excessively will require parts re- placement. Rocker Arm Installation R400motr68A NOTE: Use the same procedure for exhaust and...
  • Page 116 Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) ROCKER ARM Remove rocker arms (see in this subsection). Remove the camshaft. vmr2015-032-001_a 1. Intake cam 2. Exhaust cam 3. Camshaft of cylinder 1 4. Camshaft of cylinder 2 5.

  • Page 117: Cylinder Head

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) NOTICE The camshafts are not identical in CAMSHAFT LOBE (INTAKE) design. Do not invert the camshafts during 32.110 mm to 32.310 mm assembly. Any mix-up of the components will (1.2642 in to 1.272 in) lead to engine damage.
  • Page 118 Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) TIMING CHAIN Refer to the subsection to remove Check mating surface between cylinder and cylin- the following parts: der head for contamination. If so, clean both sur- faces. – Chain tensioner –...

  • Page 119: Tightening Torque

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) Cylinder Head Installation NOTE: Never invert front and rear cylinder heads. On the 650 engine, cylinder heads are not identi- cal. For installation, reverse the removal procedure. Pay attention to the following details. Ensure dowel pins are in place.

  • Page 120: Valve Springs

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) tmr2011-013-011_d 1. M6 Screws R400motr79A M6 CYLINDER HEAD SCREWS LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF THE VALVE TIGHTENING 10 N•m ± 1 N•m Remove valve cotters. TORQUE (89 lbf•in ±...

  • Page 121: Valve Spring Free Length

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) Valve Spring Inspection After spring is installed, ensure it is properly locked by tapping on valve stem end with a soft Check valve spring for visible damage. If so, re- hammer so that valve opens and closes a few place valve spring.
  • Page 122 Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) Replace valve if valve stem is out of specification or has other damages such as wear or friction sur- face. vmr2006-043-023 R400motr83A Valve Inspection A. Valve stem diameter Whenever valves are removed always inspect VALVE STEM DIAMETER VALVE GUIDES valve guides.

  • Page 123: Valve Guides

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) Ensure to seat valves properly. Apply some lap- ping compound to valve face and work valve on VALVE GUIDES its seat with a lapping tool (see this subsection). Measure valve face contact width. NOTE: The location of contact area should be in center of valve seat.
  • Page 124 Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) NOTICE Push valve guide in the cold cylinder REQUIRED TOOL head as per following illustration. VALVE GUIDE REMOVER 5 MM (P/N 529 035 924) Hammer R400motr87B 1. Thrust surface of cylinder head 2.

  • Page 125: Cylinder Taper

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) CYLINDER HEAD Remove the cylinder head (see CYLINDER TAPER SPECIFICATION in this subsection). NEW (MAXIMUM) 0.038 mm (.0015 in) Pull cylinder. SERVICE LIMIT 0.090 mm (.0035 in) Discard cylinder base gaskets. Distance between measurements should not ex- ceed the service limit.
  • Page 126 Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) NOTE: The cylinder can not be pushed fully over WARNING the piston unless the piston is located at TDC. Piston circlips are spring loaded. Then remove the CRANKSHAFT LOCKING BOLT (P/N 529 035 617) Remove one piston circlip and discard it.

  • Page 127: Piston/Cylinder Clearance

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) R400motr96A 1. Measuring perpendicularly (90°) to piston pin A. 8 mm (.315 in) The measured dimension should be as described F00B09A in the following tables. If not, replace piston. 1.

  • Page 128: Piston Pin Diameter

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) Connecting Rod/Piston Pin Clearance Compare measurements to obtain the connecting rod/piston pin clearance. Using synthetic abrasive woven, clean piston pin from deposits. CONNECTING ROD/ PISTON PIN CLEARANCE Inspect piston pin for scoring, cracking or other damages.

  • Page 129: Ring/Piston Groove Clearance

    Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) REQUIRED TOOL PISTON CIRCLIP INSTALLER (P/N 529 035 921) NOTICE Always replace disassembled piston circlip(s) by NEW ones. Place a rag on cylinder base to avoid dropping the circlip inside the en- gine.
  • Page 130 Section 02 ENGINE, CVT AND GEARBOX Subsection 09 (TOP END (650)) R400motr103A 1. Piston vmr2007-036-009_a 2. Feeler gauge 1. Upper compression ring 2. Lower compression ring Ring End Gap 3. Oil scraper ring RING END GAP NOTICE Ensure that top and second rings are not interchanged.

  • Page 131: Service Tools

    Section 02 ENGINE, CVT AND GEARBOX Subsection 11 (TIMING CHAIN (650)) TIMING CHAIN (650) SERVICE TOOLS Description Part Number Page 529 036 268 ......... 205 CAMSHAFT TIMING TOOL............529 036 201 ......... 205, 209 CRANKSHAFT TDC POSITION TOOL ........... SERVICE PRODUCTS Description Part Number Page...
  • Page 132 Section 02 ENGINE, CVT AND GEARBOX Subsection 11 (TIMING CHAIN (650)) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 0.1 N•m 10 ± 1 N•m (0.89 lbf•in) (89 ± 9 lbf•in) Engine oil Loctite 243 6 ± 0.7 N•m (53 ± 6 lbf•in) Loctite 243 6 ±...

  • Page 133: Troubleshooting

    Section 02 ENGINE, CVT AND GEARBOX Subsection 11 (TIMING CHAIN (650)) TROUBLESHOOTING Timing Chain Tensioner Removal 1. Make sure the applicable cylinder is set to TDC UNUSUAL ENGINE NOISE OR VIBRATION ignition. Refer to CAMSHAFT TIMING GEARS in this subsection. 1.
  • Page 134 Section 02 ENGINE, CVT AND GEARBOX Subsection 11 (TIMING CHAIN (650)) vmr2006-043-005_a 1. Screws tmr2011-045-003_a 2. Chain tensioner housing MOVE GEAR BACK AND FORTH 3. O-ring 1. Apply engine oil on the chain tensioner plunger Timing Chain Tensioner Inspection before installation. Check chain tensioner housing and screw plug for 2.
  • Page 135 Section 02 ENGINE, CVT AND GEARBOX Subsection 11 (TIMING CHAIN (650)) 8. Tighten the chain tensioner screw plug. CAMSHAFT TIMING GEARS Camshaft Timing Gear Removal TOP END 1. Remove valve cover, refer to subsec- tion. 2. Set applicable piston to TDC ignition and lock CAMSHAFT TIM- magneto flywheel.

  • Page 136: Timing Chain Tensioner

    Section 02 ENGINE, CVT AND GEARBOX Subsection 11 (TIMING CHAIN (650)) 4. Properly align tube of camshaft timing tool with machined radius on cylinder head. tmr2013-069-013_a 1. Timing chain 2. Camshaft timing gear 3. Printed marks on camshaft timing gear tmr2013-069-011_a 7.

  • Page 137: Required Tool

    Section 02 ENGINE, CVT AND GEARBOX Subsection 11 (TIMING CHAIN (650)) tmr2011-045-011_a vmr2015-033-006_a TYPICAL 1. CPS 1. Cylinder head base 2. Screw 2. Marks on timing gear of the opposite cylinder 5. Set rear piston no. 2 to TDC ignition by turning Camshaft Timing Piston No.
  • Page 138 Section 02 ENGINE, CVT AND GEARBOX Subsection 11 (TIMING CHAIN (650)) 3. To set front piston no. 1 to TDC ignition turn crankshaft 280° counterclockwise. REQUIRED TOOL Allen key 14 mm vmr2007-037-008_b PISTON NO. 2 AT TDC 1. Piston no. 2 identifier 2.

  • Page 139: Magneto System

    Section 02 ENGINE, CVT AND GEARBOX Subsection 11 (TIMING CHAIN (650)) vmr2015-033-008_a MAGNETO COVER 1. Crankshaft TDC position tool installed in CPS bore tmr2011-045-003_c TYPICAL - PISTON AT TDC IGNITION NOTICE Tool must be fully inserted. 1. Printed marks on camshaft timing gear 2.

  • Page 140: Timing Chain Inspection

    Section 02 ENGINE, CVT AND GEARBOX Subsection 11 (TIMING CHAIN (650)) 3. Refer to following procedures in this subsection and remove following parts: – Chain tensioner – Camshaft timing gear. 4. Remove timing chain guide (tensioner side) and lower timing chain guide. tmr2011-045-015_a 1.

  • Page 141: Timing Chain Guide

    Section 02 ENGINE, CVT AND GEARBOX Subsection 11 (TIMING CHAIN (650)) Timing Chain Guide Inspection (Tensioner Side) Check timing chain guide for wear, cracks or de- formation. Replace if necessary. Timing Chain Guide Installation (Tensioner Side) vmr2006-044-018_a 1. Timing chain The installation is the reverse of the removal pro- If chain is excessively worn or damaged, replace cedure.

  • Page 142: Bottom End

    Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) BOTTOM END (650) SERVICE TOOLS Description Part Number Page 529 036 031 ......... 239 CRANKCASE SUPPORT MAG/PTO ..........529 035 617 ......... 242 CRANKSHAFT LOCKING BOLT............. 529 036 028 ......... 231–232 DRIVE SHAFT OIL SEAL INSTALLER ...........
  • Page 143 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) ENGINE DRIVE SHAFT Engine oil 10 ± 1 N•m (89 ± 9 lbf•in) Loctite 767 (antiseize lubricant) Petamo grease Loctite 5910 Engine oil Loctite 10 ± 1 N•m 5910 (89 ±...
  • Page 144 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) CRANKCASE AND PTO COVER 10 ± 1 N•m (89 ± 9 lbf•in) 10 ± 1 N•m (89 ± 9 lbf•in) Loctite 648 Loctite 648 Engine oil 25 ± 3 N•m (18 ±...
  • Page 145 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) CRANKSHAFT See torquing procedure inside Engine See torquing procedure inside Engine oil = Component must be replaced when removed. vmr2015-120-003_a vmr2015-120...

  • Page 146: Engine Removal

    Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) GENERAL The engine drive shaft transmits the power from the gearbox to the front differential and is located inside the crankcase. IMPORTANT: Note position of parts on disas- sembly. This may help to find the root cause of a problem.
  • Page 147 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) tmr2011-014-009_a 1. Bearing cover 2. Drive shaft bearing Check drive shaft for cracks, bend, pitting or other F12R17A visible damages. Do not apply in excess as it will spread out inside Check drive shaft splines for wear or damages.

  • Page 148: Front Oil Seal

    Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) Front Bearing Cover Installation tmr2013-018-005_a 1. Bearing cover 2. Oil seal tmr2011-014-004_a 5. Install drive shaft oil seal using the following FRONT OF ENGINE tool. 1. Water pump cover 2.
  • Page 149 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) 3. Remove O-ring from bearing cover. vmr2013-018-002_a 1. Bearing cover 2. Oil seal vmr2013-018-003_a 3. Oil seal installer 1. Bearing cover 2. O-ring 6. Install O-ring in rear bearing cover. 4.
  • Page 150 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) PTO COVER NOTICE Avoid scoring surfaces with tool. PTO Cover Removal CONTINUOUSLY VARIABLE TRANS- 1. Refer to MISSION (CVT) subsection to remove the fol- lowing parts: – CVT cover –...

  • Page 151: Service Limit

    Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) Plain Bearing Replacement WARNING (PTO Cover) Always wear skin and eye protection. Chem- icals can cause skin rash, skin burns and se- Plain Bearing Removal vere eye injury. NOTICE Unless otherwise instructed, never use a hammer to install plain bearings.

  • Page 152: Drive Gears

    Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) Tighten PTO cover screws following the sequence illustrated. vmr2006-044-008_a 1. Mark position of oil bore on PTO cover 2. Mark position of oil bore on plain bearing remover/installer NOTICE Misalignment of plain bearing and PTO cover oil bores will prevent proper oil supply to plain bearings.
  • Page 153 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) tmr2011-014-014_a tmr2011-014-016_a 1. Breather gear 1. Thrust washer 2. Intermediate gear 2. Water pump drive gear 3. Water pump drive gear 3. Needle pin 4. Oil pump drive gear Drive Gears Inspection Drive Gears Removal Intermediate Gear/Oil Pump Drive Gear/Water...
  • Page 154 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) CRANKCASE – Oil cooler – Oil pump drive gear. Crankcase Disassembly NOTE: Oil pump removal from crankcase is not PERIODIC MAINTENANCE PROCE- 1. Refer to necessary, but recommended to see condition of DURES subsection and carry out the following: oil pump.

  • Page 155: Tion System

    Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) tmr2011-014-023_a 1. Engine oil strainer 2. Retaining plate tmr2011-014-022 3. Screws NOTE: During disassembly, do not damage the Crankcase Cleaning sealing surfaces of the crankcase halves. Clean crankcase using a part cleaner. 15.
  • Page 156 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) tmr2011-014-025_a vmr2006-044-025_a PRESS PLAIN BEARINGS OUTSIDE 1. Plain bearing 1. Crankcase half 2. Oil bore 2. Plain bearing remover/installer A. Measure plain bearing inside diameter 3. Crankcase support sleeve (P/N 529 036 031) Plain Bearing Installation (Main) MAIN BEARING INSIDE DIAMETER (PTO/MAG) SERVICE LIMIT...
  • Page 157 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) tmr2011-014-028_a 1. Plain bearing joint 2. Oil bore tmr2011-014-026_a 3. Crankcase half PTO (inside surface) 1. Oil bore position marked on plain bearing remover/installer 2. Plain bearing oil bore Crankcase Assembly 3.

  • Page 158: Camshaft Timing

    Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) CRANKCASE SCREWS 10 N•m ± 1 N•m Tightening torque - M6 (89 lbf•in ± 9 lbf•in) 25 N•m ± 3 N•m Tightening torque - M8 (18 lbf•ft ± 2 lbf•ft) CRANKSHAFT vmr2015-033-005_a 1.
  • Page 159 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) tmr2011-014-034_a 1. Screwdriver vmr2015-033-007_a 7. Lock crankshaft. 1. Allen key 14 mm REQUIRED TOOL NOTE: When the piston no. 2 is at TDC, the num- ber 2 piston index mark on the magneto flywheel CRANKSHAFT LOCKING and the notch on the magneto cover are aligned.

  • Page 160: Connecting Rod Big End Axial Play

    Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) vmr2006-044-036_a 1. Crankshaft timing gears Crankshaft Axial Play NOTE: Axial play must be measured before split- ting the crankcase. Measure axial play on PTO end of crankshaft using vmr2006-044-037_a a dial indicator.

  • Page 161: Crank Pin Diameter

    Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) vmr2007-037-003_a 1. Connecting rod screws vmr2006-044-039_a A. Connecting rod big end plain bearing 2. Measure crankpin. Compare to inside diameter of connecting rod big end. CONNECTING ROD BIG END DIAMETER SERVICE LIMIT 40.100 mm (1.5787 in) If connecting rod big end diameter is out of spec-...
  • Page 162 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) vmr2006-044-041_a 1. Micrometer 2. Crankshaft PTO side main bearing journal vmr2006-044-042_a CRANKSHAFT MAIN BEARING JOURNAL 1. Micrometer 2. Crankshaft journal (PTO support bearing) DIAMETER (MAG/PTO SIDE) CRANKSHAFT JOURNAL DIAMETER 42.016 mm to 42.040 mm (1.6542 in to 1.6551 in) (PTO COVER BEARING)

  • Page 163: Required Tools

    Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) R1004motr20A 1. Half plain bearing of connecting rod big end 2. Mating surface of the connecting rod 3. Joining surface of plain bearing in line with connecting rod groove Oil the plain bearing surface of the connecting rod and crankshaft pin before installation.
  • Page 164 Section 02 ENGINE, CVT AND GEARBOX Subsection 13 (BOTTOM END (650)) vmr2006-044-035_a 1. Crankcase half MAG side 2. Connecting rod cylinder 1 3. Connecting rod cylinder 2 vmr2015-120...

  • Page 165: Continuously Variable Transmission (Cvt)

    Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650) SERVICE TOOLS Description Part Number Page 529 036 238 ......278, 285, 291 CLUTCH HOLDER................. 529 035 746 ......... 278 CLUTCH PULLER ................529 036 098 .........
  • Page 166 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) Loctite 767 Isoflex grease Topas NB 52 engine Pulley flange cleaner 1000 engine Loctite 243 10 ± 1 N•m (89 ± 9 lbf•in) Isoflex grease Topas NB 52 5 ±...
  • Page 167 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) 5 ± 1 N•m (44 ± 9 lbf•in) 2.5 ± 0.5 N•m (22 ± 4 lbf•in) 7 ± 1 N•m (62 ± 9 lbf•in) 2.5 ± 0.5 N•m (22 ±...
  • Page 168 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) GENERAL 3. Reinstall drain reservoir. NOTICE NOTE: For a better understanding, the following If an appreciable amount of water or illustrations are taken with engine out of vehicle. any debris entered the CVT cover, CVT must be To perform the following instructions, it is not nec- cleaned and inspected.

  • Page 169: Drive Belt

    Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) Drive Belt Inspection CVT COVER SCREWS For drive belt inspection refer to DRIVE BELT 7 N•m ± 0.8 N•m Tightening torque INSPECTION in the PERIODIC MAINTENANCE (62 lbf•in ± 7 lbf•in) PROCEDURES subsection.
  • Page 170 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) CAUTION Sliding sheave of drive pulley is spring loaded. vmr2006-021-011_a 1. Mark on drive pulley sliding sheave 2. Mark on governor cup 3. Lock the drive pulley. tmr2011-015-004_a Step 1: Push REQUIRED TOOL...
  • Page 171 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) NOTICE Always replace all rollers as a set. Partly worn rollers may cause damage to the CVT system. tmr2011-015-005_a 1. Governor cup 2. Slider shoes 3. Sliding sheave vmr2006-021-015_a 4.
  • Page 172 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) Remove centrifugal lever and both thrust wash- ers. Vmr2012-018-024_a 1. Lock nut vmr2006-021-021_a 2. Centrifugal lever pivot bolt 1. Springs 3. Centrifugal lever 2. Spring sleeves 4. Thrust washers Fixed Sheave Drive Pulley Cleaning Clean pulley faces and shaft with fine steel wool...
  • Page 173 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) Check slider shoes for visible wear and replace if damaged. NOTE: If necessary, use a screwdriver to remove slider shoes. vmr2015-121-002_a 1. Taper of fixed sheave Only use petrol base cleaner when cleaning slid- ing sheave bushings.
  • Page 174 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) tmr2011-015-007_a 1. Centrifugal lever 2. Bushing A. Bushing inner diameter CENTRIFUGAL LEVER BORE DIAMETER 6.035 mm to 6.078 mm (.238 in to .239 in) 6.200 mm (.244 in) SERVICE LIMIT vmr2006-021-024_a A.
  • Page 175 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) Check for any marks on fixed sheave plate. Re- SLIDING SHEAVE LARGE BUSHING place if necessary. 55.000 mm to 55.040 mm Spring (2.165 in to 2.167 in) Measure spring free length and squareness.
  • Page 176 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) Lubricate springs, spring sleeves and between one way clutch bearings using recommended product. REQUIRED PRODUCT ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021) Sliding Sheave Install centrifugal levers with their thrust washers. NOTICE Centrifugal levers must move easily after installation.

  • Page 177: Driven Pulley

    3. Thrust washer WARNING Never substitute conical spring washer and/or screw with aftermarket parts. Al- ways use genuine BRP parts. Lock the drive pulley as per removal procedure. Tighten drive pulley screw to specification. NOTICE Never use any type of impact wrench for drive pulley installation.
  • Page 178 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) Vmr2012-018-011_a 1. Driven pulley screw 2. Thrust washer 6. Remove the driven pulley with the spring and vmr2006-021-035_a 1. Retaining ring the cam. 2. Torque gear 3. Fixed sheave of driven pulley NOTE: The following procedure is not necessary except if ball bearing or shaft must be removed.
  • Page 179 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) Using a paper towel with PULLEY FLANGE , clean countershaft CLEANER (P/N 413 711 809) end and shaft bore. NOTICE To avoid damage, make sure cleaner does not contact the countershaft oil seal. R610tran18A 1.
  • Page 180 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) REQUIRED TOOL BUSHING INNER DIAMETER Dial bore gauge 30.060 mm to 30.100 mm (1.183 in to 1.185 in) MEASURING POINT SERVICE LIMIT 30.200 mm (1.189 in) At least 5 mm (1/4 in) from bushing edge Check torque gear for visible damage and cracks.
  • Page 181 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) vmr2006-021-042_a 1. Ball bearing 2. Fixed sheave of driven pulley NOTICE Do not use a hammer, bearing must vmr2006-021-041_a be pressed in only. 1. Caliper 2. Sliding sheave 3.
  • Page 182 Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) Driven Pulley Installation For installation, reverse the removal procedure. Pay attention to the following details. Place O-ring on countershaft splines and move it and the distance sleeve into position. NOTICE Chamfer on inside diameter of the distance sleeve must face to gearbox side.

  • Page 183: Specification

    Section 02 ENGINE, CVT AND GEARBOX Subsection 15 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (650)) TIGHTENING SEQUENCE (DRIVEN PULLEY SCREW) 20 N•m ± 1 N•m STEP 1 (15 lbf•ft ± 1 lbf•ft) STEP 2 180° ± 5° Check driven pulley end play. SPECIFICATION Driven pulley end play 0 mm (0 in)
  • Page 184 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) GEARBOX AND COUPLING UNIT SERVICE TOOLS Description Part Number Page 529 036 117 ......... 332 BLIND HOLE BEARING PULLER SET........... 529 036 222 ......... 325 COUNTERSHAFT OIL SEAL PUSHER .......... 529 036 166 .........
  • Page 185 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) GEARBOX COMPONENTS AND COUPLING MECHANISM Petamo grease 10 ± 1 N•m 3 ± 0,3 N•m (89 ± 9 lbf•in) (27 ± 3 lbf•in) Loctite 5910 10 ± 1 N•m (89 ±...

  • Page 186: Troubleshooting

    Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) GENERAL 3. Damaged or worn gears. - Inspect gears for damages or missing teeth. Re- place respective gears. GEARBOX OVERVIEW GEAR INDICATION FAILS 1. Defective gearbox position sensor (GBPS). - Perform a gearbox position sensor test.
  • Page 187 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) 3. Turn ignition switch ON. 4. Set emergency engine stop switch to RUN. 5. Back-probe the VSS connector. REQUIRED TOOL FLUKE RIGID BACK-PROBE (P/N TP88) Tmr2011-016-006_a 1. Right housing of gearbox 2.
  • Page 188 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) VEHICLE SPEED SENSOR SIGNAL TEST RESULT TEST PROBES (WHILE ROTATING WHEELS) Alternate reading PIN B PIN C between battery WHITE wire BLACK wire voltage and 0 Vdc NOTE: Since we measure pulsating voltage, the numeric display will continuously change.
  • Page 189 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) – Setting tab NOTE: The vehicle must be in movement to complete the procedure on R, H and L posi- – ECM tab. tions. GBPS Access BODY To reach the GBPS sensor, refer to and re- move the following parts: –...
  • Page 190 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) GBPS Signal Wire Continuity Test IMPORTANT: Do not force to install GBPS if shaft flat is not properly aligned. If alignment is incor- Unplug ECM connector and connect it to the rect, check shift rod adjustment.
  • Page 191 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) If the vehicle harness is good, replace the actua- SWITCH SWITCH WIRE RESISTANCE tor. POSITION BLACK/ Engine Actuator Removal Infinite (OL) BEIGE ground NOTE: Before beginning any servicing on the ac- tuator, make sure the vehicle is in 4WD position.
  • Page 192 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Tmr2011-016-026_a Tmr2011-016-025_a 1. Coupling fork in 4WD position 1. Actuator 2. Washer Align the actuator fork with the pin on coupling 3. Screw fork then push the actuator in the housing. See Pull the actuator out of housing.
  • Page 193 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) If the front propeller shaft turns, the actuator is not installed correctly. Remove actuator and reinstall Set ignition switch to ON. Set emergency engine stop switch to RUN. Select the 2WD position.
  • Page 194 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Use a suitable tube with the proper diameter to install the oil seal. If gearbox housing is apart, use following tools for shift shaft oil seal installation. REQUIRED TOOL OIL SEAL INSTALLER (GEARBOX) (P/N 529 035 758) HANDLE (P/N 420 877 650)

  • Page 195: Removal And Installation

    Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) GEARBOX Gearbox Removal ENGINE Remove engine from vehicle. Refer to REMOVAL AND INSTALLATION for the proce- dure. CONTINUOUSLY VARIABLE TRANSMIS- Refer to SION (CVT) subsection to remove following parts: –...
  • Page 196 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Tmr2011-016-039_a Tmr2011-016-044 RH SIDE OF ENGINE POSITION FOR SOFT HAMMER 1. Nut M8 Pull gearbox to separate it from engine. Gearbox Disassembly NOTE: During gearbox disassembly, inspect the condition of each part closely.
  • Page 197 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Tmr2011-016-074_a Tmr2011-016-046_a 1. Index lever 1. Bearing pin 2. Index washer 2. Reverse intermediate gear 3. Shift drum 3. Needle bearing 4. Thrust washers Remove the index lever with washer, step ring and spring.
  • Page 198 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) vmr2012-020-007_a Tmr2011-016-048_a 1. Snap ring 2. Free pinion (HIGH range gear) 1. Main shaft assembly 3. Free pinion (LOW range gear) 2. Shift fork 4. Needle bearing 5. Main shaft assembly Remove shifting sleeve (HIGH range gear) and shift fork.
  • Page 199 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Tmr2011-016-071_a 1. Shift shaft assembly Remove screw retaining the shifting intermediate Tmr2011-016-031_a gear. 1. 5 screws M8 x 55 2. 2 screws M6 x 85 3. 2 screws M6 x 55 4.
  • Page 200 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Tmr2011-016-034_a 1. Output shaft 2. coupling sleeve 3. Soft hammer Tmr2011-016-076_a 1. Shift fork shaft Remove hexagonal screw, coupling fork shaft and 2. Shift fork 3. Shift drum coupling fork from right cover.
  • Page 201 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Tmr2011-016-052_a 1. Ball bearing countershaft 2. Right cover Tmr2011-016-042_a 1. Countershaft 2. Distance sleeve 3. O-ring Gearbox Bearings If necessary heat housing up to 100°C (212°F) be- fore removing ball bearings. WARNING Clean oil, outside and inside, from housing before heating.
  • Page 202 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Gearbox Inspection Always verify for the following when inspecting gearbox components: – Gear teeth damage – Worn or scoured bearing surfaces – Rounded engagement dogs and slots – Worn shift fork engagement groove –...
  • Page 203 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Tmr2011-016-057_a 1. Bearing pin A. Outer diameter BEARING PIN OUTER DIAMETER Tmr2011-016-059_b A. Bearing journal MAG side 24.987 mm to 25.000 mm B. Free pinion bearing C. Bearing journal CVT side (.984 in to .984 in) 24.977 mm (.9833 in) SERVICE LIMIT...
  • Page 204 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Output Shaft Check output shaft and its gear for cracks, bend, pitting or other visible damages. Check output shaft splines for wear or other dam- ages. Check if the output shaft bearings turn freely and smoothly.
  • Page 205 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) vmr2006-022-032_a 1. Coupling fork 2. Micrometer vmr2012-020-011_a COUPLING FORK CLAW THICKNESS 1. Main shaft 2. Free pinion (REVERSE range gear) 4.95 mm to 5.05 mm 3. Snap ring (.195 in to .199 in) 4.
  • Page 206 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Tmr2011-016-075_b vmr2012-020-006_a 1. Index spring 1. Shifting sleeve (HIGH range gear) 2. Step ring 2. Shift fork 3. Index lever 4. Washer Carefully fit main shaft assembly with shift fork 5.

  • Page 207: Loctite Chisel

    Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Install coupling fork, coupling fork shaft and Clean all metal components in a solvent. hexagonal screw in right cover before applying Gearbox housing mating surfaces are best sealant to the mating surface. cleaned using a combination of LOCTITE CHISEL and a brass...
  • Page 208 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) At installation of left cover, engage parking lock lever slot onto index washer pin. Tmr2011-016-067_a COUNTERSHAFT END CVT SIDE 1. O-ring 2. Distance sleeve 3. Countershaft end CVT side Right Cover Tmr2011-016-065_a Apply sealing compound on mating surfaces of...
  • Page 209 Section 02 ENGINE, CVT AND GEARBOX Subsection 17 (GEARBOX AND COUPLING UNIT) Before gearbox installation check O-ring in bearing cover if brittle, hard or damaged. Replace if nec- essary. Tmr2011-016-040_a 1. Bearing cover 2. O-ring PERI- After installation, refill gearbox oil. Refer to ODIC MAINTENANCE PROCEDURES vmr2015-123...
  • Page 210 Section 02 ENGINE, CVT AND GEARBOX Subsection 18 (SHIFTER) SHIFTER Loctite 243 5 ± 1 N•m (44 ± 9 lbf•in) 10 ± 2 N•m (89 ± 18 lbf•in) 9 ± 1 N•m (80 ± 9 lbf•in) = Component must be replaced when removed. vmr2015-124-001_a vmr2015-124...
  • Page 211 Section 02 ENGINE, CVT AND GEARBOX Subsection 18 (SHIFTER) PROCEDURES SHIFT LEVER Shift Lever Access BODY 1. Refer to subsection and remove the fol- lowing components: – Seat – Console – RH side panel. Shift Lever Removal SHIFT 1. Remove body parts as required. Refer to LEVER ACCESS in this subsection.

  • Page 212: Shift Rod

    Section 02 ENGINE, CVT AND GEARBOX Subsection 18 (SHIFTER) 5. Turn rod adjuster to center shift lever in neutral notch. – Ensure there is the same threaded length each side of rod adjuster. – Be aware that a nut has LH threads. vmr2012-021-005_a SHIFT LEVER HANDLE ALIGNMENT 1.
  • Page 213 Section 02 ENGINE, CVT AND GEARBOX Subsection 18 (SHIFTER) vmr2012-021-008_a vmr2012-021-008_c 1. Remove nut 1. Shift plate nut 3. Trace an index mark on shift plate and shift 5. Remove shift plate. shaft. Shift Plate Inspection Check shift plate for: –...

  • Page 214: Tightening Torque

    Section 02 ENGINE, CVT AND GEARBOX Subsection 18 (SHIFTER) vmr2012-021-010_a SHIFT PLATE ANGLE FROM THE SHOWN RIB 1. "ATV OUT" marking this side A. 34° Ensure that shift shaft protrudes shift plate as per illustration. vmr2012-021-011_a 1. Shift shaft end 2.

  • Page 215: Engine Management System (Ems)

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS)) ENGINE MANAGEMENT SYSTEM (EMS) GBPS INJ 1 INJ 2 IACV MAPTS IGN COIL COOLING FAN IGN SW START SW STARTER SOLENOID FUEL PUMP vmr2015-125-001_a vmr2015-125...
  • Page 216 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS)) HIC2 HIC1 IACV INJ1 MAPTS INJ2 GBPS vmr2015-125-002_a ABBREVIATION DEFINITION Ignition coil Crankshaft position sensor Coolant temperature sensor Electronic control module GBPS Gear box position sensor vmr2015-125...
  • Page 217 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS)) ABBREVIATION DEFINITION Harness interconnect 1 HIC1‡ HIC2‡ Harness interconnect 2 IACV Idle air control valve INJ1 Injector 1 (front) INJ2 Injector 2 (rear) MAPTS Manifold absolute pressure and temperature sensor 4WD Actuator Oil pressure switch 4WD Signal...

  • Page 218: Fault Codes

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS)) tomer information, and other engine information, These performance-reduced modes allow the even when the battery is removed from the vehi- rider to go back home which would not be oth- DIAGNOSTIC AND cle.

  • Page 219: Controller Area Network (Can)

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 02 (CONTROLLER AREA NETWORK (CAN)) CONTROLLER AREA NETWORK (CAN) GENERAL SYSTEM DESCRIPTION The CAN (Controller Area Network) protocol is an ISO standard for serial data communication. The CAN bus links the ECM, multifunction gauge and DPS module together so that they can communi- cate to each other and interact as required.

  • Page 220: Service Tools

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.) COMMUNICATION TOOLS AND B.U.D.S. SERVICE TOOLS Description Part Number Page 710 000 851 ......... 355 MPI-2 DIAGNOSTIC CABLE............529 036 018 ......... 355 MPI-2 INTERFACE CARD .............. SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page...

  • Page 221: Number Of Modules

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.) Message Box: "Some of the Information MODEL NUMBER OF MODULES Normally Displayed..." Models If the following message box is displayed in (ECM and multifunction without DPS B.U.D.S.: gauge) Models with (ECM, DPS and multifunction gauge) smr2009-028-016 1.

  • Page 222: Interface Card

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.) Connecting the PC to the Vehicle WARNING If the computer you are using is connected to the 110 Vac power outlet, there is a poten- tial risk of electrocution when working in con- tact with water.

  • Page 223: Service Bulletins

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.) For more information pertaining to the use of the When clicking on the Read Data button, B.U.D.S. B.U.D.S., use its Help menu which contains de- will read the modules through CAN bus. tailed information on its functions.
  • Page 224 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.) vmr2006-012-100_ben After clicking on Write Data, the following mes- sage may appear. lmr2010-019-001 TYPICAL - MODULE SUBMENU LIST 1. If the Update option is greyed out, no update file is available for this module. 2.
  • Page 225 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (DIAGNOSTIC SYSTEM AND FAULT CODES) DIAGNOSTIC SYSTEM AND FAULT CODES GENERAL A message may also be displayed to provide ad- ditional information related to the fault that turned MONITORING SYSTEM on the pilot lamp. Refer to the following chart. NOTE: In some cases, the CHECK ENGINE mes- The Engine Management System (EMS) features sage can be displayed along with other messages.
  • Page 226 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (DIAGNOSTIC SYSTEM AND FAULT CODES) Limp Home Mode Fault Code States When a major component of the Engine Man- agement System (EMS) is not operating properly, Fault codes have 3 possible states: limp home mode will be set. –...

  • Page 227: Communication Tools

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (DIAGNOSTIC SYSTEM AND FAULT CODES) by the ECM and multifunction gauge, which may become active or occurred if the monitoring sys- tem detects an applicable fault. These codes can be viewed in B.U.D.S. How to Display Fault Codes in the Multifunction Gauge NOTE: A fault code must be in an "Active"...
  • Page 228 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT NOMENCLATURE COLUMN INFORMATION Fault code number. When 2 stars (**) precedes the code, detailed conditions when the Code fault occurred, can be displayed by clicking the "More details" button Display the fault state (active, occurred, State inactive)
  • Page 229 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (DIAGNOSTIC SYSTEM AND FAULT CODES) rmr2008-039-009 FAULTS PAGE TAB, CLEAR OCCURRED FAULTS 4. Click YES on the following message box. rmr2011-021-050_a 1. Click here vbl2012-007-013 The following message will appear. rmr2011-070-002_a MORE DETAILS PAGE vbl2012-007-012 1.
  • Page 230 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (DIAGNOSTIC SYSTEM AND FAULT CODES) HISTORY PAGE DESCRIPTION ITEM INFORMATION Display the minimum and maximum Minimum/ values encountered. Click "Clear Maximum Min/Max" to reset the values Display the time proportion in what Run time mode the engine was running in Display the RPM range proportion in profile...
  • Page 231 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (DIAGNOSTIC SYSTEM AND FAULT CODES) GENERAL GUIDELINES TO SOLVE FAULT CODES CONDITION ACTION Use B.U.D.S. to: Read fault codes. Display "Active" faults to see components currently not operating normally. Display "Occurred" faults to troubleshoot intermittent problems. Monitor system(s), sensor(s), switches and actual conditions.

  • Page 232: Fault Code Table

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (DIAGNOSTIC SYSTEM AND FAULT CODES) GENERAL GUIDELINES TO SOLVE FAULT CODES CONDITION ACTION May have been generated due to a system or component that was momentarily operating outside normal parameters. May be generated when disconnecting and reconnecting a component, replacing a burnt fuse, or may be due to a momentary high or low voltage.

  • Page 233: Diagnostic And Fault Codes

    Subsection XX (DIAGNOSTIC AND FAULT CODES) DIAGNOSTIC AND FAULT CODES GENERAL FAULT CODE TABLE PCODE MODULE DESCRIPTION CAUSE ACTION 1- Go to Activations - SCM and start Rear Test routine. If the test passed, the system is working properly. Check the harness and connection to see a potential source of intermittent dysfunction, if nothing is found clear the occurred fault and...
  • Page 234 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Go to Activations - SCM and start Rear Test routine. Verify that the Shock Absorber Pressure and the Auxiliary Line Pressure correlates in BUDS. If the test is done with no fault, the system is working properly.
  • Page 235 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Check for leaks. If no leak found go to next action step. 2- Go to Activations - SCM and start Rear Test routine. If the test is done with no fault, the system is working properly.
  • Page 236 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Disconnect the air line to the rear shocks. Go to Activations - SCM and start Rear Test routine. If the air blows out the system is working properly. Check the harness and connection to see a potential source of intermittent dysfunction, if nothing is found clear the occurred...
  • Page 237 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Check for leaks. If no leak found go to next action step. 2- Go to Activations - SCM and start Rear Front routine. If the test is done with no fault, the system is working properly.
  • Page 238 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Disconnect the air line from the front shocks. Go to Activations - SCM and start Front Test routine. If the air blows out of both shocks the system is working properly. Check the harness and connection to see a potential source of intermittent dysfunction, if nothing is found clear...
  • Page 239 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Make sure sensor connector is fully inserted. Measure voltage between harness connector pins 1 and 3 . (Expected value: 4.8 to 5.1 volts) Measure resistance from Damaged sensor, connector: ECM-F3 to MAPTS-2 Manifold Air damaged circuit wires, (Expected value: <...
  • Page 240 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Make sure sensor connector is fully inserted. Measure voltage between harness connector pins 1 and 3 . (Expected value: 4.8 to 5.1 volts) Measure resistance from connector: ECM-F3 to MAPTS-2 Intake Air Damaged sensor, wires (Expected value: <...
  • Page 241 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Disconnect the sensor. Measure resistance from connector: ECM-F4 to CTS-1 (Expected value: < 2 ohms) Engine Coolant Temperature Disconnected sensor, or Measure resistance from P0118 Sensor 1 circuit sensor resistance too High. connector: ECM-C3 to CTS-2 High (Expected value: <...
  • Page 242 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check fuse Measure voltage between harness connector PF1-12B and ground (Expected value: 11 to 13 volts) Measure voltage between harness Blown fuse, damaged connector PF1-11B and ground Fuel Pump or disconnected (Expected value: 11 to 13 volts) circuit shorted to...
  • Page 243 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Disconnect injector 1 Measure resistance between injector pin 1 and 2 (Expected value = 14 to15 ohms). Damaged injector, Measure resistance from Cylinder 1 injector damaged circuit wires, harness connector: INJ1-1 to P0262 shorted to battery damaged connector or...
  • Page 244 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check fuse Disconnect relay. Measure resistance between Blown fuse, damaged terminals 85 and 86 on relay. or disconnected relay, (Expected value: 70 to 90 Ohms) Radiator cooling damaged circuit wires P0480 Measure resistance between fan relay...
  • Page 245 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Measure resistance between harness connector OPS and ground When engine stopped. Damaged switch, (Expected value < 2 ohms) Engine oil damaged circuit wires, Measure resistance between P0523 pressure sensor damaged connector, harness connector OPS and sticking...

  • Page 246: Calibration Fault

    Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Measure battery voltage with engine stopped. (Expected value: 11 to 13 volts) Measure battery voltage with system voltage Rectifier failure, damaged engine Running at 3500RPM. P0563 high circuit wires or connection. (Expected value: 13 to 14.7 volts) Check connections on voltage regulator.
  • Page 247 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check start button, Check Run/Stop button, check if free weeling diode is in the good way. Disconnect starter solenoid relay Damaged relay, Measure resistance from harness Danaged start switch, Starter Relay connector: ECM-L3 to SS2 damaged circuit wires,...
  • Page 248 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check fuse Disconnect Accessory relay and Lights relay & turn key switch (on w/lights) Measure voltage between harness connector PF1-10E and ground. diagnosis related to (Expected value: 11 to 13 volts) Accessories or Light relay, Measure voltage between harness Blown fuse, damaged...
  • Page 249 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check fuse Disconnect radiator fan relay Measure voltage between harness Blown fuse, damaged or connector PF1-3D and ground. Radiator fan disconnected fan relay, (Expected value: 11 to 13 volts) circuit shorted P0691 damaged circuit wires,...
  • Page 250 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Verify that gear position information change when you change the position of gear on vehicle. Disconnect GBPS Measure voltage between harness Gear position connector GBPS-1 and GBPS-3. sensor shorted to (Expected value: 4.8 to 5.1 volts) P0707 ground, or open...
  • Page 251 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Power output Motor short circuit or Reset fault, If fault re-occur, replace P1F01 overload power output failed DPS unit Measure battery voltage with engine stopped. (Expected value: 11 to 13 volts) Power output High voltage at the unit Measure battery voltage with...
  • Page 252 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Open the ECM Activation page in BUDS Perform an ignition coil activation and check if ignition coil is reacting as expected Damaged ignition coil, Measure resistance from harness Cyllinder 2 damaged circuit wires, connector: ECM-M1 to BA-1 P2303...
  • Page 253 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Go to Activations - SCM and start Test routine. Verify that the Shock Absorber Pressure and the Auxiliary Line Pressure correlates in BUDS. If the test is done with no fault, the system is working properly.
  • Page 254 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Check for leaks. If no leak found go to next action step. 2- Go to Activations - SCM and start Test routine. If the test is done with no fault, the system is working properly.
  • Page 255 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Go to Activations - SCM and start Test routine. If the test passed, the system is working properly. Check the harness and connection to see a potential source of intermittent dysfunction, if nothing is found clear the occurred fault and no more actions have to be done.
  • Page 256 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Disconnect MPI2 from DB connector. Measure resistance between DB-1 and DB-2 (Expected value = 50 to 70 ohms). CAN bus off, no Damaged circuit wires or Measure resistance U0073 messages damaged CLUSTER pins.
  • Page 257 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check for Cluster fault or ECM fault Measure voltage between harness connector CL-17 and ground. (Expected value = 11 to 13 volts) Disconnect MPI2 from DB connector. Measure resistance between DB-1 and DB-2 (Expected value = 50 to 70 ohms).
  • Page 258 Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Verify in Setting - Vehicle Configuration page is correctly set up. Variant coding Faulty variant coding U0400 SCM-XMR 2- If Update File is available reflash failure Faulty programming the SCM.

  • Page 259: Electronic Fuel Injection (Efi)

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) ELECTRONIC FUEL INJECTION (EFI) SERVICE TOOLS Description Part Number Page 529 036 166 ......... 371 ECM ADAPTER TOOL..............529 035 868 ......... 371 FLUKE 115 MULTIMETER ............295 000 070 ......... 377 OETIKER PLIERS................
  • Page 260 Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Fuel Rail Two fuel rails, one for each injector, are mounted on the intake manifold. The fuel rails, which are used to secure the injectors to the manifold, also provide to the injectors the fuel pressure that they receive from the fuel pump.

  • Page 261: Closed Throttle And Idle Actuator Reset

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2012-026-150_a vmr2006-014-064_b VERIFYING ENGINE RPM USING B.U.D.S. 1. Monitoring tab 1. Contact here 2. Engine RPM indication 2. Free-play here NOTE: The multifunction gauge and B.U.D.S. use Open throttle approximately one quarter then the same signal to provide the engine RPM indi- quickly release.

  • Page 262: Troubleshooting

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Start engine and make sure it operates normally When probing terminals, pay attention not to de- through its full engine RPM range. If fault codes form the terminals as this could cause a loose or DIAGNOSTIC SYSTEM AND appear, refer to intermittent connection that would be difficult to...

  • Page 263: Power Distribution

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) ECM Connector If voltage is not measured, check the following: – ECM fuse There is one connector connected to the ECM. It links: – Main relay – Engine harness – Wiring and connections, refer to the WIRING DIAGRAM –...

  • Page 264: Ecm Replacement

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) 5. Reconnect DPS1 to DPS module, ECM Removal NOTE: If a new ECM is to be installed, first read ECM REPLACEMENT the procedures in in this subsection. 1. Disconnect battery cables. NOTICE Always disconnect the BLACK nega- tive (–) battery cable first, then disconnect RED...
  • Page 265 Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2006-012-100_aen NOTE: Keep B.U.D.S. running while replacing ECMs. The data will remain stored in the PC computer as long as B.U.DS. is running. 3. Get the Data from the saved .mpem file. vmr2015-042-011_a 3.1 Click on the Open button.
  • Page 266 Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) – Model number 9. Click on the following tabs: – Customer. – History – Part Replacement – Add Part in History. 10. Enter the old ECM serial number in the Add Part In History window.

  • Page 267: Fuel Injector

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) FUEL INJECTOR ENGINE MANAGEMENT SYSTEM Refer to the subsection for component and connector loca- tions. Fuel Injector Leak Test Carry out the FUEL PUMP PRESSURE TEST detailed in the FUEL TANK AND FUEL PUMP sub- section.
  • Page 268 Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Fuel Injector Installation FUEL INJECTOR RESISTANCE TEST AT ECM ADAPTER The installation is the reverse of the removal pro- cedure. However, pay attention to the following. FUSE BOX RESISTANCE INJECTOR TERMINAL ADAPTER @ 20°C (68°F)

  • Page 269: Throttle Cable Adjustment

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Firmly push injector until it bottoms out. NOTE: Activate fuel pump a few times to built fuel pressure. Reinstall fuel rail. WARNING FUEL RAIL Perform a fuel pressure test and ensure that Fuel Rail Replacement FUEL TANK AND there is no leak.

  • Page 270: Throttle Body

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) CAUTION If there is no free-play at idle position, it may cause poor idling and starta- bility problems. Improper cable adjustment will cause strain on cable and/or damage cable bracket or throttle lever at handlebar. WARNING Make sure idle speed stopper contacts throt- tle cam when throttle lever is fully released at...
  • Page 271 Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) – Check if TPS is loose. – Check if idle air control valve is loose. – Check for corroded or damaged connectors. Throttle Body Cleaning 1. Check throttle body cleanliness using a flash- light.
  • Page 272 Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2006-014-060_b vmr2006-014-064_a 1. Throttle lever 2. Cable barrel Rotate throttle body into position and ensure to index throttle body tab with boot notch. 10. Remove barrel from cable. 11. Pull out throttle cable. 12.

  • Page 273: Throttle Position Sensor

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Tighten clamps. – Check throttle cable adjustment. Refer to THROTTLE CABLE in this subsection. – If throttle body was replaced, perform the Closed Throttle And Idle Actuator Reset pro- cedure. Refer to CLOSED THROTTLE AND IDLE ACTUATOR RESET in this subsection.

  • Page 274: Input Voltage Test

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Disconnect the ECM connector and connect to ECM adaptor. Using a multimeter, check resistance values as per following table. THROTTLE WIDE OPEN ECM ADAPTER IDLE THROTTLE POSITION POSITION RESISTANCE ( ) @ 20°C (68°F) 900-1600 2600-3100...
  • Page 275 Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Apply If resistance test of valve windings is good, check LOCTITE 243 (BLUE) (P/N 293 800 060) the TPS retaining screws, then torque to 3 N•m continuity of circuits as per following table. If not (27 lbf•in).

  • Page 276: Crankshaft Position Sensor (Cps)

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Clean all remaining parts and install the idle air If resistance value is incorrect, check or repair the control valve on the throttle body. connectors and the wiring harness between ECM connector and the CPS.
  • Page 277 Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) MANIFOLD ABSOLUTE – Monitoring tab PRESSURE AND TEMPERATURE – ECM tab. SENSOR (MAPTS) vmr2012-026-150_b TYPICAL 1. Monitoring tab 2. MAPTS pressure reading 3. Look for and take note of the MAPTS pressure reading while the engine is stopped.
  • Page 278 Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) MAPTS CONNECTOR MEASUREMENT VOLTAGE 5 Vdc If voltage test is good, replace the MAPTS. MAPTS If voltage test is not good, carry out the CIRCUIT CONTINUITY TEST (PRESSURE FUNC- TION) MAPTS Circuit Continuity Test (Pressure Function) 1.

  • Page 279: Engine Management

    Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) 529036166 Using a multimeter, recheck resistance value as per following table. ECM ADAPTER MEASUREMENT RESISTANCE @ 20°C (68°F) 2280 - 2740 vmr2006-012-004_e MAPTS TEMPERATURE SENSOR TEST RESULTS 1. MAPTS 2. Retaining screw RESULT SERVICE ACTION Disconnect MAPTS connector and remove the...
  • Page 280 Section 04 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) CTS Access CTS Replacement Remove the LH panel. Refer to BODY subsection. 1. Refer to CTS ACCESS in this subsection to reach CTS. Remove the CVT duct. 2. Remove heat shield over exhaust pipe to ex- EXHAUST SYSTEM pose CTS.

  • Page 281: Fuel Tank And Fuel Pump

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP SERVICE TOOLS Description Part Number Page 529 035 868 ......... 399 FLUKE 115 MULTIMETER ............529 036 023 ......... 393 FUEL HOSE ADAPTER..............529 035 899 ......... 401 FUEL PUMP NUT TOOL ...............
  • Page 282 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) = Component must be replaced when removed. vmr2015-130-100_a vmr2015-130...

  • Page 283: Fuel Pressure Test

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) GENERAL WARNING Fuel is flammable and explosive under cer- tain conditions. Ensure work area is well ven- tilated. Do not smoke or allow open flames or sparks in the vicinity. vmr2015-130-001_a WARNING FUEL TANK VENT SYSTEM...

  • Page 284: Required Tool

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) Fuel Filters The system comprises two levels of filtration: – A replaceable prefilter element attached to the bottom of the fuel pump. – A non-replaceable fine filter element that is in- tegral to the fuel pump module.

  • Page 285: Fuel System Pressure Test

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) vmr2012-028-006_b 1. Fuel pump relay fuse vmr2012-028-008_a 1. Fuel tank vent inlet hose 6. Release fuel pressure by running engine until it 2. Gauge connector runs out of gas. TIME WITHOUT 7.
  • Page 286 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) vmr2012-028-010_a PRESSURE GAUGE SETUP 1. Pressure gauge to fuel hose adapter 2. Fuel hose adapter to fuel rail 3. Fuel hose adapter to fuel pump pressure hose 10. Reinstall the fuel pump relay fuse (F15) in the forward fuse box.

  • Page 287: Troubleshooting

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) TROUBLESHOOTING FUEL SYSTEM DIAGNOSTIC FLOW CHART Fuel pump does not run Activate electric system to enable fuel pump Fuel pump runs for 2 sec. then stops Install fuel pressure gauge Check fuse.

  • Page 288: Fuel Hose And Oetiker Clamps

    PROCEDURES 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 vmr2012-028-006_b 1. Fuel pump relay fuse...
  • Page 289 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) vmr2012-028-014_a TYPICAL vmr2012-028-012_a 1. Battery support TYPICAL 2. Rear frame extension 1. Starter solenoid 2. Positive (+) battery cable to disconnect 12. Remove the upper mounting bolt from both 10.
  • Page 290 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) NOTE: When lifting up on the frame extension, the shock absorbers will fall backwards. vmr2015-130-003_a 15. Loosen the front 2 nuts and remove the 4 bolts retaining the frame extension. vmr2012-028-021_a TYPICAL 1.

  • Page 291: Fuel Pump

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) Fuel Pump Connector Access TIGHTENING TORQUE The fuel pump connector can be accessed from Fuel tank retaining 6.5 N•m ± 0.5 N•m under the RH rear fender, just above the forward screws (58 lbf•in ±...
  • Page 292 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) FUEL PUMP POWER WIRE TEST VOLTAGE TEST PROBES READING Fuel pump connector Battery ground Battery voltage Pin 3 If battery voltage is now read, check fuel pump ground circuit between fuel pump connector 5-FP-4 and battery ground.
  • Page 293 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) 3. Disconnect the following from the fuel pump: – Fuel pump electric connector – Fuel system vent hose – Fuel pump pressure hose. vmr2012-028-026_a FUEL PUMP REMOVAL 1. Fuel pump retaining nut 5.
  • Page 294 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) 2. Place gasket so that it is properly located be- TIGHTENING TORQUE tween fuel pump and fuel pump mounting neck 29 N•m ± 1 N•m on fuel tank. Fuel pump retaining nut (21 lbf•ft ±...

  • Page 295: Fuel Level Sender

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) 2. Unlock 3 tabs on strainer plastic ring. vmr2008-135-223_a NOTE: A non-serviceable filter is located within the fuel pump module. If it is clogged, replace fuel vmr2008-135-220_a pump. Step 1: Lift these tabs to unlock ring Step 2: Pull ring off pump inlet 6.
  • Page 296 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) FUEL LEVEL SENDER RESISTANCE TEST FUEL LEVEL SENDER INPUT VOLTAGE TEST RESISTANCE FUEL PUMP GAUGE BATTERY VOLTAGE FUEL LEVEL CONNECTOR CONNECTOR @ 20°C (68°F) Negative Pin 2 Full ± 1 terminal Pins 4 and 21 Empty...

  • Page 297: Maintenance Procedures

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) – Ensure inlet check valve is properly installed, re- FUEL TANK VENT VALVE INSTALLATION fer to in this subsection. – Test inlet check valve separately. If good, re- PERIODIC place the breather filter, refer to MAINTENANCE PROCEDURES Pressure Relief Valve Test...
  • Page 298 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) vmr2015-130-002_f vmr2015-130-002_f 1. Pressure relief valve flow direction arrow 1. Pressure relief valve flow direction arrow Fuel Tank Vent Valve Installation Inlet Check Valve Installation Ensure white portion of inlet check valve is to- wards the vent breather filter.

  • Page 299: Section 05 Electrical System

    Section 05 ELECTRICAL SYSTEM Subsection 01 (POWER DISTRIBUTION AND GROUNDS) POWER DISTRIBUTION AND GROUNDS GENERAL POWER DISTRIBUTION DIAGRAM COMMUNICATION CONNECTOR FUSE BOX 1 MAIN RELAY (R2) GAUGE FUSE BOX 2 - TAILLIGHTS - LICENSE PL IGNITION COIL BRAKE LIGHT RELAY (R8) FUEL INJECTORS VEHICLE SPEED SENSOR...

  • Page 300: Fuse Identification

    Section 05 ELECTRICAL SYSTEM Subsection 01 (POWER DISTRIBUTION AND GROUNDS) FUSE BOX 1 vmr2012-028-006_e FUSES FUSE IDENTIFICATION 10 A 25 A Fuse 30 A 15 A 15 A Jumper 15 A vmr2012-028-006_d RELAYS vmr2015-131...
  • Page 301 Section 05 ELECTRICAL SYSTEM Subsection 01 (POWER DISTRIBUTION AND GROUNDS) RELAY RELAY STATE (ON) RELAY STATE (OFF) IDENTIFICATION COOLING SYSTEM Cooling fan When ignition key is turned ON Approximately 30 seconds after ignition Main key is turned OFF Run/Stop switch is set to RUN When ignition key is turned OFF Accessories Same as main relay...

  • Page 302: Wiring Harness And Connectors

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) WIRING HARNESS AND CONNECTORS SERVICE TOOLS Description Part Number Page 529 035 730 ......... 426 CRIMPING TOOL (HEAVY GAUGE WIRE) ........529 036 166 ......... 423 ECM ADAPTER TOOL..............529 036 175 ......... 424 ECM TERMINAL REMOVER 2.25..........
  • Page 303 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) ABBREVIATION DESCRIPTION RH License plate light (Used on European models only) LH License plate light (Used on European models only) Rear RH light Rear LH light Trailer harness (Used on European models only) Voltage regulator/rectifier Starter motor...

  • Page 304: Wiring Harness Routing

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) WIRING HARNESS ROUTING Main Harness (Front 1/2) HIC1 HIC2 DPS2 vmr2015-132-100_a vmr2015-132...
  • Page 305 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) Main Harness (Front 2/2) HICa DPS3 DPS1 vmr2015-132-101_a vmr2015-132...
  • Page 306 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) Main Harness (Rear) To rear extension To rear extension To rear extension To rear extension To rear extension vmr2015-132-102_aen vmr2015-132...
  • Page 307 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) Rear Extension Harness To main harness To main harness vmr2015-132-103_aen vmr2015-132...
  • Page 308 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) WIRING HARNESS SPLICE LOCATION Main Harness (Rear Part) JT WH/BK JT WH/BE JT WH/OR Diode 2 JT RD/PK JT OR/GN JT BK2 vmr2015-132-104_a Main Harness (Front Part 1/2) Diode 5 Diode 6 JT RD/GN JT RD/GY...
  • Page 309 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) Main Harness (Front Part 2/2) JT RD/YL JT VI/RD JT RD/BE JT BU/GY JT OR/BK JT BE JT BK/WH HICa JT VI/BE JT BU JT RD/BU JT GN JT BK/BR JT RD/BK JT RD/BR JT BK3...
  • Page 310 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) Rear Extension Harness JT GN/RD To main harness JT BK1 JT BN1 JT GY1 JT OG/GN JT WH/OG vmr2015-132-107_aen PROCEDURES Deutsch Connector Disassembly and Reassembly DEUTSCH CONNECTORS Deutsch Connector Application A variety of Deutsch connectors are used on var- ious systems: –...
  • Page 311 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) Terminal Removal To remove terminals from connector, proceed as follows: 1. Using long nose pliers, pull out the secondary plastic lock from between the terminals. V01G0QA TYPICAL — FEMALE CONNECTOR 1.

  • Page 312: Packard Connectors

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) PACKARD CONNECTORS Packard Connector Application Packard connectors are used to connect: – Electrical harnesses – Gauges. 3-Pin Packard Connector vmr2006-032-001_a F04H45A VIEW OF A 3-PIN PACKARD CONNECTOR 1. Identification letters NOTE: This type of connector also comes in other pin configurations.

  • Page 313: Molex Connector

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) A33Z01A TYPICAL 1. Retainer 2. Tab (one on each side) A32E3XA TYPICAL Open housing by lifting 4 tabs. 1. Lift and hold plastic lock 2. Lift to unlock and push out MOLEX CONNECTOR Molex Connector Application Molex connectors are used on the following sys-...
  • Page 314 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) Rotate connector lock until it snaps locked. vmr2008-022-014_a Pull out connector. vmr2008-022-013 _b 1. Locked here Molex Connector Probing The most recommended and safest method to probe ECM connector terminals is to use the .
  • Page 315 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) 529036175 1. Remove rear protector from connector. vmr2008-139-016_a 2. Pull out the connector lock. 1. ECM connector (harness side) 2. ECM adapter NOTICE Never probe directly on ECM har- ness connector. This could change the shape or enlarge the terminals and create intermit- tent or permanent contact problems.

  • Page 316: Battery And Starter Cable Terminals

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) smr2010-050-022_a Step 2: Insert GM terminal extractor tool (P/N 12094430) smr2009-045-027_a 3. Gently pull on the wire to extract the pin out the NOTICE Before installing wire terminals in back of the connector. the connector, ensure all terminals are prop- erly crimped on wires.

  • Page 317: Parts Catalog

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) A32E2QA A. 10 mm (3/8 in) NOTE: Make sure not to cut wire strands while stripping the wire. Install the appropriate terminal on the wire ac- A32E2SA cording to the requirement. Refer to appropriate POSITIONING THE CRIMPING PLIERS PARTS CATALOG Step 1: Press...
  • Page 318 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) NOTICE Never weld the wire to the terminal. Welding can change the property of the wire and it can become brittle and break. Install the protective heat shrink rubber tube on the terminal.

  • Page 319: Ignition System

    Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page 529 036 166 ......430, 433–434 ECM ADAPTER TOOL..............529 035 868 ......... 433 FLUKE 115 MULTIMETER ............GENERAL 3. Defective trigger wheel - Inspect trigger wheel. Refer to MAGNETO SYS- SYSTEM DESCRIPTION TEM subsection.

  • Page 320: Emergency Engine Stop Switch

    Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) PROCEDURES FUNCTION WIRE COLOR Ground signal to ECM in IGNITION SWITCH BLACK/WHITE OFF position Ignition Switch Quick Test D.E.S.S. signal ORANGE/RED Turn ignition switch to ON position. 12 Vdc output to ECM (through emergency If multifunction gauge turns on (assuming it engine stop switch)
  • Page 321 Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) EMERGENCY ENGINE STOP SWITCH TEST AT ECM FUSE BOX FUNCTION RESULT CONTACT ADAPTER Close to position — G2 to K3 Open circuit STOP Close to position — G2 to K3 vmr2012-039-007_a EMERGENCY EN- If switch fails the test, refer to STEERING CONNECTOR IDENTIFICATION GINE STOP SWITCH TEST AT MULTIFUNCTION...

  • Page 322: Ignition Coil

    Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) IGNITION COIL vmr2012-031-003_a VIEW RH SIDE OF VEHICLE, OUTLANDER XT 1000 MODEL 1. Ignition coil 2. DPS 3. Winch relay 4. Cooling system thermostat (1000 engine) vmr2006-018-100 Remove the LH inner fender panel(s) for access Ignition Coil Access to the ignition coil connector.
  • Page 323 Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) tmr2011-026-002_a 1. Ignition coil connector vmr2012-031-005_b 2. Set emergency engine stop switch to RUN. TYPICAL 1. ECM 3. Turn ignition switch to ON. 2. ECM connector cover 4. Read voltage as per following table. REQUIRED TOOLS REQUIRED TOOL ECM ADAPTER TOOL...

  • Page 324: Required Tool

    Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) creased fuel consumption. This is due to a loss of compression. Other possible causes are: pro- longed idling or low-speed riding, a clogged air filter, incorrect fuel, defective ignition system, incorrect spark plug gap, lubricating oil entering the combustion chamber, or too cold spark plug.

  • Page 325: Charging System

    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page 380941 ......... 436 EXTECH INDUCTIVE AMMETER ..........95260 ......... 436–438 NAPA ULTRA PRO BATTERY LOAD TESTER ....... GENERAL COMPONENT VOLTAGE Vdc Minimum 12.5 SYSTEM DESCRIPTION Voltage Regulator...

  • Page 326: Battery Load Test

    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) CHARGING SYSTEM LOAD TEST 3. Defective magneto stator. - Test stator, refer to MAGNETO AND STARTER SYSTEM subsection. 4. Defective regulator/rectifier. - Test system voltage. 5. Damaged magneto rotor or Woodruff key. - Replace magneto rotor or Woodruff key, refer to MAGNETO AND STARTER SYSTEM subsection.

  • Page 327: Specification

    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) TEST CONDITIONS As required to decrease Load battery voltage to 12 Vdc Time 15 seconds ‡ Required for accurate testing 6. Read amperage on ammeter. MODEL SPECIFICATION vmr2015-134-003_a All models 50 ± 5 Amps TEST CONDITIONS NOTE: With a fully charged battery and no electri- RD1-1...
  • Page 328 Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) BATTERY Battery Information These vehicles are equipped with a VRLA battery (Valve Regulated Lead Acid). It is a maintenance- free type battery. Refer to battery manufacturer's instructions for proper filling, activation and routine charging pro- cedures.

  • Page 329: Battery Cleaning

    Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) Battery Storage Battery Voltage Below 12.8 V and Above 11.5 It is not necessary to remove the battery during vehicle storage but it is recommended for long STANDARD CHARGING term storage. (RECOMMENDED) If the battery is left in the vehicle during storage or BATTERY TIME...

  • Page 330: Starting System

    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 085 ......... 443 ECM ADAPTER TOOL (ONE CONNECTOR)......... 529 035 868 ......... 445 FLUKE 115 MULTIMETER ............GENERAL ENGINE TURNS Starting system is OK. STARTING SYSTEM OPERATION 1.

  • Page 331: Starter Solenoid

    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) TEST CONDITION Engine stop switch Ignition switch Pressed Start button vmr2015-048-012_a 1. SS1 2. Activate the starter solenoid. 2.1 Apply 12Vdc to SS1 2.2 Ground SS2 vmr2015-048-003_a SS1 IS ON THE RIGHT PROBE PROBE SPECIFICATION...

  • Page 332: Electronic Fuel Injection

    Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) TEST CONDITION Pressed Start button Engine Cranking ‡ Will prevent engine from starting 1. Measure voltage drop. vmr2008-139-016_a 1. ECM connector 2. ECM adapter tool PROBE PROBE SPECIFICATION ECM-L3 Close to 0 If resistance is not as specified, repair or replace wiring/connections.
  • Page 333 Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) vmr2015-048-003_d SPECIFICATION PROBE PROBE @ 20°C (68°F) vmr2015-048-009_a SS1 IS ON THE RIGHT Close to 6 PROBE PROBE SPECIFICATION If resistance is not as per specification, replace the Terminal from Terminal to solenoid.
  • Page 334 Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) WIRING Use the If test failed, replace diode. Refer to FLUKE 115 MULTIMETER (P/N 529 035 868) HARNESS AND CONNECTORS and set it to the diode symbol as shown. for diode loca- tion.

  • Page 335: Digitally Encoded Security System (D.e.s.s.)

    Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) GENERAL 2. Turn ignition switch to ON using any of the key provided with the vehicle. DO NOT start the SYSTEM DESCRIPTION engine. 3. Click the Read Data button in B.U.D.S. The ignition key contains a ROM chip with a unique digital code that is the equivalent of a unique teeth pattern on a conventional key.
  • Page 336 Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) 20. Disconnect all cables and hardware from vehi- KEY TYPE cle. Performance key BLACK key 21. Ensure to reinstall the connector into its hous- GRAY key Normal key ing. 8.

  • Page 337: Lights, Gauge And Accessories

    Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) LIGHTS, GAUGE AND ACCESSORIES SERVICE TOOLS Description Part Number Page 529 035 868 ......... 455 FLUKE 115 MULTIMETER ............SERVICE PRODUCTS Description Part Number Page 293 550 004 ......... 451 DIELECTRIC GREASE ..............
  • Page 338 Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Transmission Position Display Low fuel level Indicator Lamp This display will show transmission position. When this indicator turns ON, it indicates that there is approximately 5 L (1.3 U.S. gal.) of fuel left in fuel tank.
  • Page 339 Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Circuit Testing Check the related-circuit fuse condition with a fuse tester or test lamp (a visual inspection could lead to a wrong conclusion). NOTE: If the ignition switch is left ON for more than 50 minutes, the accessory relay will shut down.
  • Page 340 Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) MULTIFUNCTION GAUGE COMMUNICATION ERROR 1. Multifunction gauge CAN circuit open. - Ensure multifunction gauge is properly connected and powered up. - Check for applicable fault code using B.U.D.S., refer to MONITORING SYSTEM AND FAULT CODES subsection.
  • Page 341 Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) vmr2013-035-001_a TYPICAL 1. Cluster Language box Units of Display Selection In B.U.D.S., select the: – Setting page tab vmo2012-012-029_o 1. Time (Display 2) – Cluster page tab. 2. Message (Display 3) Select Imperial or Metric in the Cluster Units 2.
  • Page 342 Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Multifunction Gauge Test Using B.U.D.S. Connect to the latest applicable B.U.D.S. software COMMUNICATION TOOLS version. Refer to AND B.U.D.S. subsection. Wow Test This function is used to check if the indicator lights, display and analog indicators (if applicable) are functional.
  • Page 343 Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) NOTE: There are a total of 6 tabs that retain the gauge support. vmr2012-023-003_a 1. Diagnostic link connector (DB) 4. Measure the resistance of the CAN resistors as follows. vmr2012-035-001_a 1.

  • Page 344: Volt Power Outlet

    Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) HEADLIGHTS RELAY (R5) FUNCTION COLOR 12 volt input from ignition switch pin A YELLOW/BLUE (relay winding input) 12 volt output to headlights low beam and RED/BLUE vmr2006-020-058_a low/high beam switch IMPORTANT: If a multifunction gauge from an- Relay winding ground other vehicle model is installed and is not regis-...
  • Page 345 Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Low beam aiming is correct when the crest of the SWITCH WIRE COLOR VOLTAGE low beam is below the applicable horizontal cen- POSITION ter line traced on the test surface as per specifi- Battery LO beam GREEN...

  • Page 346: Taillights/Brake Lights

    Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) vmo2012-012-059_b vmo2012-012-060_a LOW BEAM LOW AND HIGH BEAMS 1. Adjustment knobs 1. Adjustment knobs TAILLIGHTS/BRAKE LIGHTS Brake Light Switch For brake light switch location and testing, refer to BRAKES subsection. Brake Light Wire Identification BRAKE LIGHT RELAY (R8) FUNCTION...
  • Page 347 Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Taillight Wire Identification WINCH RELAY CIRCUIT FUNCTION COLOR FUNCTION PROTECTION 12 volt input from LIGHT BLUE Supplied when main relay switch (OUT) ORANGE/GREEN R2 activated Motor power (switches RED (with blue polarity depending on Ground from BK2 BLACK...

  • Page 348: Circuit Protection

    Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Winch Switch Circuit Protection CONDITION CIRCUIT PROTECTION Supplied when Fuse 7 of fuse block accessories relay 1 (from accessories activated relay R3) Winch Removal 1. Disconnect, the battery BLACK (-) cable first, then the RED (+) cable.

  • Page 349: Tightening Torque

    Section 05 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) vmr2012-035-011_a 1. Front bumper support 2. Winch retaining screws 7. Remove winch. Winch Installation For the installation, reverse the removal proce- dure, however pay attention to the following. Connect winch power cables as noted at removal. NOTE: If the winch power cables are not con- nected correctly, the winch motor will operate in the reverse direction of selection.

  • Page 350: Front Drive

    Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) FRONT DRIVE SERVICE TOOLS Description Part Number Page 529 035 665 ......... 469 BACKLASH MEASUREMENT TOOL..........529 036 120 ......... 467 CV BOOT CLAMP PLIER .............. 529 036 005 ......... 467 CV JOINT EXTRACTOR..............529 035 649 .........
  • Page 351 Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) FRONT DRIVE SHAFTS AND FRONT PROPELLER SHAFT 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) (M8) 61 ± 9 N•m (45 ± 7 lbf•ft) (M10) STEERING SYSTEM Loctite XPS Synthetic Synthetic grease grease 205 ±...

  • Page 352: Front Differential

    Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) FRONT DIFFERENTIAL XPS synthetic grease 37 ± 3 N•m (27 ± 2 lbf•ft) 33 ± 3 N•m (24 ± 2 lbf•ft) 22.5 ± 2.5 N•m (17 ± 2 lbf•ft) For backlash adjustment 180 ±...
  • Page 353 Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) GENERAL The procedure explained below is the same for the RH and LH sides unless otherwise instructed. SYSTEM DESCRIPTION The Visco-Lok ® system constantly monitors front wheel speed and, if it detects one wheel spinning faster than its mate, it progressively sends more power to the wheel with the better traction.

  • Page 354: Front Drive Shaft

    Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) FRONT DRIVE SHAFT Front Drive Shaft Removal Lift and support vehicle. BODY Remove inner fender panel(s). Refer to subsection. Remove the KNUCKLE . Refer to STEERING SYS- subsection. Remove shock absorber lower bolt. Lift and attach the following parts to make room.
  • Page 355 Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) 529036005 vmr2012-036-003_a FROM LH SIDE 1. Vent hose 4. Remove bolts securing front differential to frame. vmr2007-053-010_a TYPICAL — CV JOINT SHOWN 1. Joint extractor tool With an hammer, hit on the tool to separate joint from shaft.
  • Page 356 Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) vmr2012-036-005_a vmr2006-023-015_a FRONT PROPELLER SHAFT MOVED REARWARD 1. Tab of backlash measurement tool 2. Mark on tab 7. Remove front differential by pulling it from RH A. 25.4 mm (1 in) side. Position the dial indicator tip against the tab at a NOTICE Be careful not to knock or to bend...
  • Page 357 Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) BACKLASH ADJUSTMENT GUIDELINE BACKLASH WHAT TO DO MEASUREMENT Remove shim(s) and Below 0.1 mm (.004 in) recheck backlash Add shim(s) and recheck Above 0.25 mm (.01 in) backlash vmr2015-051-006_a PRELOAD SPECIFICATION Maximum 0.50 N•m (4 lbf•in) If preload is out of specification, split front differ- ential housing and check all bearings conditions.
  • Page 358 Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) Visco-Lok Carrier/Ring Gear Remove Visco-Lok carrier/ring gear out of half housing. vmr2015-051-010_a 1. Visco-Lok unit 2. Ring gear Pinion Gear Remove screw retaining front propeller shaft vmr2015-051-002_a adapter. Remove screws securing ring gear to Visco-Lok unit.
  • Page 359 Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) 529035649 vmr2008-142-010_a 1. O-ring 2. Pinion gear 3. Bearing Remove and discard the needle bearing. Front Differential Assembly vmr2012-036-011_a Adjustment is required when any of the following 1. Pinion nut part is changed. Remove bearing and pinion gear together.
  • Page 360 Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) Visco-Lok Carrier/Ring Gear The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Tighten Visco-Lok / ring gear screws to specifica- tion. TIGHTENING TORQUE Visco-Lok / ring gear 37 N•m ±...

  • Page 361: Front Propeller Shaft

    Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) TIGHTENING TORQUE M8 nut securing front 24.5 N•m ± 3.5 N•m differential to frame (18 lbf•ft ± 3 lbf•ft) M10 nuts securing front 61 N•m ± 9 N•m differential to frame (45 lbf•ft ± 7 lbf•ft) Install NEW Oetiker clamps.
  • Page 362 Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) 9. Remove front propeller shaft adapters from en- gine and from front differential. Front Propeller Shaft Inspection Inspect if propeller shaft is not bent or twisted. Check propeller shaft splines for wear or damage. Check if propeller shaft bellows is pierced or brit- tle.

  • Page 363: Service Tools

    Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) MIDDLE AND REAR FINAL DRIVE SERVICE TOOLS Description Part Number Page 529 035 665 ......... 486, 491 BACKLASH MEASUREMENT TOOL..........529 036 120 ......... 482 CV BOOT CLAMP PLIER .............. 529 036 005 .........
  • Page 364 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) 205 ± 15 N•m (151 ± 11 lbf•ft) XPS synthetic grease 90 ± 5 N•m (66 ± 4 lbf•ft) Loctite 648 75 ± 5 N•m (55 ± 4 lbf•ft) 22.5 ±...
  • Page 365 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) MIDDLE DRIVE 22.5 ± 2.5 N•m (17 ± 2 lbf•ft) 180 ± 15 N•m (133 ± 11 lbf•ft) LH threads 32.5 ± 3.5 N•m (24 ± 3 lbf•ft) For preload adjustment For backlash adjustment...

  • Page 366: Rear Drive

    Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) REAR DRIVE 22.5 ± 2.5 N•m (17 ± 2 lbf•ft) 32.5 ± 3.5 N•m For backlash adjustment (24 ± 3 lbf•ft) 180 ± 15 N•m For preload (133 ± 11 lbf•ft) adjustment XPS synthetic grease...
  • Page 367 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) PROCEDURES Wheel Hub Inspection Remove disk from RH wheel hub as necessary. WHEEL HUB Check wheel hub for cracks or other damages. Wheel Hub Removal Check inner splines for wear or other damages. If any damage is detected on wheel hub, replace Lift and support vehicle.

  • Page 368: Drive Shaft

    Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) Drive Shaft Inspection TIGHTENING TORQUE Inspect the condition of boots. If there is any dam- 205 N•m ± 15 N•m Wheel hub nut age or evidence of leaking lubricant, replace them. (151 lbf•ft ±...

  • Page 369: Propeller Shaft

    Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) PROPELLER SHAFT Remove boot from drive shaft. Remove and discard the circlip. A new one is in- Middle Propeller Shaft Removal cluded in the boot kit. With the Special Tool Place drive shaft in vice with the joint downward.
  • Page 370 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) Rear Propeller Shaft Removal vmr2012-037-008_a TYPICAL — RH SIDE OF VEHICLE 1. Propeller shaft screw vmr2015-139-002_b 4. From LH side of vehicle, remove middle pro- 1. Remove middle and rear wheels. Refer to peller shaft screw from middle drive yoke.
  • Page 371 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) Check propeller shaft splines for wear or damage. Check if propeller shaft bellow is cracked, pierced or brittle. Propeller Shaft Installation The installation is the reverse of the removal pro- cedure.
  • Page 372 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) Using a suitable pusher, fully seat bearing cap on one side. vmr2006-023-015_a 1. Tab of backlash measurement tool V01H12A 2. Mark on tab A. 25.4 mm (1 in) Install snap ring. Position the dial indicator tip against the tab at a Complete installation for the other bearing caps.
  • Page 373 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) BACKLASH ADJUSTMENT GUIDELINE BACKLASH WHAT TO DO MEASUREMENT Add shim(s) and recheck Below 0.05 mm (.002 in) backlash Remove shim(s) and Above 0.36 mm (.014 in) recheck backlash vmr2006-023-012 TYPICAL PRELOAD SPECIFICATION 0.06 N•m (.5 lbf•in) to 0.50 N•m (4 lbf•in)
  • Page 374 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) vmr2015-139-005 vmr2015-139-012_a Unscrew the pinion nut. Use the SPANNER 1. Housing screws SOCKET (P/N 529 035 649) Split middle drive housings. NOTE: Be careful to keep track of shims on ring gear.

  • Page 375: Pinion Gear

    Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) vmr2015-139-007 vmr2015-139-009 Middle Drive Assembled Adjustment is required when any of the following part is changed. – Pinion gear – Ring gear – Housing. As a preliminary setup, install shims according to the following table.

  • Page 376: Tightening Torque

    Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) vmr2015-139-004_c vmr2015-139-010 1. Backlash shim Install NEW bearings. vmr2015-139-004_b 1. Preload shim vmr2015-139-011 Tighten middle drive housing screws to specifica- Prior to finalizing assembly, proceed in this order: tion. –...
  • Page 377 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) TIGHTENING TORQUE 180 N•m ± 15 N•m (133 lbf•ft ± 11 lbf•ft) Pinion nut (LH THREADS) LOCTITE 277 (P/N 293 800 073) Lubricate and install a NEW oil seal. Middle Drive Installation The installation is the reverse of the removal pro- cedure.
  • Page 378 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) Position the dial indicator tip against the tab at a 90° angle and right on the previously scribed mark. Gently, move the tool tab back and forth. Note the backlash result.
  • Page 379 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) PRELOAD SPECIFICATION 0.06 N•m to 0.5 N•m (1 lbf•in to 4 lbf•in) to 0.50 N•m (4 lbf•in) If preload is out of specification, split final drive housing and adjust shim thickness as per follow- ing guideline.
  • Page 380 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) vmr2015-052-008_a TYPICAL vmr2015-052-010_a Unscrew the pinion nut. Use the SPANNER TYPICAL SOCKET (P/N 529 035 649) 529035649 vmr2015-052-011_a TYPICAL 1. O-ring 2. Ball bearing 3. Pinion gear shim 4. Pinion gear The pinion gear and bearing can be easily removed using the following suggested tool: vmr2015-052-009_a...
  • Page 381 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) vmr2015-052-012_a TYPICAL vmr2015-139-013_a 1. Backlash shim Rear Final Drive Assembly Adjustment is required when any of the following part is changed. – Pinion gear – Ring gear – Housing. As a preliminary setup, install shims according to the following table.
  • Page 382 Section 06 DRIVE SYSTEM Subsection 02 (MIDDLE AND REAR FINAL DRIVE) TIGHTENING TORQUE 180 N•m ± 15 N•m (133 lbf•ft ± 11 lbf•ft) Pinion nut LOCTITE 277 (P/N 293 800 073) Lubricate and install a NEW oil seal. Rear Final Drive Installation The installation is the reverse of the removal pro- cedure.

  • Page 383: Wheels And Tires

    Section 07 CHASSIS Subsection 01 (WHEELS AND TIRES) WHEELS AND TIRES SERVICE PRODUCTS Description Part Number Page 293 800 070 ......... 497 LOCTITE 767 (ANTISEIZE LUBRICANT) ........PROCEDURES TIRES WARNING Do not rotate tires. The front and rear tires have a different size. Respect direction of ro- tation when applicable.

  • Page 384: Wheel Lug Nuts

    Section 07 CHASSIS Subsection 01 (WHEELS AND TIRES) tmr2011-033-002_a TYPICAL 1. Direction of rotation Install wheel with the tire in the right direction of rotation. Install lug nuts with the taper towards the wheel. Tighten wheel lug nuts to the specified torque us- ing the illustrated sequence.

  • Page 385: Steering System

    Section 07 CHASSIS Subsection 02 (STEERING SYSTEM) STEERING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 059 ......... 501 STEERING ALIGNMENT TOOL............. SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page 16 ga ......... 502 SMOOTHFLOW™ TAPERED TIP..........#511 rtt-b SERVICE PRODUCTS Description Part Number...
  • Page 386 Section 07 CHASSIS Subsection 02 (STEERING SYSTEM) Loctite (Without heated grips) Synthetic grease Loctite (Without heated grips) 31.5 ± 3.5 N•m (23 ± 3 lbf•ft) Loctite 767 Antiseize 72.5 ± 7.5 N•m (53 ± 6 lbf•ft) 72.5 ± 7.5 N•m 72.5 ±...
  • Page 387 Section 07 CHASSIS Subsection 02 (STEERING SYSTEM) GENERAL The procedures described below are the same for the RH and LH sides, unless otherwise instructed. ADJUSTMENT STEERING ALIGNMENT 1. Place vehicle on a level surface. 2. Check pressure in each tire. Adjust to recom- mended pressure.

  • Page 388: Handlebar Cover

    Section 07 CHASSIS Subsection 02 (STEERING SYSTEM) PROCEDURES HANDLEBAR GRIP Handlebar Grip Removal OPTION If equipped with heated grips, refer to PACKAGE subsection. 1. Loosen the screw at the end of handlebar grip. 2. Remove the handlebar grip cap. 3. Cut and remove the handlebar grip. vmr2008-068-009 TYPICAL —...
  • Page 389 Section 07 CHASSIS Subsection 02 (STEERING SYSTEM) Handlebar Cover Inspection Check covers for cracks or other damages. Re- place if necessary. Handlebar Cover Installation The installation is the reverse of the removal pro- cedure. HANDLEBAR Handlebar Removal 1. Remove handlebar cover. NOTE: Remove handlebar grips, throttle handle, brake handle and multifunction switch only if the vmr2015-141-002...

  • Page 390: Throttle Lever

    Section 07 CHASSIS Subsection 02 (STEERING SYSTEM) Steering Connector Identification 4. Take note of the positions of the locking ties securing the steering harness, then cut them and remove the multifunction switch steering harness from the vehicle. Multifunction Switch Installation For installation, reverse the removal procedure.

  • Page 391: Brake Lever

    Section 07 CHASSIS Subsection 02 (STEERING SYSTEM) V07I0GA 1. Cable protector 2. Throttle cable adjuster 3. Lock nut 4. Throttle lever housing V07I0IA 5. Loosen lock nut and screw in the throttle cable 8. Remove throttle cable from housing. adjuster. 6.

  • Page 392: Steering Column

    Section 07 CHASSIS Subsection 02 (STEERING SYSTEM) Brake Lever Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following: Tighten brake lever mounting screw to specifica- tion. TIGHTENING TORQUE Brake lever mounting 9 N•m ± 1 N•m screw (80 lbf•in ±...
  • Page 393 Section 07 CHASSIS Subsection 02 (STEERING SYSTEM) TIE-ROD NOTE: Use the same procedure for RH and LH side. Tie-Rod Removal 1. Place vehicle on jack stands and remove the ap- plicable wheel. 2. Remove tie-rod end from steering knuckle by removing: –...
  • Page 394 Section 07 CHASSIS Subsection 02 (STEERING SYSTEM) Tie-Rod Inspection TIGHTENING TORQUE Inspect tie-rod for straightness, cracks and other 34 N•m ± 2 N•m Tie-rod lock nut damages. Replace as required. (25 lbf•ft ± 1 lbf•ft) Inspect tie-rod ends for wear or excessive play. If 72 N•m ±...

  • Page 395: Wheel Bearings

    Section 07 CHASSIS Subsection 02 (STEERING SYSTEM) WHEEL BEARINGS Wheel Bearing Inspection (Maintenance) PERIODIC MAINTENANCE PROCE- Refer to DURES subsection. Wheel Bearing Inspection (During Component Removal) Whenever the drive axle or knuckle is removed, check if wheel bearing turns freely and smoothly. Replace if necessary.

  • Page 396: Dynamic Power Steering (Dps)

    Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) DYNAMIC POWER STEERING (DPS) SERVICE TOOLS Description Part Number Page 529 035 868 ......... 520 FLUKE 115 MULTIMETER ............529 036 225 ......... 532, 534 PITMAN ARM JIG ................. 529 036 227 ......... 533 PITMAN ARM PULLER ..............
  • Page 397 A fourth mode of operation is available as an ac- cessory to adjust the steering assist level for op- eration with an approved BRP track kit. Derating Explanation Derating is an internal protection system inte- vmr2010-003-003 grated in the DPS electronic module.

  • Page 398: Steering Alignment

    Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Steering Torque Sensor PART ADJUSTED OR WHAT TO DO REPLACED – DPS unit – Steering column half bushings – Steering column – Tie rod – Tie rod end Reset Torque Offset –...

  • Page 399: Dps Assist Mode

    Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) DPS ASSIST MODE TROUBLESHOOTING 1. To view the active DPS ASSIST mode, momen- TROUBLESHOOTING FLOW tarily press and release the OVERRIDE/DPS CHARTS button on the LH multifunction switch assem- bly. Use the troubleshooting flow charts to diagnose a problem.
  • Page 400 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart A vbs2014-009-001_aen vmr2015-142...
  • Page 401 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart B vbs2014-009-002_aen vmr2015-142...
  • Page 402 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart C vbs2014-009-003_aen vmr2015-142...
  • Page 403 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart D vbs2014-009-004_aen vmr2015-142...
  • Page 404 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart E vbs2014-009-006_aen vmr2015-142...

  • Page 405: Required Tool

    Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) PROCEDURES DPS UNIT DPS Unit Fuse Test A 40 A DPS fuse located in a fuse holder, on the RH side of the frame, under the battery support, provides power for the DPS motor. vmr2012-029-002_a TYPICAL 1.
  • Page 406 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) MULTIMETER PROBE POSITIONS VOLTAGE MULTIMETER PROBE VOLTAGE POSITIONS DPS2 power connector pin A DPS control connector (pin A) Battery ground and battery ground DPS2 power connector pin B Battery voltage Battery voltage rmr2008-028-093_a rmr2008-028-091_a...
  • Page 407 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) If resistance measured is out of specification, MULTIMETER PROBE READING check wires and connector pins. Carry out re- POSITIONS pairs as required and reset fault codes using DPS GDN B.U.D.S software. connector pin A Continuity Battery ground...
  • Page 408 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-007 If the electrical system cannot sustain at least mmr2009-023-027_e 12 Vdc, check the following: 1. MIN function selected – Battery 7. Turn the handlebar momentarily against the – Battery connections steering frame stops to each side.

  • Page 409: Torque Offset Reset

    Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) 5. With the vehicle engine running in PARK, turn – Steering column shim adjustment at half bush- DPS UNIT INSTALLA- the handlebar side to side, momentarily against ings as described in the TION each stop and observe the indications on the procedure detailed in this section.
  • Page 410 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) 6. Remove the steering column pinch bolt and re- taining nut. Discard the retaining nut. vmr2010-003-023 TYPICAL - TIE ROD ENDS (HARDWARE REMOVED) vmr2010-003-017_a TYPICAL 9. Pull up on the steering column to partly disen- 1.
  • Page 411 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2012-039-014_a DPS REMOVAL - RH SIDE 1. DPS vmr2012-039-016_a 2. RH DPS support bracket TYPICAL - LH DPS SUPPORT BRACKET 3. Remove these screws (2) 1. DPS unit 2. DPS support bracket NOTE: Discard the conical spring washers on the 3.

  • Page 412: Tightening Torque

    Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) NOTE: Important: Install the retaining screws to the DPS support bracket loosely at this time. This is required to ensure proper DPS alignment at a later step when all steering and DPS fasteners are tightened to specified torque.
  • Page 413 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2012-039-018_a vmr2010-003-031 A. XPS synthetic grease (P/N 293 550 010) here TYPICAL - STEERING COLUMN INDEXED TO DPS SHAFT SPLINES 5. Insert the steering column onto the DPS input shaft 7. Ensure the following are properly positioned on the lower steering shaft and lower steering 6.
  • Page 414 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-023_a TYPICAL 1. Pitman arm 2. Tie rod ends inserted in pitman arm 3. Hardened steel washer on tie rod end 9. Install the lower half bushing retainer loosely using NEW fasteners. vmr2012-039-100_a DPS AND STEERING TORQUE SEQUENCE (1 OF 3) vmr2012-039-021_a...
  • Page 415 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) NOTE: Ensure the locking tie is on the tube part of the steering column, not on the forged end. Bel- lows should cover end of ring flange on DPS unit but not cover the drainage hole at the bottom of the ring flange.

  • Page 416: Pitman Arm

    Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-040 DPS SOFTWARE UPDATE 4. Once the correct DPS software file is installed, vmr2010-003-039_a TYPICAL - LH ILLUSTRATED go to the Faults page and clear the fault codes. 1. Pitman arm 2.
  • Page 417 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) REQUIRED TOOLS REQUIRED TOOL POSITIONING ADAPTOR PITMAN ARM JIG (P/N 529 036 230) (P/N 529 036 225) 4. Insert the DPS input shaft in the Pitman arm jig receptacle with the Pitman arm facing up. vmr2012-039-024_a 1.
  • Page 418 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2012-039-026_b vbs2011-015-008_a 1. Extractor nut 1. Jig upper bar 2. No space here 2. Positioning screw 3. Lock nut 8. Install the universal Pitman arm puller over the Pitman arm and the extractor thrust bearing. 10.
  • Page 419 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) REQUIRED TOOL PITMAN ARM JIG (P/N 529 036 225) 2. Apply antizeize lubricant on DPS output shaft splines; completely cover all the splines with a light coat. PRODUCT vmr2012-039-030_a LOCTITE 767 1.
  • Page 420 Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) 9. Carry out a steering alignment as described in this subsection. vmr2012-039-032_a vmr2012-039-033_a 1. Ensure proper contact here 7. Unscrew positioning screw and remove pusher adapter and pull out DPS unit. 8.

  • Page 421: Front Suspension

    Section 07 CHASSIS Subsection 04 (FRONT SUSPENSION) FRONT SUSPENSION SERVICE TOOLS Description Part Number Page 529 036 310 ......... 543 BALL JOINT REMOVAL TOOL............vmr2015-056...
  • Page 422 Section 07 CHASSIS Subsection 04 (FRONT SUSPENSION) UPPER SUSPENSION ARMS AND COMPONENTS 61 ± 9 N•m (45 ± 7 lbf•ft) 3 ± 0.5 N•m (27 ± 4 lbf•in) 73 ± 7 N•m Suspension (54 ± 5 lbf•ft) Grease 90° from arm axis Suspension Grease 3 ±...
  • Page 423 Section 07 CHASSIS Subsection 04 (FRONT SUSPENSION) LOWER SUSPENSION ARMS AND COMPONENTS 48 ± 6 N•m (35 ± 4 lbf•ft) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 3.0 ± 0.5 N•m (27 ± 4 lbf•in) Suspension Grease 3.0 ± 0.5 N•m (27 ±...

  • Page 424: Lower Suspension Arm

    Section 07 CHASSIS Subsection 04 (FRONT SUSPENSION) GENERAL Check the following conditions that will denote a defective shock: The procedure explained below is the same for – A skip or a hang back when reversing stroke at the RH and LH sides unless otherwise noted. mid travel.

  • Page 425: Upper Suspension Arm

    Section 07 CHASSIS Subsection 04 (FRONT SUSPENSION) PERIODIC Lubricate suspension arm. Refer to MAINTENANCE PROCEDURES subsection. Tighten ball joint nut to specification. TIGHTENING TORQUE Nut securing ball joint 48 N•m ± 6 N•m to knuckle (35 lbf•ft ± 4 lbf•ft) Perform steering alignment procedure.
  • Page 426 Section 07 CHASSIS Subsection 04 (FRONT SUSPENSION) 9. Remove screws and nuts securing suspension arm to frame. vsi2015-143-006 6. Carefully move brake hose aside. 7. Using a plastic hammer, carefully hit on the vsi2015-143-008 knuckle side to separate ball joint from knuckle. 10.

  • Page 427: Ball Joints

    Section 07 CHASSIS Subsection 04 (FRONT SUSPENSION) vmr2015-056-010 vsi2015-143-009_a LOWER BALL JOINT UPPER SUSPENSION ARM 1. Wear plates 2. Bushings 3. Sleeves vsi2015-143-010_a vmr2015-056-009_a UPPER BALL JOINT LOWER SUSPENSION ARM 1. Wear plates 2. Bushings 3. Install suspension arm on a press. 3.
  • Page 428 Section 07 CHASSIS Subsection 04 (FRONT SUSPENSION) 529036310 vmr2015-056-013 vmr2015-056-014_a CONTACT BETWEEN TOOL AND BALL JOINT ON THE OUTSIDE EDGE ONLY 4. Remove ball joint from suspension arm. NOTICE Make sure that suspension arm is properly supported on the press during ball joint removal.

  • Page 429: Rear Suspension

    Section 07 CHASSIS Subsection 05 (REAR SUSPENSION) REAR SUSPENSION SERVICE TOOLS Description Part Number Page 529 036 184 ......... 548 SPRING COMPRESSOR ............... SERVICE PRODUCTS Description Part Number Page 293 550 033 ......... 552 SUSPENSION GREASE ..............vmr2015-144...
  • Page 430 Section 07 CHASSIS Subsection 05 (REAR SUSPENSION) TRAILING ARMS AND ANTI-SWAY BAR Suspension 255 ± 10 N•m grease (188 ± 7 lbf•ft) 255 ± 10 N•m (188 ± 7 lbf•ft) Suspension 3 ± 0.5 N•m grease (27 ± 4 lbf•in) 4.5 ±...

  • Page 431: Shock Absorbers

    Section 07 CHASSIS Subsection 05 (REAR SUSPENSION) SHOCK ABSORBERS = Component must be replaced when removed. vmr2015-144-100_a vmr2015-144...
  • Page 432 Section 07 CHASSIS Subsection 05 (REAR SUSPENSION) GENERAL TIGHTENING TORQUE The procedure described below is the same for 61 N•m ± 9 N•m Shock absorber nuts (45 lbf•ft ± 7 lbf•ft) the RH and LH sides, unless otherwise instructed. PROCEDURES SHOCK ABSORBER BUSHINGS Shock Absorber Bushing Replacement SHOCK ABSORBERS...

  • Page 433: Anti-Sway Bar

    Section 07 CHASSIS Subsection 05 (REAR SUSPENSION) 529036184 2. Position the shock absorber in the tool. 3. Install the spring compressor pins. 4. Tighten spring remover screw until the spring is sufficiently compressed to remove spring cap. 5. Remove spring cap from shock absorber. sfvmr2014-010-032 RH SIDE SHOWN - SOME PARTS REMOVED FOR CLARITY 6.

  • Page 434: Trailing Arm

    Section 07 CHASSIS Subsection 05 (REAR SUSPENSION) 4. Remove nut and washer securing trailing arm pivot shaft. vmr2015-144-004_a TYPICAL 1. Head towards inside Tighten anti-sway bar retaining bolts to specifica- sfvmr2014-010-035 tion. 1. Pivot nut 2. Pivot washer TIGHTENING TORQUE 5.
  • Page 435 Section 07 CHASSIS Subsection 05 (REAR SUSPENSION) 7. Firmly hold trailing arm then remove: – Shock absorber lower bolt – Trailing arm pivot shaft (pull from opposite side). NOTE: If only one trailing arm is removed, pull pivot shaft just enough to clear trailing arm. vmr2012-041-013_b 1.
  • Page 436 Section 07 CHASSIS Subsection 05 (REAR SUSPENSION) vmr2012-041-016_a TYPICAL - LH TRAILING ARM Step 1: Insert inner bearing on RH side Step 2: Insert outer bearing on RH side Step 3: Center inner spacer with RH side bearings using a shaft vmr2012-041-015_b Step 4: Insert inner bearing on LH side 1.
  • Page 437 Section 07 CHASSIS Subsection 05 (REAR SUSPENSION) sfvmr2014-010-020 TYPICAL 1. Head towards inside Tighten trailing arm fasteners to specification. TIGHTENING TORQUE Bolts securing trailing 61 N•m ± 9 N•m arm to link arm (45 lbf•ft ± 7 lbf•ft) 61 N•m ± 9 N•m Shock absorber nuts (45 lbf•ft ±...
  • Page 438 Section 07 CHASSIS Subsection 06 (BRAKES) BRAKES SERVICE TOOLS Description Part Number Page 529 036 166 ......... 560 ECM ADAPTER TOOL..............SERVICE PRODUCTS Description Part Number Page 219 701 705 ......... 563 XPS BRAKES AND PARTS CLEANER (USA) ......... 293 550 010 ......... 561 XPS SYNTHETIC GREASE.............
  • Page 439 Section 07 CHASSIS Subsection 06 (BRAKES) FRONT CIRCUIT 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 5.5 ± 1.5 N•m To rear circuit (49 ± 13 lbf•in) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 33.5 ±...
  • Page 440 Section 07 CHASSIS Subsection 06 (BRAKES) REAR CIRCUIT 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 28.5 ± 1.5 N•m 61 ± 9 N•m (21 ± 1 lbf•ft) (45 ± 7 lbf•ft) 61 ± 9 N•m (45 ± 7 lbf•ft) 28.5 ±...
  • Page 441 Section 07 CHASSIS Subsection 06 (BRAKES) CALIPERS AND BRAKE LEVERS REAR FRONT Brake caliper 8.5 ± 1.5 N•m synthetic grease (75 ± 13 lbf•in) Brake caliper synthetic grease 8.5 ± 1.5 N•m (75 ± 13 lbf•in) LH SIDE 1.4 ± 0.1 N•m (12 ±...
  • Page 442 Section 07 CHASSIS Subsection 06 (BRAKES) GENERAL WARNING Always check brake system operation after removing or servicing a brake component. NOTICE Avoid spilling brake fluid on plastic, rubber or painted parts. Protect these parts with a rag when servicing brake system. Sealing washers must be discarded and replaced with new ones every time a Banjo bolt is un- screwed.
  • Page 443 Section 07 CHASSIS Subsection 06 (BRAKES) PERIODIC MAINTENANCE PRO- NOTE: Refer to CEDURES subsection. Brake Pedal Verification NOTE: Do not pump up the brakes repeatedly be- fore doing the validation. 1. Position force gauge perpendicularly on brake pedal edge. 2. Position a ruler perpendicularly to brake pedal. 3.

  • Page 444: Brake Pedal

    Section 07 CHASSIS Subsection 06 (BRAKES) Brake Light Switch Located on Master Cylinder or Manifold 1. Disconnect brake light switch connector. 2. Drain brake line. 3. Remove brake light switch. NOTE: Use shop rags to catch any spilled brake fluid. 4.

  • Page 445: Master Cylinder

    Section 07 CHASSIS Subsection 06 (BRAKES) TIGHTENING TORQUE Brake hose screw 28.5 N•m ± 1.5 N•m (banjo fitting) (21 lbf•ft ± 1 lbf•ft) 8.5 N•m ± 1.5 N•m Bleeder (75 lbf•in ± 13 lbf•in) Refill and bleed brake system, refer to PERIODIC MAINTENANCE PROCEDURES subsection.

  • Page 446: Brake Pads

    Section 07 CHASSIS Subsection 06 (BRAKES) vmr2012-042-008_a TYPICAL vmr2012-042-009_a 1. Caliper screws 1. Pin retainer 6. Place caliper assembly onto a support. 3. Remove brake pad pin from caliper. NOTICE Do not let caliper hangs by the hose and do not stretch or twist hose. Caliper Installation The installation is the reverse of the removal pro- cedure.

  • Page 447: Brake Disc

    Section 07 CHASSIS Subsection 06 (BRAKES) vmr2012-042-014_a 1. Caliper support vmr2012-042-011_a 13. Install caliper, refer to CALIPER INSTALLA- BRAKE PAD SPRING TION in this subsection. 8. Ensure pad stopper is properly aligned with BRAKE DISC caliper support protrusion. Brake Disc Inspection 1.
  • Page 448 Section 07 CHASSIS Subsection 06 (BRAKES) vmr2012-042-013_a 1. Brake disc screw 4. Replace brake disc. 5. Install NEW brake disc screws. 6. Tighten brake disc screws to specification. TIGHTENING TORQUE 33.5 N•m ± 3.5 N•m Brake disc screws (25 lbf•ft ± 3 lbf•ft) 7.
  • Page 449 Section 07 CHASSIS Subsection 07 (BODY) BODY SERVICE TOOLS Description Part Number Page 295 000 070 ......... 573 OETIKER PLIERS................BODY PARTS NOMENCLATURE vmr2015-146-101_a 1. Gauge support 8. Inner fender panels 2. Console 9. Footrest panel 3. Seat 10. Front fender 4.
  • Page 450 Section 07 CHASSIS Subsection 07 (BODY) FRONT BODY MODULE vmr2015-146-100 vmr2015-146...

  • Page 451: Body Parts

    Section 07 CHASSIS Subsection 07 (BODY) BODY PARTS 0.5 ± 0.1 N•m (4 ± 1 lbf•in) 2.25 ± 0.25 N•m (20 ± 2 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 2.75 ± 0.25 N•m (24 ± 2 lbf•in) See AIR INTAKE SYSTEM See FRAME 4.5 ±...
  • Page 452 Section 07 CHASSIS Subsection 07 (BODY) RACKS AND BODY PARTS 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) Tightening sequence 1.6 ±...
  • Page 453 Section 07 CHASSIS Subsection 07 (BODY) BUMPERS AND BODY PARTS See FRAME 16 ± 2 N•m (142 ± 18 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 1.6 ± 0.4 N•m (14 ± 4 lbf•in) XT models = Component must be replaced when removed. vmr2015-146...

  • Page 454: Cargo Bed

    Section 07 CHASSIS Subsection 07 (BODY) CARGO BED 23 ± 2 N•m (17 ± 1 lbf•ft) 11 ± 1 N•m (97 ± 9 lbf•in) 23 ± 2 N•m (17 ± 1 lbf•ft) 7 ± 1 N•m (62 ± 9 lbf•in) 5 ±...
  • Page 455 Section 07 CHASSIS Subsection 07 (BODY) PROCEDURES FRONT BODY MODULE Front Body Module Removal PLASTIC RIVET 1. Disconnect battery negative (-) cable. Plastic rivets are used in the riveting of the vari- 2. Remove the following panels, see procedure in ous body parts.
  • Page 456 Section 07 CHASSIS Subsection 07 (BODY) 8. Remove screws securing front body module to frame. vmr2012-043-003_a 1. Headlight connectors 6. Remove screw securing front fender to footrest vmr2012-043-006_a panel (on both sides). RH SIDE 1. Front body module retaining screw vmr2012-043-004_a 1.
  • Page 457 Section 07 CHASSIS Subsection 07 (BODY) 10. With the assistance of a person, pull front body module forward. 11. Install front body module on a stable and clean support. Front Body Module Installation The installation is the reverse of the removal pro- cedure.
  • Page 458 Section 07 CHASSIS Subsection 07 (BODY) 3. Pull console rearwards. Console Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Align console front tabs with slots, then push con- sole forward. vmr2012-043-019_a TYPICAL 1.

  • Page 459: Side Panel Removal

    Section 07 CHASSIS Subsection 07 (BODY) The installation is the reverse of the removal pro- cedure. SIDE PANELS Side Panel Removal CONSOLE 1. Remove . See procedure in this sub- section. 2. Remove plastic rivet securing side panel to in- ner fender panel.
  • Page 460 Section 07 CHASSIS Subsection 07 (BODY) vmr2012-043-004_a vmr2013-045-002_a 1. Screw securing front fender 1. Tabs securing panel extension to side panel 2. Side panel extension 3. Remove both plastic rivets securing inner fender panel to footrest panel. 5. Remove panel extension. Panel Extension Installation Installation is the reverse of removal.

  • Page 461: Front Rack

    Section 07 CHASSIS Subsection 07 (BODY) 7. Detach rear fender from footrest panel by relea- sing retaining tabs. vmr2012-043-018_a 1. Screw securing rear fender 5. Remove screw securing footrest panel to frame. vmr2012-043-019_a 1. Rear fender retaining tabs 8. Remove footrest panel from vehicle. Footrest Panel Installation The installation is the reverse of the removal pro- cedure.
  • Page 462 Section 07 CHASSIS Subsection 07 (BODY) vmr2013-045-020_a PARTS REMOVED FOR CLARITY vmr2013-045-021_a 1. Retaining screw locations 1. Retaining bolt securing rack support to rail 2. Remove rack assembly from vehicle. 6. Remove retaining screws securing rack to rails. 3. Remove the 4 retaining screws securing rack Front Rack Installation moulding to rack assembly.
  • Page 463 Section 07 CHASSIS Subsection 07 (BODY) sfvmr2014-010-050 vmr2015-146-001_a 1.2 Lift and tilt it rearwards. 3. Remove the rear lights receiver. 3.1 Remove the rear light retaining screws. sfvmr2014-010-051 1.3 Lift hatch limiters and open the hatch com- sfvmr2014-010-054_a pletely. 1. Retaining screws 3.2 Pull the rear light receiver out.
  • Page 464 Section 07 CHASSIS Subsection 07 (BODY) sfvmr2014-010-055_a sfvmr2014-010-059 1. Cargo bed retaining screws 8. Pull the rear light harness out of the cargo bed 5. Pull out the rubber grommet. support frame. sfvmr2014-010-057_a sfvmr2014-010-060 1. Rubber grommet 9. Unlock and raise the cargo bed. 6.
  • Page 465 Section 07 CHASSIS Subsection 07 (BODY) 12. Remove supports and lower the cargo bed. 13. From underneath of the cargo bed, remove the following parts. sfvmr2014-010-044 PARTS REMOVED FOR CLARITY 1. Retaining nuts 2. Support plates 3. Half housings 14. Unlock the cargo bed. 15.

  • Page 466: Side Walls

    Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) OPTION PACKAGES SERVICE PRODUCTS Description Part Number Page 293 800 005 ......... 594 LOCTITE 271 (RED)............... PROCEDURES This section handles all accessories which are in- cluded in forestry, farmer, side walls, cargo and winter packages.
  • Page 467 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) sfvmr2014-010-094 sfvmr2014-010-104_a 1. Pin Side Walls And Tail Gate Installation 3. Lift and remove the hard top. The installation is the reverse of the removal pro- 4. Remove hinge corner plates. cedure. 4.1 Remove retaining screws. HARD TOP 4.2 Remove hinge corner plates.
  • Page 468 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) sfvmr2014-010-106_a sfvmr2014-010-100_a 1. Retaining screw 1. LinQ attchement lever 2. Bracket 4. Remove tail gate limiters. Hard Top Installation 4.1 Open tail gate limiter latche. The installation is the reverse of the removal pro- 4.2 Turn tail gate limiter to the side.
  • Page 469 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) sfvmr2014-010-080_a sfvmr2014-010-083_a 1. Supports 1. Retaining screws 2. Remove retaining screws. sfvmr2014-010-084_a 1. Retaining screws sfvmr2014-010-081_a 3. Remove mounting plates. 1. Retaining screws sfvmr2014-010-082_a sfvmr2014-010-085_a 1. Retaining screws 1. Mounting plate Log Bars Installation The installation is the reverse of the removal pro- cedure.
  • Page 470 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) FULL BODY SKID PLATE Skid Plate Removal 1. Remove the following retaining screws. sfvmr2014-010-089_a 1. Retaining screws sfvmr2014-010-086_a 1. Retaining screws sfvmr2014-010-090_a 1. Retaining screws sfvmr2014-010-087_a 1. Retaining screws sfvmr2014-010-091_a 1. Retaining screws sfvmr2014-010-088_a 1.
  • Page 471 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) vsi2012-025-005_a 1. Lever in unlatched position 2. Rack extension mount (LH shown) sfvmr2014-010-092_a 1. Retaining screws 3. Lift LinQ rack rear mounts out. 2. Remove skid plate. 4. Pull front mounts out and remove the rack. Skid Plate Installation The installation is the reverse of the removal pro- cedure.
  • Page 472 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) tsi2012-040-110_a 1. Protective cap 3. From underneath of console, remove the visor vsi2012-060-011_a jack connector. 1. Locking screw 2. Turn lever to unlatched position and lift to re- move the LinQ grip. sfvmr2014-010-127_a 1.

  • Page 473: Ing System

    Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) tsi2012-040-105_a 1. Accessory connector 2. Visor jack harness connector 6. Remove the visor jack harness; pull it off under the air intake hose then by the LH side of steer- vmr2015-147-002 ing column. 5.
  • Page 474 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) Heating Control Module Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Install new locking ties. Gently tighten retaining screw to a snug fit. NOTICE Do not over tighten as it may cause the heating control module to crack.
  • Page 475 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) V07I0HA V07I0HB 1. Inner housing protector 1. Retaining screw 2. Throttle cable clip 10. Slide cable in clip slot and remove end of cable NOTE: Take note of spring and washers location. from clip. 12.
  • Page 476 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) TIGHTENING TORQUE CAUTION Make sure spring squeezed between throttle lever and hous- Housing Retaining 4.8 N•m ± .7 N•m ing. Screws (42 lbf•in ± 6 lbf•in) TIGHTENING TORQUE 7. Install new locking ties. Throttle Lever Retaining 3.5 N•m ±...
  • Page 477 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) vsi2012-009-004 8. Carefully cut and remove handlebar grips. NOTICE Ensure not to cut all the way through vsi2012-009-023 HEATED GRIPS LUBRICATION as it will scratch the surface of the handlebar and make the insertion of the new grip more 3.
  • Page 478 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) NOTE: The grips are quite hard to push over so be prepared to apply a considerable amount of force to install them. It is recommended to turn the han- dlebars completely to the left or right and to firmly secure them so that they do not move when the grips are installed.
  • Page 479 Section 07 CHASSIS Subsection 08 (OPTION PACKAGES) TIGHTENING TORQUE Handlebar cap retaining 5 N•m ± 0.5 N•m screw (44 lbf•in ± 4 lbf•in) vmr2015-147...
  • Page 480 Section 07 CHASSIS Subsection 09 (FRAME) FRAME SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page model 9600 ......... 601 BLIND THREADED INSERT INSTALLER........61 ± 9 N•m (45 ± 7 lbf•ft) 61 ± 9 N•m (45 ± 7 lbf•ft) = Component must be replaced when removed.
  • Page 481 Section 07 CHASSIS Subsection 09 (FRAME) 11 ± 1 N•m (97 ± 9 lbf•in) 11 ± 1 N•m (97 ± 9 lbf•in) 8.75 ± 1.25 N•m 23 ± 2 N•m (77 ± 11 lbf•in) (17 ± 1 lbf•ft) 23 ± 2 N•m (17 ±...
  • Page 482 Frame Welding EXHAUST SYSTEM 3. Remove muffler. Refer to subsection. No welding should be done on frame except if mentioned or required on an approved BRP Bul- 4. Cut locking ties and disconnect electrical con- letin. nectors. Frame Insert Replacement...
  • Page 483 Section 07 CHASSIS Subsection 09 (FRAME) 9. Remove cargo bed latch lever handle. sfvmr2014-010-069_a 1. Electrical connectors 5. Remove seat BODY 6. Remove RH side panel. Refer to subsec- vmr2015-146-004_a tion. 10. Remove rear side panels. 7. Disconnect electrical connectors and pull the harness backwards.
  • Page 484 Section 07 CHASSIS Subsection 09 (FRAME) North American Models 15. Remove retaining screws and nuts (both sides). 12. Remove rivet (both sides). Refer to HUCK RIVET REMOVAL in this subsection. vmr2015-148-002_a 1. Retaining screws and nuts vmr2015-148-001_a All Models 13. Remove retaining screws. sfvmr2014-010-115_a 1.
  • Page 485 Section 07 CHASSIS Subsection 09 (FRAME) sfvmr2014-010-110_a sfvmr2014-010-117_a 1. Retaining screws 1. Retaining screws 2. Vent hose 2. Retaining screws and nuts 21. Remove all bottom supports. sfvmr2014-010-111_a 1. Retaining screws sfvmr2014-010-118 20. Remove retaining screws and nuts (both sides). sfvmr2014-010-119 sfvmr2014-010-116_a 22.
  • Page 486 Section 07 CHASSIS Subsection 09 (FRAME) Rear Frame Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. First, fit all the supports, screws and nuts in their proper places. Start tighten the screws and nuts only when everything is set in place.

  • Page 487: Section 08 Technical Specifications

    Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 6X6 (650)) OUTLANDER 6X6 (650) ENGINE ROTAX 660, 4-stroke, 2 cylinders (V-twin), Engine type liquid cooled 4 valves/cylinder (mechanical adjustment), single Valve train over head camshaft (SOHC) with timing chain Bore 82 mm (3.23 in) Stroke 61.5 mm (2.42 in) Displacement...
  • Page 488 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 6X6 (650)) ENGINE 0.20 mm to 0.40 mm (.008 in to .016 in) Rectangular Service limit 0.60 mm (.024 in) 0.20 mm to 0.40 mm (.008 in to .016 in) Ring end gap Tapered face Service limit 0.70 mm (.028 in)
  • Page 489 API service classification SG, SH or SJ COOLING SYSTEM Ethyl glycol/destilled water mix (50%/50%). Use Type BRP Long life antifreeze (P/N 219 702 685) or Coolant coolant specifically designed for aluminum engines Capacity 3.5 L (.9 U.S. gal.) Starts to open 65°C (149°F)
  • Page 490 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 6X6 (650)) TRANSMISSION Drive pulley spring free length Service limit 85 mm (3.346 in) Drive pulley spring free squareness Service limit 4 mm (.157 in) 9.2 mm to 9.4 mm (.362 in to .37 in) Spring sleeve length Service limit 9.0 mm (.354 in)
  • Page 491 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 6X6 (650)) GEARBOX 19.977 mm to 19.990 mm (.7865 in to .787 in) MAG side 19.973 mm (.7863 in) Service limit Countershaft 24.977 mm to 24.990 mm (.9833 in to .9839 in) CVT side Service limit 24.970 mm (.9831 in) Free pinion...
  • Page 492 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 6X6 (650)) ELECTRICAL SYSTEM -Main 30 A -Fan 40 A -Main accessories power -DPS motor 40 A -Brake lights relay control -Gauge -Taillights 10 A -Brake relay -DPS control -Ignition coils -Fuel injectors -Speed sensor -Engine control module (ECM) Fuses...
  • Page 493 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 6X6 (650)) DRIVE SYSTEM Capacity 400 ml (13.53 U.S. oz) Middle drive oil XPS synthetic gear oil (75W 140) (P/N 293 600 140) Type or synthetic gear oil 75W140 API GL-5 Capacity 300 ml (10.2 U.S. oz) Rear final drive oil XPS synthetic gear oil (75W 140) (P/N 293 600 140) Type...
  • Page 494 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER 6X6 (650)) TIRES UP TO 234 kg 34.5 kPa (5 PSI) (516 lb) Front FROM 234 kg to 460 kg 48.2 kPa (7 PSI) (516 lb to 1,014 lb) Pressure UP TO 234 kg 34.5 kPa (5 PSI) (516 lb) Middle and rear...

  • Page 495: Section 09 Wiring Diagram

    Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) WIRING DIAGRAM INFORMATION GENERAL Rear Fuse Holder The fuses are identified on the WIRING DIAGRAM WIRING DIAGRAM LOCATION as per the following example: The wiring diagram are located in the back cover pocket.
  • Page 496 Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) Multifunction Switch Identification XX/XX- 18 2-BF-A V06G1GA THE SHADED PART INDICATES THE WIRE GAUGE Example: The number that follows the wire color indicates the wire size used, in this case 18 gauge wire.
  • Page 497 Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) TROUBLESHOOTING XX/XX-18 2- BF -A DIAGNOSTIC TIPS IMPORTANT: When trying to solve an electrical V06G1JA problem, check the following: THE SHADED PART INDICATES A CONNECTOR – The ignition switch is turned ON. NOTE: For a complete list of the connector iden- –...
  • Page 498 Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) Simplifying Electrical System Tests IMPORTANT: In an electrical circuit, the battery usually provides power to a switch, which then For complex systems where there are electronic supplies the electric component when the switch modules, sensors, actuators, relays etc., it is of- contacts are closed (low power circuits).

  • Page 499: General System

    FRAME GROUND COLOR CODE AWG MAX. CURRENT MAX. FUSE CURRENT MAX. WATT ZONE # ZONE DESCRIPTION WELDED JOINT TERMINAL IDENTIFICATION BEIGE OUTLANDER / RENEGADE 2015 EGINE GROUND 100 amps 125 amps 1450 watts SHRINKED JOINT STEERING AREA BLACK NOTE : NAME ZONE- CONNECTOR NAME- TERMINAL #/A 65 amps...

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