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BRP Can-Am Outlander L STD 2015 Manual

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INTRODUCTION

INTRODUCTION

GENERAL INFORMATIONS

This shop manual covers the following BRP made 2015 Outlander L and Outlander L MAX Series vehi-

cles.

MODEL

YEAR

Outlander L (STD)

Outlander L (DPS)

Outlander L MAX

Outlander L MAX (DPS)

2015

Outlander L (STD)

Outlander L (DPS)

Outlander L MAX

Outlander L MAX (DPS)

The information and component/system descriptions contained in this manual are correct at time of pub-

lication. BRP however, maintains a policy of continuous improvement of its products without imposing

upon itself any obligation to install them on products previously manufactured.

Due to late changes, it may have some differences between the manufactured product and the descrip-

tion 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.

VEHICLE INFORMATION

VEHICLE IDENTIFICATION

NUMBER (VIN) LOCATIONS

1

vmr2015-005-005_a

VIN LOCATIONS

1. VIN decal under seat

2. VIN decal on lower frame member, RH side

3. VIN stamped on lower frame member, RH side

XIV

MODEL

2

3

ENGINE

MODEL NUMBER

5AFA, 5AFB, 5AFC, 5AFD, 5AFE

2WFA, 2WFB, 2WFC, 2WFD

450 EFI

5CFA, 5CFB, 5CFC

2XFA, 2XFB, 2XFC, 2XFD

2TFA, 2TFB, 2TFC, 2TFD

2CFA, 2CFB, 2CFC, 2CFD, 2CFE, 2CFF

500 EFI

2FFA, 2FFB, 2FFC, 2FFD, 2FFE, 2FFF

VIN Decal Description

MANUFACTURED BY :

FABRIQUÉ PAR:

12/2003

MFD. DATE FAB :

2BPS1234X2V000123

VIN / NIV:

MADE IN/FABRIQUÉ AU:

XXXXX

vmr2015-005-004_a

TYPICAL — VEHICLE SERIAL NUMBER DECAL UNDER SEAT

1. VIN (Vehicle Identification Number)

2. Vehicle manufacturing date and model number

3. VIN bar code

2EFA, 2EFB

1234

2

MODEL:

1

3

TYPE: ATV / VTT

vmr2015-005

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Summary of Contents for BRP Can-Am Outlander L STD 2015

Page 1 INTRODUCTION INTRODUCTION GENERAL INFORMATIONS This shop manual covers the following BRP made 2015 Outlander L and Outlander L MAX Series vehi- cles. MODEL MODEL ENGINE MODEL NUMBER YEAR Outlander L (STD) 5AFA, 5AFB, 5AFC, 5AFD, 5AFE Outlander L (DPS) 2WFA, 2WFB, 2WFC, 2WFD...
Page 2 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 3 INTRODUCTION The responsibilities listed above are general and in no way a complete listing of the rules and regu- lations pertaining to the EPA requirements on ex- haust emissions. For more detailed information on this subject, you may contact the following lo- cations: FOR ALL COURIER SERVICES: U.S.
Page 4 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 5 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 6 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 7 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 8 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 9 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 10 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 11 SERVICE TOOLS INDEX ADAPTER HOSE BEARING INSTALLER (GEARBOX) CAMSHAFT TIMING TOOL (P/N 529 035 652) (P/N 529 035 763) (P/N 529 036 268) Page: 408 Page: 154–155, 329 Page: 85, 260 BEARING INSTALLER (GEARBOX) CLUTCH HOLDER (P/N 529 035 762) BACKLASH MEASUREMENT TOOL (P/N 529 036 238) (P/N 529 035 665)
Page 12 SERVICE TOOLS INDEX CRANKCASE SUPPORT (MAG SIDE) CRANKSHAFT PROTECTOR DISCONNECT TOOL (P/N 529 035 916) (P/N 529 036 034) (P/N 529 035 714) Page: 85, 260 DRIVE PULLEY HOLDER (CVT) Page: 291 (P/N 529 006 400) Page: 169–170 CRANKSHAFT TDC POSITION TOOL CRANKCASE SUPPORT MAG/PTO (P/N 529 036 201) (P/N 529 036 031)
Page 13 SERVICE TOOLS INDEX ECM ADAPTER TOOL ENGINE LIFTING TOOL MAGNETO PULLER (P/N 529 036 166) (P/N 529 036 022) (P/N 529 035 748) Page: 241 FLUKE 115 MULTIMETER Page: 115, 291 (P/N 529 035 868) MPI-2 DIAGNOSTIC CABLE Page: 446–447, 451, 457, 459,...
Page 14 SERVICE TOOLS INDEX OIL SEAL INSTALLER PITMAN ARM JIG POSITIONING ADAPTOR (P/N 529 036 069) (P/N 529 036 225) (P/N 529 036 230) Page: 169 Page: 664 OIL SEAL PUSHER (P/N 529 035 757) Page: 663, 665 PRESSURE GAUGE (P/N 529 035 709) PITMAN ARM PULLER (P/N 529 036 227) Page: 105, 280...
Page 15 SERVICE TOOLS INDEX SEAL PUSHER STEERING ALIGNMENT TOOL VALVE GUIDE INSTALLER (P/N 529 035 766) (P/N 529 036 059) (P/N 529 036 269) Page: 632 Page: 141 TDC DIAL INDICATOR Page: 105, 278, 281 VALVE GUIDE REMOVER (6 MM) (P/N 414 104 700) SMALL HOSE PINCHER (P/N 529 036 074) (P/N 295 000 076)
Page 16 Section 01 MAINTENANCE Subsection 01 (BREAK-IN INSPECTION) BREAK-IN INSPECTION Procedures are detailed in PERIODIC MAINTE- NANCE PROCEDURES subsection. BREAK-IN INSPECTION Replace engine oil and filter Check valve clearance and adjust as required Inspect engine air filter Inspect battery connections Replace gearbox oil (500) Clean vehicle speed sensor vmr2015-006...
Page 17 Section 01 MAINTENANCE Subsection 02 (PERIODIC MAINTENANCE SCHEDULE) PERIODIC MAINTENANCE SCHEDULE Procedures are detailed in PERIODIC MAINTENANCE PROCEDURES subsection. The maintenance schedule does not exempt the pre-ride inspection. 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 18 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 19 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) PERIODIC MAINTENANCE PROCEDURES (450) SERVICE TOOLS Description Part Number Page 529 035 991 ........... 18 TEST CAP ..................529 021 800 ........18, 29 VACUUM/PRESSURE PUMP ............SERVICE PRODUCTS Description Part Number Page 219 700 341 ...........
Page 20 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) 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 21: Air Intake System
Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) 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 22 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) Reinstall the clean out plug. ENGINE (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) vmr2012-005-001_a...
Page 23 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) 1. Full vmr2015-008-101_a 2. Add 1. Drain plug To add oil, remove the dipstick. Place a funnel into NOTE: Allow oil to drain completely from the the dipstick orifice. crankcase. Add a small amount of recommended oil and 8.
Page 24 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) Engine Oil Filter Replacement Engine Oil Filter Installation 1. Check and clean the oil filter inlet and outlet Engine Oil Filter Access area of dirt and other contaminations. To reach oil filter, refer to BODY and remove the following parts:...
Page 25 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) ENGINE (COOLING SYSTEM) Recommended Engine Coolant COOLANT BRP premixed coolant RECOMMENDED LONG LIFE ANTIFREEZE PRODUCT (P/N 219 702 685) ALTERNATIVE, Distilled OR IF NOT water/antifreeze solution AVAILABLE (50%/50%) NOTICE Always ethylene-glycol...
Page 26 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) NOTE: Leaking coolant indicates a defective ro- 3. Pressurize cooling system as follows. tary seal. Leaking oil indicates a defective oil seal. REQUIRED TOOLS If either seal is leaking, both seals must be re- WATER PUMP placed at the same time.
Page 27 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) vmr2015-016-105_a vmr2015-008-103_a TYPICAL - SOME PARTS REMOVED FOR CLARITY 1. Bleed screw 1. Coolant drain plug 4. Fill cooling system until coolant comes out of 4. Drain cooling system into a suitable container. bleed screw.
Page 28 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) ENGINE (CYLINDER HEAD) CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Engine Valve Clearance Inspection and Adjustment CVT Air Inlet/Outlet Cleaning NOTE: Check and adjust valve clearance only 1. Remove CVT cover, refer to CONTINUOUSLY when engine is cold.
Page 29 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) FUEL SYSTEM Throttle Body Inspection and Cleaning AIR INTAKE SYSTEM 1. Refer to subsection and remove the following. – Air filter housing. 2. Visually inspect throttle plate and throttle body venturi for cleanliness. 3.
Page 30 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) V07I0JA TYPICAL V07I0IA NOTE: Place a rag around the throttle cable ad- juster to prevent the lubricant from splashing. Remove the throttle body side cover. Add lubricant until it runs out at throttle body end of the throttle cable.
Page 31 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) FUEL TANK LEAK TEST 3. Carry out a , refer to 2. Clean the spark plug area using pressurized air. FUEL TANK AND FUEL PUMP subsection. 3. Remove spark plug. WARNING Spark Plug Installation All fuel system leaks must be repaired.
Page 32 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) Front Differential Oil Replacement Rear Final Drive Oil Level Verification 1. Place vehicle on a level surface. Set transmis- 1. Ensure vehicle is on a level surface. sion in park position. 2.
Page 33 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) Rear Propeller Shaft U-Joint Lubrication PROPELLER SHAFT U-JOINT LUBRICATION Use Hi-temp bearing grease NLGI-2 or an equivalent CHASSIS (WHEELS AND TIRES) Wheel Lug Nut Torque Inspection Tighten wheel lug nuts to the specified torque us- ing the illustrated sequence.
Page 34 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) CHASSIS (STEERING SYSTEM) Steering System Inspection Steering Column Turn and move steering column back and forth to detect any abnormal play. If abnormal play is detected, inspect upper and lower steering column half bushings. Replace halve bushings and O rings as necessary, refer to STEERING SYSTEM subsection.
Page 35 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) 5. Check ball joint bellows for: – Damage – Cracks. Rear Suspension Arm Inspection 1. Check suspension arm for: – Cracks – Pitting – Bending – Distortion. 2. Check suspension arm for abnormal play: –...
Page 36 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) Brake Fluid Replacement – Check pistons movement – Check pistons for scratches, rust or other Brake Fluid Draining damages. 1. Clean and remove reservoir cover with its di- 2. Clean the following components using aphragm.
Page 37 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) 6. Continue to pump until no more air bubbles ap- pear in clear hose. 7. Close then tighten bleeder. BLEEDER 5.5 N•m ± 1.5 N•m Tightening torque (49 lbf•in ± 13 lbf•in) 8.
Page 38 Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES (450)) CHASSIS (BODY) Seat Latch Inspection and Operation Ensure seat latch functions properly and that seat is properly secured when latched. CHASSIS (FRAME) Frame Inspection Inspect frame for damages such as: – Cracks –...
Page 39 SERVICE PRODUCTS Description Part Number Page 293 110 001 ........... 55 BRP HEAVY DUTY CLEANER ............219 701 709 ........... 55 XPS ALL PURPOSE CLEANER ............. 219 701 713 ........... 55 XPS ATV CLEANING KIT ............... 219 701 704 ........... 55 XPS ATV FINISHING SPRAY............
Page 40 Section 01 MAINTENANCE Subsection 05 (STORAGE PROCEDURE) 3. Protect pulleys by spraying XPS LUBE (P/N 293 on pulley faces. 600 016) NOTE: Do not reinstall drive belt. 4. Close CVT cover. 5. Remove CVT outlet from exhaust system heat shield and from CVT outlet hose. vmr2015-009-001_a ELECTRICAL SYSTEM Battery...
Page 41 To clean heavily soiled parts of the vehicle, includ- ing metallic parts use the following. RECOMMENDED PRODUCT FOR HEAVILY SOILED PARTS BRP HEAVY DUTY CLEANER (P/N 293 110 001) Inspect the vehicle and repair any damage. Touch up all metal spots where paint has been scratched off.
Page 42 Section 01 MAINTENANCE Subsection 06 (PRESEASON PREPARATION) PRESEASON PREPARATION Proper vehicle preparation is required after a stor- age period. Any worn, broken or damaged parts found must be replaced. Remove rags that were installed for storage: en- gine air inlet hose, CVT outlet hose and muffler. Clean drive and driven pulleys to remove storage protective lubricant, then reinstall drive belt.
Page 43 Section 01 MAINTENANCE Subsection 07 (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE PRODUCTS Description Part Number Page 293 600 016 ........... 61 XPS LUBE..................GENERAL NOTE: Component failures resulting from these events are not warrantable. Refer to the appropriate subsections in this man- ual for details of the required tasks as outlined in these procedures.
Page 44 Section 01 MAINTENANCE Subsection 07 (SPECIAL PROCEDURES) WARNING Do not use vehicle if any of the controls, steering, suspension or brakes are damaged or inoperative. WHAT TO DO IF VEHICLE IS IMMERSED IN WATER In the event the vehicle was immersed, proceed with the following.
Page 45 Section 01 MAINTENANCE Subsection 07 (SPECIAL PROCEDURES) CAUTION Keep away from spark plug hole(s) to avoid being splashed when cranking engine. Add a small quantity of engine oil in cylinder(s) (ap- proximately 2 teaspoonfuls). Install spark plug(s) (replace if required). WARNING Before starting engine, use B.U.D.S.
Page 46 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 01 (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number Page 529 035 898 ........... 68 ENGINE LIFTING TOOL ..............5 ± 1 N•m (44 ± 9 lbf•in) 4 ±...
Page 47 Section 02 ENGINE, CVT AND GEARBOX (450) 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 procedures in following table. REFERENCES OPERATIONS (SUBSECTION)
Page 48 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 01 (ENGINE REMOVAL AND INSTALLATION) vmr2015-012-101_a 1. Remove front propeller shaft bolt and washer vmr2015-012-005_a ENGINE GROUND AND STARTER CABLE DISCONNECT Step 1: Disconnect engine ground wire Step 2: Disconnect starter power wire Step 3: Cut locking ties (3) vmr2015-012-102_a 4 X 4 COUPLING UNIT DISCONNECT...
Page 49 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 01 (ENGINE REMOVAL AND INSTALLATION) ELECTRONIC FUEL INJECTION NOTE: Refer to (EFI) subsection for fuel injector disconnect. vmr2015-012-014_a CVT AIR INLET DUCT DISCONNECT 1. Loosen clamps 2. Remove CVT air inlet adapter vmr2015-012-016_a CRANKCASE VENT DISCONNECT 1.
Page 50 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 01 (ENGINE REMOVAL AND INSTALLATION) 6. Remove the gear switch connector and VSS connectors from their support. 7. Disconnect magneto connector from voltage regulator rectifier. vmr2015-012-017_a AIR INTAKE MANIFOLD REMOVAL 1. Remove air intake manifold vmr2012-043-013_b TYPICAL 1.
Page 51 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 01 (ENGINE REMOVAL AND INSTALLATION) Engine Lifting REQUIRED TOOL ENGINE LIFTING TOOL (P/N 529 035 898) vmr2015-012-022_a RH SIDE, ENGINE MOUNTING PLATE REMOVAL 1. Remove these fasteners 2. Remove right side engine mounting plates vmr2015-012-021_a 1.
Page 52 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 01 (ENGINE REMOVAL AND INSTALLATION) ENGINE INSTALLATION Remove the engine mount brackets on the right hand side. Reverse the removal procedure. However, pay at- tention to the following. When installing a part, refer to its applicable subsection for tightening torques and products required.
Page 53 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 01 (ENGINE REMOVAL AND INSTALLATION) Engine Mount Installation Push in each mount bushing until it bottoms out. vmr2015-012...
Page 54: Table Of Contents
Section 02 ENGINE, CVT AND GEARBOX (450) 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 ±...
Page 55: Air Filter Housing
Section 02 ENGINE, CVT AND GEARBOX (450) 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 56 Section 02 ENGINE, CVT AND GEARBOX (450) 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 TYPICAL 1. Link rod retaining bolt 8.
Page 57 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 02 (AIR INTAKE SYSTEM) vmr2015-013-003_a vmr2015-013-002_a SCREW ACCESSED FROM UNDER SHIFT LEVER 1. Remove crankcase vent hose here 1. Screw 14. Remove fasteners retaining aft end of air filter 15. Detach throttle body from intake adapter and housing.
Page 58 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 02 (AIR INTAKE SYSTEM) vmr2015-013-005 _a 1. Air filter housing 2. 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 59: N•M (22 ± 4 Lbf•In)
Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 03 (EXHAUST SYSTEM) EXHAUST SYSTEM Outlander L Max Models Outlander L 10 ± 2 N•m (89 ± 18 lbf•in) 9 ± 1 N•m (80 ± 9 lbf•in) Bolt down, nut facing outwards 40 ±...
Page 60 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 03 (EXHAUST SYSTEM) GENERAL WARNING Never touch exhaust system components im- mediately after the engine has run. PROCEDURES MUFFLER Muffler Removal vmr2015-014-503_a 1. Loosen exhaust pipe clamp. Muffler Inspection Check muffler and cover for cracks or other dam- ages.
Page 61 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 03 (EXHAUST SYSTEM) vmr2015-014-505_a OUTER HEAT SHIELD - SHORT MODEL SHOWN vmr2013-011-002_a 1. Heat shield bolts 1. Outer heat shield extension 2. M6 x 16 bolts 3. Remove muffler for rear and inner heat shield removal.
Page 62 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 03 (EXHAUST SYSTEM) vmr2015-014-508_a vmr2015-027-101_a 1. Retaining nuts REAR HEAT SHIELD TIGHTENING SEQUENCE 4. Remove front head pipe from vehicle. HEAD PIPE NOTE: The space to remove the front head pipe is limited. Remove it without force. Head Pipe Removal Head Pipe Inspection MUFFLER...
Page 63 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 03 (EXHAUST SYSTEM) vmr2015-014-002_a EXHAUST SYSTEM TIGHTENING SYSTEM SEQUENCE vmr2015-014...
Page 64 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 04 (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number Page 529 035 652 ........... 85 ADAPTER HOSE ................529 035 714 ........... 85 DISCONNECT TOOL ..............529 035 709 ........... 85 PRESSURE GAUGE...............
Page 65 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 04 (LUBRICATION SYSTEM) 10 ± 1 N•m (89 ± 9 lbf•in) Engine oil 12 ± 1 N•m (106 ± 9 lbf•in) 12 ± 1 N•m Engine oil (106 ± 9 lbf•in) Loctite 243 10 ±...
Page 66 Section 02 ENGINE, CVT AND GEARBOX (450) 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 (P/N 529 done with a warm engine (100°C (212°F)) and the 035 714) recommended oil.
Page 67 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 04 (LUBRICATION SYSTEM) Oil Pressure Switch Activation 2. Cylinder head or cylinder base gasket leak. - Retighten cylinder head to specified torque, refer The oil pressure switch activates when the engine to TOP END subsection. Replace gasket if tight- oil pressure is lower than following specified pres- ening does not solve the problem.
Page 68 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 04 (LUBRICATION SYSTEM) vmr2015-015-100_a vmr2008-124-104_a TYPICAL If resistance values are incorrect, replace the oil pressure switch. If the values are correct, check the continuity of the wiring harness. Disconnect the ECM connector and check conti- nuity of circuit between switch and ECM.
Page 69 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 04 (LUBRICATION SYSTEM) Remove: Inspect O-ring on the oil collector and rubber ring on the oil strainer cover if brittle, cracked or hard. – Retaining screws Replace the defective parts. – Oil strainer cover Clean both contact surfaces of oil strainer cover.
Page 70 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 04 (LUBRICATION SYSTEM) Remove: MAGNETIC DRAIN PLUG – Oil pressure regulator plug Gasket ring – Compression spring 30 N•m ± 2 N•m – Valve piston. Tightening torque (22 lbf•ft ± 1 lbf•ft) NOTE: Oil pressure regulator plug on oil pump housing is spring loaded.
Page 71 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 04 (LUBRICATION SYSTEM) Oil Pump Removal Remove: – Oil pump cover screws Remove: – Oil pump module with O-ring. – Engine from vehicle (refer to ENGINE RE- MOVAL AND INSTALLATION subsection) NOTICE Do not loose oil pump cover O-ring.
Page 72 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 04 (LUBRICATION SYSTEM) vmr2015-015-011_a 1. Flat screwdrivers 2. Oil pump gear Remove: vmr2015-015-013_a – Needle pin 1. Oil pump shaft assembly 2. Outer rotor 3. Oil pump housing Oil Pump Inspection Inspect oil pump shaft assembly, housing and cover for marks or other damages.
Page 73 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 04 (LUBRICATION SYSTEM) Clean oil passages and make sure they are not clogged. R400motr127A 1. Outer rotor vmr2015-015-014_a 2. Inner rotor OIL PUMP HOUSING 1. Suction side of the oil pump OUTER AND INNER ROTOR CLEARANCE 2.
Page 74 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 04 (LUBRICATION SYSTEM) NOTE: When the axial clearance of the oil pump shaft assembly increases, the oil pressure de- creases. Oil Pump Installation For installation, reverse the removal procedure. When installing the oil pump rotors, make sure both markings are on the same side.
Page 75 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 04 (LUBRICATION SYSTEM) vmr2015-015-006_b 1. O-ring After engine is completely reassembled, start en- gine and make sure oil pressure is within specifi- ENGINE OIL PRESSURE TEST cations (refer to this subsection). vmr2015-015...
Page 76 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 056 ......... 104 BLIND HOLE PULLER KIT ............420 877 650 ......... 105 HANDLE ..................529 035 757 ......... 105 OIL SEAL PUSHER................
Page 77 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) RADIATOR 2.5 ± 0.5 N•m (22 ± 4 lbf•in) 10 ± 2 N•m (89 ± 18 lbf•ft) Engine 10 ± 2 N•m (89 ± 18 lbf•ft) = Component must be replaced when removed. vmr2015-016-100_a vmr2015-016...
Page 78 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) WATER PUMP AND THERMOSTAT 10 ± 1 N•m (89 ± 9 lbf•in) 2,5 ± 0,3 N•m (22 ± 3 lbf•in) Engine oil 5 ± 0,6 N•m (44 ± 5 lbf•in) Molycote 111 6 ±...
Page 79 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) GENERAL Thermostat Removal Install a hose pincher on both radiator hoses. WARNING Never start engine without coolant. Engine parts and ceramic seal on water pump shaft can be damaged. During assembly/installation, use the torque val- ues and service products as in the exploded views.
Page 80 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) Radiator Removal 1. Drain engine coolant. Refer to PERIODIC MAINTENANCE PROCEDURES subsection. BODY 2. Remove front body module. Refer to subsection. 3. Disconnect radiator and fan assembly. vmr2015-016-004_a 1. Thermostat with gasket Thermostat Test To test thermostat, put it in water and heat the water.
Page 81 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) PERI- Refill and bleed cooling system, refer to ODIC MAINTENANCE PROCEDURES subsec- tion. Check cooling system for leaks. RADIATOR COOLING FAN Radiator Cooling Fan Operation The ECM controls the radiator cooling fan via the input of the coolant temperature sensor (CTS) and the manifold air pressure and temperature sensor (MAPTS).
Page 82 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) 3. Connect cooling fan connector pin A (BK wire) COOLING FAN TROUBLESHOOTING CHART directly to the negative battery post.  Is fan working? Everything is OK 4. Check if cooling fan works properly. ...
Page 83 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) COOLANT TEMPERATURE 2. Remove radiator cooling fan retaining screws. SENSOR (CTS) The coolant temperature sensor is located next to the thermostat housing on the RH rear side of the cylinder head.
Page 84 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) WATER PUMP IMPELLER Water Pump Impeller Removal Remove water pump housing, see procedure in this subsection. Unscrew impeller from water pump shaft. R400motr138A WATER PUMP COVER 1. Gasket vmr2015-016-007_a 1.
Page 85 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) vmr2015-016-008_a 1. Circlip 2. Water pump gear vmr2015-016-014_a 1. Water pump shaft Remove: 2. Soft hammer 3. Magneto cover – Water pump gear – Needle pin Install expander snugly against outer part of rotary –...
Page 86 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) Water Pump Shaft and Gear Inspection Inspect water pump gear for: – Wear – Cracks – Broken teeth – Damage on snap mechanism to the needle pin. Replace if damaged. Inspect shaft and rotary seal for wear or damages.
Page 87 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 05 (COOLING SYSTEM) OIL SEAL SEALING LIP DOW CORNING 111 Service product (P/N 413 707 000) Apply a light coat of engine oil on the water pump shaft. Press the water pump shaft assembly into the magneto cover using the outside area of the ro- tary seal.
Page 88 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) MAGNETO AND STARTER SERVICE TOOLS Description Part Number Page 529 036 117 ......... 119 BLIND HOLE BEARING PULLER SET........... 420 876 557 ......... 115 CRANKSHAFT PROTECTOR (MAG)..........529 035 868 ......... 113 FLUKE 115 MULTIMETER ............
Page 89 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) 10 ± 1 N•m 10 ± 1 N•m (89 ± 9 lbf•in) (89 ± 9 lbf•in) 25 ± 3 N•m (18 ± 2 lbf•ft) 6 ± 0,7 N•m (53 ±...
Page 90 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) 10 ± 1 N•m (89 ± 9 lbf•in) Super Lube Grease Isoflex Grease Topas NB52 Isoflex Grease Topas NB52 Loctite 243 10 ± 1 N•m (89 ± 9 lbf•in) = Component must be replaced when removed.
Page 91 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) PROCEDURES MAGNETO COVER Magneto Cover Removal 1. Remove engine from vehicle. 2. Remove 4WD coupling unit. 3. Lock crankshaft at TDC (refer to BOTTOM END subsection. 4. Disconnect stator, CPS and vehicle speed sen- sor connectors.
Page 92 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) uniform coat on the plate (spread as necessary). When ready, apply the sealant on magneto cover and bearing cover mating surfaces. NOTE: It is recommended to apply this specific sealant as described here to get an uniform appli- cation without lumps.
Page 93 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) Install a NEW gasket ring on M6 magneto cover screw beside the CPS. NOTICE Never use the gasket ring a second time. Always install a new one. vmr2015-017-022_a 1.
Page 94 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) Let the sealant dry before starting engine. Refer 3. Connect multimeter between YELLOW wires. to the manufacturer's label for the sealant curing 4. Read resistance. time. RESISTANCE @ TERMINAL 20°C (68°F) STATOR...
Page 95 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) Check if stator wires are brittle, hard or otherwise damaged. Stator Installation For installation, reverse the removal procedure. However, pay attention to the following. NOTICE When installing the stator take care to route wires properly and install holding strip.
Page 96 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) vmr2015-017-012_a vmr2015-017-011_a 1. Rotor 1. Nut 2. Magneto puller 2. Lock washer 3. Rotor Screw magneto puller bolt to remove rotor. Remove crankshaft plug screw. Rotor Inspection Check inner side of rotor for scratches or other damage.
Page 97 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) Tighten rotor retaining nut to specification. PULLEY FLANGE CLEANER (P/N 413 711 809) clean following parts: ROTOR RETAINING NUT – Crankshaft taper LOCTITE 243 (BLUE) – Oil passage in crankshaft taper Service product (P/N 293 800 060) –...
Page 98 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) vmr2012-033-003_a 1. Power cable from starter solenoid to starter 2. Power cable from battery to starter solenoid (not visible) vmr2015-017-102_a 3. Fuel tank 1. Radiator coolant hose 4. RH rear fender 2.
Page 99 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) 8. Pull starter out from gear box. STARTER TERMINAL AND RETAINING NUT DIELECTRIC GREASE Starter Installation Service product (P/N 293 550 004) Reverse the removal procedure. However, pay 6 N•m ±...
Page 100 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) vmr2015-017-020_a vmr2015-017-018_a 1. Starter drive needle bearing 1. Retaining screws 2. Starter drive cover 3. Shim Check starter drive cover for cracks and clean it 4. Spring before reinstallation. 5.
Page 101 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 06 (MAGNETO AND STARTER) REQUIRED TOOL STARTER DRIVE NEEDLE INSTALLER (P/N 529 035 934) HANDLE (P/N 420 877 650) vmr2015-017-021_a 1. Starter drive needle bearing 2. Starter drive needle bearing installer 3. Handle Starter Drive Installation For installation, reverse the removal procedure.
Page 102 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 07 (INTAKE MANIFOLD) INTAKE MANIFOLD ELECTRONIC FUEL INJECTION (EFI) 0.7 ± 0.1 N•m (6 ± 1 lbf•in) Loctite 6 ± 0.7 N•m 10 ± 1 N•m (53 ± 6 lbf•in) (89 ± 9 lbf•in) ELECTRONIC FUEL INJECTION (EFI) 20 ±...
Page 103 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 07 (INTAKE MANIFOLD) PROCEDURES INTAKE MANIFOLD Intake Manifold Access BODY Refer to subsection and remove the follow- ing: – Console – LH side panel and extension – RH side panel and extension. EXHAUST SYSTEM Refer to subsection and re-...
Page 104 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 07 (INTAKE MANIFOLD) vmr2015-018-005_a 1. Fuel injector connector 2. MAPTS connector 6. Remove intake manifold from engine and intake adapter. vmr2015-018-006_a 1. Remove 2 manifold retaining screws Intake Manifold Inspection Check intake manifold for cracks, warping at flanges or any other damage.
Page 105 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) TOP END SERVICE TOOLS Description Part Number Page 529 036 159 ......... 129 DIAL INDICATOR ADAPTER ............529 035 661 ......... 129 ENGINE LEAK DOWN TEST KIT ........... 529 036 083 ......... 146 PISTON CIRCLIP INSTALLER............
Page 106 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) CYLINDER HEAD 7 ± 0,8 N•m (62 ± 7 lbf•in) Engine oil 12 ± 1 N•m (106 ± 9 lbf•in) Engine oil See tightening procedure Engine oil Engine oil 10 ±...
Page 107 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) CYLINDER AND PISTON Engine oil Engine oil Engine oil Engine oil = Component must be replaced when removed. vmr2015-019-002_a vmr2015-019...
Page 108 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) GENERAL When diagnosing an engine problem, always per- form a cylinder leak test. NOTE: Even though the following procedures do not require the engine removal, many illustrations show the engine out of the vehicle for more clar- ity.
Page 109 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) NOTICE Do not scratch or damage piston/ cylinder surface. NOTE: At TDC ignition the marks on the camshaft timing gear have to be parallel to cylinder head base as per following illustration. vmr2015-019-005_a 1.
Page 110 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) Reassembly Reverse the preparation procedure. Ensure to respect torque values and use of appropriate products/lubricants. Refer to exploded views in other subsections of this manual as required. PROCEDURES VALVE COVER Valve Cover Access BODY Refer to...
Page 111 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) vmr2015-019-004_a 1. Valve cover screws 2. Valve cover vmr2015-020-008_b 3. Gasket 1. Pan head screw 2. Camshaft retaining plate Valve Cover Inspection 3. Cylinder head Check the gasket on the valve cover if it is brittle, Remove rocker arm shafts.
Page 112 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) Measure rocker arm bore diameter. If diameter is out of specification, change the rocker arm as- sembly. ROCKER ARM BORE DIAMETER 12.036 mm to 12.050 mm (.4739 in to .4744 in) SERVICE LIMIT 12.060 mm (.4748 in) Check adjustment screws for free movement,...
Page 113 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) Install a thrust washer at timing chain side, then the proper rocker arm (exhaust side or intake side). Push in rocker arm shaft until its chamfer reaches the end of rocker arm bore. vmr2015-020-008_b 1.
Page 114 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) NOTICE Using a micrometer to measure: The camshafts are not identical in design. Do not invert the camshafts during – camshaft lobe height assembly. Any mix-up of the components will –...
Page 115 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) tmr2011-013-011_a 1. Cylinder head screws M10 2. Cylinder head screws M6 vmr2015-019-100_a Pull up cylinder head. 1. Seat Remove timing chain guide (fixed). 2. Console 3. RH side panel Remove and discard the cylinder head gasket.
Page 116 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) tmr2013-068-016_a 1. Oil port to lubricate camshaft lobes intake/exhaust 2. Oil supply to camshaft bearing journal (timing chain side) vmr2015-019-018_a 3. Oil supply to camshaft bearing journal (spark plug side) 1.
Page 117 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) VALVE SPRINGS Valve Spring Removal Refer to following procedures in this subsection to remove: CAMSHAFT – CYLINDER HEAD – Compress valve spring. REQUIRED TOOL VALVE SPRING COMPRESSOR (P/N 529 035 724) VALVE SPRING COMPRESSOR vmr2015-019-019_a TIGHTENING SEQUENCE - M10 CYLINDER HEAD SCREWS...
Page 118 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) VALVE SPRING FREE LENGTH 40.41 mm (1.591 in) SERVICE LIMIT 39.00 mm (1.535 in) Replace valve springs if not within specifications. Valve Spring Installation The installation is the reverse of the removal pro- cedure.
Page 119 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) mmr2009-115-072_a tmr2013-068-022_a VALVE OUT OF ROUND 1. Intake valves 36.5 mm (1.437 in) 2. Exhaust valves 31 mm (1.22 in) (INTAKE AND EXHAUST VALVES) Remove valve stem seal and discard it. 0.005 mm (.0002 in) 0.060 mm (.0024 in) REQUIRED TOOL...
Page 120 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) Valve Face and Seat R400motr84A V01C1HA 1. Valve seat A. Valve face contact width 2. Exhaust valve contaminated area B. Valve seat contact width 3. Valve face (contact surface to valve seat) Valve Installation Check valve face and seat for burning or pittings and replace valve or cylinder head if there are...
Page 121 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) Measure valve guide in three places using a small Clean the valve guide bore before reinstalling the bore gauge. valve guide into cylinder head. NOTE: Clean valve guide to remove carbon de- NOTE: Apply LOCTITE 767 (ANTISEIZE LUBRICANT) posits before measuring.
Page 122 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) CYLINDER Cylinder Removal TIMING CHAIN Refer to subsection and remove the following parts: – Timing chain tensioner – Camshaft timing gear. Remove the cylinder head (see CYLINDER HEAD in this subsection). Pull cylinder.
Page 123 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) – On the piston rings CYLINDER TAPER MEASUREMENTS – On the piston ring compressor. MEASUREMENT SPECIFICATION Compress piston rings. 5 mm (.197 in) Apply engine oil on the band of the tool. 58 mm (2.283 in) REQUIRED TOOL 52 mm (2.047 in)
Page 124 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) R400motr96A 1. Measuring perpendicularly (90°) to piston pin A. 8 mm (.315 in) vmr2015-019-013_a 1. Piston circlip The measured dimension should be as described in the following tables. If not, replace piston. NOTE: The removal of both piston circlips is not necessary to remove piston pin.
Page 125 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) Connecting Rod/Piston Pin Clearance Using synthetic abrasive woven, clean piston pin from deposits. Inspect piston pin for scoring, cracking or other damages. Measure piston pin. See the following illustration for the proper measurement positions.
Page 126 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) Compare measurements to obtain the connecting rod/piston pin clearance. CONNECTING ROD/ PISTON PIN CLEARANCE SERVICE LIMIT 0.080 mm (.0031 in) Piston Installation The installation is the reverse of the removal pro- cedure.
Page 127 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) R400motr103A 1. Piston 2. Feeler gauge Ring End Gap RING END GAP R400motr102A CORRECT POSITION OF THE PISTON CIRCLIP UPPER COMPRESSION RING 0.20 mm to 0.35 mm PISTON RINGS (.008 in to .014 in) Ring Removal SERVICE LIMIT...
Page 128 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 08 (TOP END) vmr2015-019-017_a 1. Upper compression ring 2. Lower compression ring 3. Oil scraper ring NOTICE Ensure that top and second rings are not interchanged. Check that rings rotate smoothly after installation. Space the piston ring end gaps 120°...
Page 129 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 09 (TIMING CHAIN) TIMING CHAIN SERVICE TOOLS Description Part Number Page 529 036 268 ......... 154–155 CAMSHAFT TIMING TOOL............SERVICE PRODUCTS Description Part Number Page 293 800 060 ......... 155, 157 LOCTITE 243 (BLUE)..............vmr2015-020...
Page 130 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 09 (TIMING CHAIN) TIMING CHAIN 10 ± 1 N•m (89 ± 9 lbf•in) Loctite 243 10 ± 1 N•m (89 ± 9 lbf•in) Loctite 243 Loctite 243 Engine oil 6 ± 0,7 N•m (53 ±...
Page 131 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 09 (TIMING CHAIN) GENERAL IMPORTANT: Note position of parts on disas- sembly. This may help to find the root cause of a problem. A component that is not replaced should be reinstalled in the same position as originally mounted.
Page 132 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 09 (TIMING CHAIN) – Chain tensioner housing – O-ring. vmr2015-020-005_a MOVE GEAR BACK AND FORTH 2. Apply engine oil on the plunger before installa- tion. vmr2015-020-004_a 1. Screws 3. Slightly turn the camshaft timing gear in order 2.
Page 133 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 09 (TIMING CHAIN) vmr2015-020-006_a tmr2013-069-006_a Step 1: Compress spring 1. Plug Step 2: Screw in plug 2. Slot 3. Spring 9. Remove the crankshaft locking bolt and install 4. Spring end 5. O-Ring all other removed parts.
Page 134 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 09 (TIMING CHAIN) Remove: – Camshaft timing gear retaining screws – Camshaft timing gear. vmr2015-020-005_b vmr2015-020-008_a 1. Camshaft timing gear retaining screws 2. Camshaft timing gear 1. Mating surface on camshaft 2. Threads for camshaft screws NOTE: Secure timing chain with a piece of wire.
Page 135: Timing Chain
Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 09 (TIMING CHAIN) 4. Set camshaft to TDC ignition position by align- 7. Install and tighten camshaft timing gear retain- ing the camshaft flange flat spot with the tool ing screws to specified torque. lever.
Page 136 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 09 (TIMING CHAIN) Check timing chain guides for wear, cracks or de- forming. Replace as required. NOTE: Check also the timing chain guide (ten- sioner side). Timing Chain Installation The installation is the reverse of the removal pro- cedure.
Page 137 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 09 (TIMING CHAIN) Timing Chain Guide Installation (Tensioner Side) The installation is the reverse of the removal pro- cedure. TIMING CHAIN GUIDE BEARING SCREW LOCTITE 243 (BLUE) Service product (P/N 293 800 060) 10 N•m ±...
Page 138 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) BOTTOM END SERVICE TOOLS Description Part Number Page 529 035 762 ......... 172 BEARING INSTALLER (GEARBOX) ..........529 035 763 ......... 171 BEARING INSTALLER (GEARBOX) ..........529 036 117 ......... 172 BLIND HOLE BEARING PULLER SET...........
Page 139: N•M (89 ± 9 Lbf•In)
Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) CRANKCASE 25 ± 3 N•m (18 ± 2 lbf•ft) Loctite 243 Petamo Grease 10 ± 1 N•m 10 ± 1 N•m (89 ± 9 lbf•in) (89 ± 9 lbf•in) Multi Purpose Loctite 5910 Grease BP LS3...
Page 140 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) CRANKSHAFT/BALANCER SHAFT Engine oil Engine oil Engine oil See tightening procedure 35 ± 4 N•m (26 ± 3 lbf•ft) Loctite 243 Engine oil = Component must be replaced when removed. vmr2015-021-002_a vmr2015-021...
Page 141 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) GENERAL This section includes the procedures pertaining to the crankcase, crankshaft and balancer shaft. For the gearbox, follow the procedure for the CRANKCASE GEARBOX AND 4X4 then refer to COUPLING UNIT subsection.
Page 142 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) Counter Shaft Oil Seal Installation Using a suitable tube with the proper diameter to install the oil seal. Install all removed parts. SHIFT SHAFT OIL SEAL Shift Shaft Oil Seal Removal Replace oil seal if brittle, hard or otherwise dam- aged.
Page 143 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) CRANKCASE NOTICE Avoid scratching the crankcase or shift shaft during oil seal removal. Crankcase Disassembly Shift Shaft Oil Seal Installation NOTE: Oil pump removal from crankcase MAG side is not necessary, but recommended to see Using a suitable tube, with the proper diameter, LUBRICATION condition of oil pump, refer to...
Page 144 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) – Intermediate gear of oil pump – Drive gear of water pump. vmr2015-021-012_a 1. 2x screws M8 x 85 2. 1x screw M6 x 16 3. 2x screws M6 x 85 4.
Page 145 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) vmr2015-021-014_a vmr2015-021-018_a POSITION FOR BIG FLAT SCREWDRIVER CRANKCASE MAG SIDE 1. Oil orifices Crankcase Cleaning Clean all metal components in a solvent. Clean oil passages and make sure they are not clogged.
Page 146 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) vmr2015-021-053_a MAGNETO COVER vmr2015-021-019_a 1. Oil orifices MAG PLAIN BEARING 1. Plain bearing 2. Oil bore A. Plain bearing inside diameter vmr2015-021-052_a MAGNETO COVER 1. Oil orifices vmr2015-021-020_a Clean crankcase mating surfaces using a com- PTO PLAIN BEARING bination of LOCTITE CHISEL (GASKET REMOVER)
Page 147 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) vmr2015-021-021_a CRANKCASE MAG 1. Balancer shaft ball bearing 2. Counter shaft needle bearing 3. Bevel gear needle bearing vmr2015-021-023_a CRANKCASE PTO 1. Starter drive needle bearing Balancer Shaft Oil Seal Replace oil seal if brittle, hard or otherwise dam- aged.
Page 148 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) NOTICE Always support crankcase properly when ball bearings, needle bearings or plain bearings are removed or installed; otherwise, crankcase could be damaged. Unless otherwise instructed, never use hammer to install ball bearings, needle bearings or plain bearings.
Page 149 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) REQUIRED TOOL PLAIN BEARING REMOVER/INSTALLER (P/N 529 035 917) CRANKCASE SUPPORT (MAG SIDE) (P/N 529 035 916) CRANKCASE SUPPORT PTO (P/N 529 035 754) O-ring (Ø 42 mm (1.65 in) 1 mm to 1.5 mm (.04 in to .06 in) thickness) vmr2015-021-028_a...
Page 150: Bearing Installer (Gearbox)
Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) Mark position of oil bore on crankcase half. Align mark on plain bearing remover/installer with mark on crankcase half. vmr2015-021-020_b CRANKCASE PTO 1. Oil bore 2. Partition Bevel Gear Needle Bearing Removal Remove bevel gear needle bearing using a punch.
Page 151: Blind Hole Bearing Puller Set
Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) vmr2015-021-032_a vmr2015-021-034_a 1. Bevel gear needle bearing 1. Counter shaft needle bearing 2. Needle bearing installer 2. Needle bearing installer 3. Handle 3. Handle Counter Shaft Needle Bearing Removal Starter Drive Needle Bearing Replacement Remove counter shaft needle bearing, using a For starter drive needle bearing replacement refer...
Page 152 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) Crankcase Assembly Balancer Shaft (MAG side) Ball Bearing Removal The assembly is the reverse of the disassembly procedure. However, pay attention to the follow- ing. on mating sur- LOCTITE 5910 (P/N 293 800 081) faces.
Page 153: Crankshaft Locking Bolt
Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) vmr2015-021-045_a vmr2015-021-012_b 1. Crankshaft locking bolt M8 SCREWS TIGHTENING SEQUENCE Align the dot of crankshaft gear with the balancer Then tighten crankcase M6 retaining screws as shaft gear dot then remove balancer shaft. per following sequence.
Page 154: Dial Indicator Adapter
Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) Align the dot on crankshaft gear with the balancer shaft gear dot. vmr2015-019-005_a 1. Plug screw 2. O-ring 3. Magneto cover Set piston to TDC ignition by turning the crank- shaft.
Page 155 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) vmr2015-020-005_d vmr2015-021-044_a TYPICAL - PISTON AT TDC IGNITION 1. Screwdriver 1. Printed marks on camshaft timing gear 2. Cylinder head base Lock crankshaft. Remove: REQUIRED TOOL – Screw CRANKSHAFT LOCKING BOLT –...
Page 156 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) vmr2015-021-048_a 1. Crankshaft vmr2015-021-046_a 2. Feeler gauge 1. Crankshaft 2. Crankcase PTO CONNECTING ROD BIG END AXIAL PLAY 0.100 mm to 0.452 mm Crankshaft Inspection and (.004 in to .018 in) Disassembly SERVICE LIMIT 0.500 mm (.02 in)
Page 157 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) If the crank pin diameter is out of specification, replace crankshaft. CONNECTING ROD BIG END DIAMETER SERVICE LIMIT 40.100 mm (1.579 in) If connecting rod big end diameter is out of spec- ification, replace plain bearings and recheck.
Page 158 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) NOTICE Strictly adhere following instruc- CRANKSHAFT MAG/PTO DIAMETER tions: 42.016 mm to 42.040 mm – Do not apply any thread locker. (1.6542 in to 1.6551 in) – The running direction of the big end bear- SERVICE LIMIT 42.000 mm (1.6535 in) ings and of the piston pins must not change.
Page 159 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 10 (BOTTOM END) vmr2015-021-051_a 1. Crankshaft 2. Balancer shaft Align the marks of crankshaft and balancer shaft. vmr2015-021-039_a 1. Mark on crankshaft gear 2. Mark on balancer shaft gear After reinstalling of crankcase MAG, measure ax- ial clearance of crankshaft with a feeler gauge be- tween PTO crankcase and crankshaft thrust sur- face.
Page 160: Service Products
Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) CONTINUOUSLY VARIABLE TRANSMISSION (CVT) SERVICE TOOLS Description Part Number Page 529 035 746 ......... 187 CLUTCH PULLER ................529 006 400 ......... 186 DRIVE PULLEY HOLDER (CVT) ............ 529 035 771 .........
Page 161 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Loctite 767 Isoflex grease Topas NB52 Pulley flange cleaner Isoflex grease Topas NB52 See tightening Isoflex grease procedure Topas NB52 5 ± 0,6 N•m (44 ± 5 lbf•in) LH threads 100 ±...
Page 162 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) 5 ± 1 N•m (44 ± 9 lbf•in) 2.5 ± 0.5 N•m (22 ± 4.5 lbf•ft) 5 ± 1 N•m (44 ± 9 lbf•in) 2.5 ± 0.5 N•m (22 ±...
Page 163 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) GENERAL NOTE: For a better understanding, the following illustrations are taken with engine out of vehicle. To perform the following instructions, it is not nec- essary to remove engine from vehicle. This CVT is lubrication free.
Page 164 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2015-022-003_a vmr2015-012-015_a CVT COVER TIGHTENING SEQUENCE CVT AIR OUTLET DUCT DISCONNECT Step 1: Loosen clamps Step 2: Remove CVT air outlet adapter CVT COVER RETAINING SCREWS 7 N•m ± 0.8 N•m Remove: Tightening torque (62 lbf•in ±...
Page 165 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) DRIVE PULLEY Slide belt over the top edge of fixed sheave. vmr2015-022-006_a vmr2015-022-007_b 1. Drive pulley Drive Belt Inspection 2. Driven pulley 3. Belt For drive belt inspection refer to DRIVE BELT INSPECTION in the...
Page 166 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Slowly release spring pressure and remove sliding sheave. Slowly release sliding sheave. Remove fixed sheave. REQUIRED TOOL CLUTCH PULLER (P/N 529 035 746) vmr2015-022-009_a 1. Drive pulley holder 2.
Page 167 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) NOTE: Whenever removing a governor cup that has the 2 boxes marked (punch marks), replace it with a new one. vmr2006-021-015_a PUSHING OUT ROLLER SLEEVE vmr2006-021-018 1. Punch 2.
Page 168 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) R400motr167A vmr2006-021-019_a 1. Lock nut 1. Spring 2. Spring sleeves 2. Centrifugal lever pivot bolt 3. Centrifugal lever 4. Thrust washers Drive Pulley Cleaning Fixed Sheave Clean pulley faces and shaft with fine steel wool and dry cloth.
Page 169 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2015-022-013_a 1. Taper tmr2011-015-006_a 2. Threads 1. Sliding sheave 3. Crankshaft 2. Bushings NOTICE Do not use acetone to clean bush- ing. Drive Pulley Inspection Governor Cup Check governor cup for cracks or other visible vmr2015-022-014_a damages.
Page 170 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) – Centrifugal lever pivot bolts ROLLER OUTER DIAMETER – Lock nuts. 13.80 mm to 14.00 mm (.543 in to .551 in) SERVICE LIMIT 13.20 mm (.52 in) ROLLER INNER DIAMETER 8.025 mm to 8.175 mm (.316 in to .322 in)
Page 171 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) CENTRIFUGAL LEVER PIVOT BOLT BORE DIAMETER 6.113 mm to 6.171 mm (.241 in to .243 in) 6.300 mm (.248 in) SERVICE LIMIT Measure bushing diameters of sliding sheave. REQUIRED TOOL Dial bore gauge MEASURING POINT...
Page 172 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Check for any marks on fixed sheave plate. Re- place if necessary. Check ring gear teeth for excessive wear or other damage. Replace fixed sheave if necessary. WARNING Fixed sheave and ring gear are balanced to- gether.
Page 173 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) NOTICE One-Way Clutch Final position of roller sleeve has to be flush with the contact surface of the slider Lubricate spring sleeves, springs and between shoes (no protrusion). one-way clutch bearings using recommended product.
Page 174 1. Drive pulley screw 2. Spring washer 3. Thrust washer WARNING Never substitute spring washer and/or screw with aftermarket parts. Always use BRP gen- uine parts. Lock the drive pulley as per removal procedure. Tighten drive pulley screw counterclockwise to specification.
Page 175 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) WARNING Driven pulley is spring loaded. Hold driven clutch pulley tight and slowly remove the driven pulley screw to release spring ten- sion. vmr2015-022-016_a 1. Drive pulley holder 2.
Page 176 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) tmr2011-015-009_a vmr2015-023-014_a 1. Ball bearing 1. Distance sleeve 2. Shaft 2. O-ring 3. Fixed sheave of driven pulley 3. Counter shaft Use a soft hammer to push shaft with bearing out Driven Pulley Disassembly of fixed sheave.
Page 177 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) NOTICE To avoid damage, make sure cleaner REQUIRED TOOL does not contact the counter oil shaft seal. Dial bore gauge MEASURING POINT At least 5 mm (1/4 in) from bushing edge BUSHINGS INNER DIAMETER 30.060 mm to 30.100 mm (1.183 in to 1.185 in)
Page 178 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) BUSHING INNER DIAMETER 30.060 mm to 30.100 mm (1.183 in to 1.185 in) SERVICE LIMIT 30.200 mm (1.189 in) Check torque gear for visible damage and cracks. Measure for wear limit using a caliper.
Page 179 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2008-127-056_a A. Squareness R400motr188A Driven Pulley Assembly 1. Shaft 2. Fixed sheave 3. Press machine For installation, reverse the removal procedure. Pay attention to following details. Install torque gear then secure it with retaining Heat ball bearing area up to 100°C (212°F) before ring.
Page 180 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Place spring behind sliding sheave then align driven pulley with cam. vmr2015-022-024_a 1. O-ring 2. Distance sleeve 3. Chamfered area of distance sleeve vmr2015-022-026_a Clean: 1. Cam –...
Page 181 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) REQUIRED TOOL PULLER/LOCKING TOOL (P/N 529 036 098) vmr2015-022-028_a 1. Puller/locking tool 2. Sliding sheave NOTE: If driven pulley sheaves cannot be opened when the service tool is screwed in, the cam is not correctly engaged in the sliding sheave.
Page 182 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) GEARBOX AND 4X4 COUPLING UNIT SERVICE TOOLS Description Part Number Page 529 036 117 ......... 227 BLIND HOLE BEARING PULLER SET........... 529 035 868 ......... 221 FLUKE 115 MULTIMETER ............
Page 183 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Loctite 767 Engine oil Engine oil Engine Engine oil 10 ± 1 N•m (89 ± 9 lbf•in) Loctite 243 vmr2015-023-001_a vmr2015-023...
Page 184 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) Loctite 5910 10 ± 1 N•m (89 ± 9 lbf•in) Loctite 5910 3 ± 0,4 N•m (27 ± 4 lbf•in) vmr2015-023-002_a vmr2015-023...
Page 185 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) 4X4 COUPLING UNIT Engine oil 7 N•m (62 lbf•in) 20 N•m (15 lbf•ft) Loctite Loctite 20 N•m (15 lbf•ft) XP-S synthetic grease 25 N•m (18 lbf•ft) Loctite synthetic grease...
Page 186 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) PROCEDURES OUTPUT SHAFT Output Shaft Removal 1. Remove engine from the vehicle. Refer to GINE REMOVAL AND INSTALLATION subsec- tion. 2. Measure output shaft axial clearance prior to re- move it.
Page 187 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) Clean crankcase and magneto cover mating sur- face and especially the bearing areas from metal particles or other contamination. Output Shaft Installation Reverse the removal procedure. However, pay at- tention to following details.
Page 188 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) NOTE: Do not apply sealant on bearing cover yet. Push output shaft as per following illustration. vmr2015-023-029_a 1. Output shaft 2. Adjustment shim 3. Ball bearing 4.
Page 189 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) GEARBOX Gearbox Disassembly ENGINE 1. Remove engine from vehicle, refer to REMOVAL AND INSTALLATION subsection. NOTE: During gearbox disassembly, inspect the condition of each part closely. 2.
Page 190 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) vmr2015-023-011_a 1. Shift fork 13. Remove: R400motr208A – Thrust washer 1. Shift fork engagement pin 2. Shift drum – Axial needle bearing – Bevel gear shaft with low range gear as- 11.
Page 191 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) 17. Remove: – Sliding gear – Needle bearing – Thrust washer – Reverse gear – Thrust washer. vmr2015-023-013_a 1. Main gear 15. Remove distance sleeve including O-ring from counter shaft on engine PTO side.
Page 192 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) vmr2015-023-031_a 1. Screw 2. Index lever 3. Step ring 4. Index spring R400motr211A Gearbox Inspection TYPICAL 1. Main gear Always verify for the following when inspecting 2.
Page 193 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) R400trans21A vmr2015-023-019_a INDEX LEVER 1. PTO side 1. Roller Shift Drum Shafts Check tracks of shift drum for scoring or heavy Check taper grooves and annular grooves of wear like rounded engagement slots.
Page 194 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) Gearbox Adjustment NOTE: Only necessary if the bevel gear backlash and the axial clearance is out of specification or if parts are changed (output shaft, bevel gear or crankcase).
Page 195 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) D (E) Crankcase mating surface MAG/PTO Magneto cover Output shaft mating surface mating surface R400trans27U Bevel Gear Backlash Procedure (MAG Side Crankcase) Use the following course of calculation to deter- mine the theoretical thrust washer thickness D: D = B - C - A Distance between the thrust surface of bevel...
Page 196 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) When all the measurements are taken, calculate the theoretical thickness D of thrust washer using the formula (D = B - C - A). Take the obtained theoretical thrust washer thick- ness D and choose the proper thrust washer num- ber E according to the following table.
Page 197 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) Distance between mating surface THEORETICAL THRUST WASHER crankcase MAG and outer race of needle THRUST WASHER NUMBER J bearing. THICKNESS I 1.22 mm to 1.31 mm (.048 in to .0516 in) 1.32 mm to 1.41 mm (.052 in to .0555 in)
Page 198 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) R400trans30A vmr2015-023-030_a 1. Mark on shift shaft 1. Intermediate gear 2. First tooth on shift drum 2. Counter shaft 3. Thrust washer after sliding gear on bevel gear 8.
Page 199 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) GEARBOX POSITION INDICATOR SWITCHES NOTE: First ensure shifter link rod is properly ad- justed, Refer to SHIFTER subsection. The multifunction gauge uses one switch state (open or closed) for each P, N and R switch to determine the gearbox position.
Page 200 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) REQUIRED TOOL FLUKE 115 MULTIMETER (P/N 529 035 868) 3. Using a multimeter, measure resistance of the position switch while selecting the gearbox to each position. Compare results with following table.
Page 201 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) vmr2015-023-027_a vmr2015-023-027_b 1. Retaining screws 1. Gearbox position switch position 1 — BLUE wire 2. Intermediate wiring harness 2. Gearbox position switch position 2 — BROWN wire 3.
Page 202 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) BODY Select 2WD position. Refer to subsection to remove; – RH inner fender panel Install the RED probe to the WHITE wire connec- tor and the BLACK probe to the WHITE/BLACK –...
Page 203 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) vmr2008-141-011_a vmr2008-141-008_a 1. Actuator fork 1. Actuator O-ring 2. Sliding sleeve dog Verify if sliding sleeve is in 2WD position. The slid- Rotate the actuator counterclockwise until it ori- ing sleeve should be pointed toward the front of ents itself to mounting position.
Page 204 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) 4WD Switch Installation Unscrew the switch from coupling unit housing. Discard the sealing washer. The installation is the reverse of the removal pro- cedure. Use a new sealing washer when installing the switch.
Page 205 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) Coupling Unit Disassembly Remove the actuator from the coupling unit by re- moving the three retaining screws. vmr2008-141-017_a 1. Sliding sleeve pin Remove sliding sleeve. vmr2008-141-014_a 1.
Page 206 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) vmr2008-141-023_a vmr2008-141-020_a 1. Coupling unit shaft 1. Coupling sleeve Using the BLIND HOLE BEARING PULLER SET Remove the inner circlip. , remove the ball bearing. (P/N 529 036 117) 529036117 vmr2008-141-021_a NOTE: Remove the ball bearing only if it does not...
Page 207 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) Measure the coupling sleeve groove. If the width Check shifter fork for visible damage, wear or bent of groove is out of specification replace the cou- claws.
Page 208 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) V07H0ZA V07H12A Insert pin and install Allen set screw. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) Move the sliding sleeve on right side and check if threads of Allen set screw.
Page 209 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT) Install the actuator onto the coupling unit. Refer ACTUATOR INSTALLATION in this section. Coupling Unit Installation The installation is the reverse of removal proce- dure. However, pay attention to the following: Apply XPS SYNTHETIC GREASE (P/N 293 550 010) coupling unit housing O-ring.
Page 210 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 13 (SHIFTER) SHIFTER SERVICE PRODUCTS Description Part Number Page 293 800 060 ......... 232 LOCTITE 243 (BLUE)..............CE Models Loctite 243 (5 ± 0.5 N•m 44 ± 4 lbf•in) Loctite 243 9 ± 1 N•m (80 ±...
Page 211 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 13 (SHIFTER) PROCEDURES HANDLE Handle Removal vmr2015-024-004_a SHIFT LEVER POSITION 3. Remove parts as indicated in following illustra- tions. vmr2015-024-002_a Step 1: Loosen lock nut Step 2: Unscrew shift lever handle Handle Installation Reverse the removal procedure.
Page 212 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 13 (SHIFTER) Shift Lever Installation Reverse the removal procedure. However, pay at- tention to the following. Adjust shift lever handle as per following illustra- tion. vmr2015-024-005_a vmr2012-021-005_a SHIFT LEVER HANDLE ALIGNMENT 1. Handle 2.
Page 213 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 13 (SHIFTER) SHIFT ROD Shift Rod Adjustment 1. Place shift lever in NEUTRAL position. NOTICE Move vehicle back and forth to en- sure gearbox is set in neutral position. 2. Secure vehicle using wheel blocks. 3.
Page 214 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 13 (SHIFTER) vmr2015-024-102_a vmr2015-024-106_a 1. Adjuster lock nuts tightened 1. Remove nut and bolt NOTE: Ensure shift rod ball joint is parallel with 3. Trace an index mark on shift plate and shift shift plate.
Page 215 Section 02 ENGINE, CVT AND GEARBOX (450) Subsection 13 (SHIFTER) Shift Plate Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Ensure gearbox is in NEUTRAL position before shift plate installation. Align shift plate using marks previously traced. If there are no index marks, adjust shift plate as per following illustration.
Page 216 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 01 (ENGINE MANAGEMENT SYSTEM (450)) ENGINE MANAGEMENT SYSTEM (450) GENERAL GBPS INJ 1 MAPTS IACV IGN COIL COOLING FAN IGN SW START SW STARTER SOLENOID FUEL PUMP vmr2015-038-001_a vmr2015-038...
Page 217 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 01 (ENGINE MANAGEMENT SYSTEM (450)) HIC2 HIC1 IACV MAPTS GBPS vmr2015-038-002_a ABBREVIATION DEFINITION ABBREVIATION DEFINITION Ignition coil Manifold absolute pressure and MAPTS temperature sensor Crankshaft position sensor 4WD Actuator Coolant temperature sensor Oil pressure switch Electronic control module 4WD Signal GBPS...
Page 218 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 01 (ENGINE MANAGEMENT SYSTEM (450)) SYSTEM DESCRIPTION Vehicle Speed Limiter The ECM will limit the maximum vehicle speed The HIC# connectors connect the vehicle harness both in 2WD and in 4WD. For this purpose, the to the powertrain harness.
Page 219 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 03 (CONTROLLER AREA NETWORK (CAN)) CONTROLLER AREA NETWORK (CAN) GENERAL SYSTEM DESCRIPTION The Controller Area Network (CAN) 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 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 04 (COMMUNICATION TOOLS AND B.U.D.S.) COMMUNICATION TOOLS AND B.U.D.S. SERVICE TOOLS Description Part Number Page 710 000 851 ......... 431 MPI-2 DIAGNOSTIC CABLE............529 036 018 ......... 431 MPI-2 INTERFACE CARD .............. SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page...
Page 221 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 04 (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 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 04 (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 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 04 (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 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 04 (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 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 05 (DIAGNOSTIC AND FAULT CODES) DIAGNOSTIC AND FAULT CODES GENERAL NOTE: In some cases, the CHECK ENGINE mes- sage can be displayed along with other messages. MONITORING SYSTEM MULTI- PILOT FUNCTION The Engine Management System (EMS) features CAUSE LAMP GAUGE...
Page 226 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 05 (DIAGNOSTIC AND FAULT CODES) FAULT CODES The active fault may or may not compromise normal operation of the system(s). Service ac- Fault Code Categories tion should be taken to correct the problem that caused the fault code.
Page 227 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 05 (DIAGNOSTIC AND FAULT CODES) 2. Press and HOLD mode button while QUICKLY toggling HI - LO beam. NOTE: A minimum of 3 HI - LO toggles must be completed within 2 seconds. rmr2011-021-001_a 1.
Page 228 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 05 (DIAGNOSTIC AND FAULT CODES) FAULT PAGE DESCRIPTION ITEM INFORMATION To display possible causes and More Details service actions related to the button selected fault Clear Fault To clear occurred faults one at a button time Clear...
Page 229 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 05 (DIAGNOSTIC AND FAULT CODES) NOTE: An active fault code cannot be cleared. MORE DETAILS PAGE DESCRIPTION In other words, the problem relevant to the fault ITEM INFORMATION code must be repaired before the fault can be cleared.
Page 230 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 05 (DIAGNOSTIC AND FAULT CODES) NOTE: The page displays data whatever there is HISTORY PAGE DESCRIPTION fault code(s) or not. 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...
Page 231 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 05 (DIAGNOSTIC AND FAULT CODES) GENERAL GUIDELINES TO SOLVE FAULT CODES CONDITION ACTION Check related fuse(s) and relay. Check related power and ground wires. Low system voltage Check for common power supply to several sensors/modules on one module.
Page 232 Section 04 ELECTRONIC MANAGEMENT SYSTEM Subsection 05 (DIAGNOSTIC AND FAULT CODES) ECUs share information and their systems may interact with each other. Certain faults may cause more than one ECU to set a fault code or indication (pilot lamp or message) as the failure of some components may affect the operation of several systems.
Page 233 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 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 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) ELECTRONIC FUEL INJECTION (450) SERVICE TOOLS Description Part Number Page 529 036 166 ......446–447, 451, ECM ADAPTER TOOL..............457, 459, 461–463 529 035 868 ..447, 451, 457, 461–463 FLUKE 115 MULTIMETER ............
Page 260 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) Fuel Injector The fuel injector is used to inject fuel into the in- take port of the cylinder head. Fuel Pump An electric fuel pump with an integrated pressure regulator and fuel system filters is used. For more FUEL TANK details on the fuel pump unit, refer to AND FUEL PUMP...
Page 261 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) CLOSED THROTTLE AND IDLE To reset IACV and TPS, perform the following: ACTUATOR RESET 1. Connect the vehicle to the latest applicable B.U.D.S. version, refer to COMMUNICATION NOTE: This operation performs a reset of the val- TOOLS AND B.U.D.S.
Page 262 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) WARNING QUICK INDICATION THAT ECM IS FUNCTIONING (assuming the observed component is Electrical actuators and electronic modules in good working order) may be powered up as soon as the ignition Multifunction gauge turns ON.
Page 263 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) 529036166 smr2009-030-010_a NOTE: This tool will prevent deforming or enlarg- If any measurement is out of specification, refer to ing terminals which would lead to bad ECM ter- POWER DISTRIBUTION and check all grounds.
Page 264 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) ECM Installation 4. Measure the resistance of the CAN resistors as per following table. Reverse removal procedure however, pay atten- tion to the following. CAN RESISTOR TEST 1. Reconnect ECM connector. DIAGNOSTIC LINK RESISTANCE CONNECTOR...
Page 265 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) mmr2009-023-080 3.2 Click once on the Folder Up button in the open box. vmr2015-042-012_a IMPORTANT: Ensure to use the file that specifi- cally matches the vehicle you are servicing. NOTE: The file name structure is as follows: BUDS version_VIN_date read (yyyymmdd)_hour read (hhmmss).mpem Example:...
Page 266 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) vmr2006-012-100_aen 8. Select the Vehicle tab and enter the informa- tion you recorded previously. – Vehicle serial number tmr2011-022-017_a – Engine number (do not enter the “M” at the ADDING PART IN HISTORY beginning of the engine number) 1.
Page 267 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) Fuel Injector Input Voltage Test Fuel Injector Resistance Test Disconnect the fuel injector electrical connector. Disconnect ECM connector. Turn on ignition switch. Install the ECM connector on the ECM ADAPTER TOOL (P/N 529 036 166) Set emergency engine stop switch to RUN.
Page 268 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) NOTICE Gently push O-ring in evenly all around while inserting injector. O-ring must be completely inserted and not visible, before completing the insertion of the injector. vmr2009-022-001_a TYPICAL - FUEL RAIL ASSEMBLY 1.
Page 269 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) To disconnect fuel rail from hose, cut clamp on Activate throttle lever a few times. Make sure fuel hose using throttle cam of throttle body rests against set OETIKER PLIERS (P/N 295 000 070) FUEL TANK AND FUEL PUMP Refer to for clamp...
Page 270 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) THROTTLE BODY Turn handlebar side to side and ensure there is still free-play in each position. Throttle Body Description To ensure there is no strain in the cable at wide open position: –...
Page 271 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) 3. Use a throttle body cleaner such as GUNK IN- TAKE MEDIC or an equivalent. NOTICE Only use an appropriate throttle body cleaner that will not damage O-rings and EFI sensors. CAUTION Use the product in a well ven- tilated area.
Page 272 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) vmr2006-014-65_a vmr2006-014-063_a Tighten clamps. Hook cable to throttle lever. – 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- CLOSED THROTTLE AND cedure.
Page 273 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) The ECM may generate several fault codes per- it indicates that the TPS needs to be replaced or DIGANOSTIC AND taining to the TPS. Refer to the computer used may be too slow to transfer FAULT CODES subsection for more information.
Page 274 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) IDLE AIR CONTROL VALVE (IACV) TPS Input Voltage Test Disconnect connector from TPS. ENGINE MANAGEMENT SYSTEM Refer to the Turn ignition key ON. subsection for component and connector loca- tions. Set emergency engine stop switch to RUN.
Page 275 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) Remove Idle air control valve from throttle body. NOTE: Take into account that a CPS fault can be triggered by bent or missing encoder wheel teeth. Check the piston and bypass channel for dirt/de- First check fault codes using B.U.D.S., then check posits which can cause a sticking piston.
Page 276 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) vmr2015-042-014_a 1. Retaining screw 2. CPS Install new CPS and secure harness with a new locking tie (as applicable). vmr2015-042-006_a CPS INSTALLATION NOTE: This sensor is a multifunction device. PRODUCT MAPTS Access O-RING XPS SYNTHETIC GREASE...
Page 277 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) MAPTS If voltage test is not good, carry out the CIRCUIT CONTINUITY TEST (PRESSURE FUNC- TION) MAPTS Circuit Continuity Test (Pressure Function) 1. Disconnect the ECM connector. 2. Install ECM connector on ECM ADAPTER TOOL (P/N 529 036 166) 3.
Page 278 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) 529036166 Using a multimeter, recheck resistance value as per following table. ECM ADAPTER MEASUREMENT RESISTANCE @ 20°C (68°F) tmr2011-022-014_b 2280 - 2740 TYPICAL 1. Monitoring tab 2. MAPTS temperature reading MAPTS TEMPERATURE SENSOR TEST RESULTS 4.
Page 279 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (450)) CTS (COOLANT TEMPERATURE ECM ADAPTER MEASUREMENT SENSOR) RESISTANCE ( ) @ 20°C (68°F) Refer to appropriate ENGINE MANAGEMENT SYSTEM subsection for component and connec- 2280 - 2736 tor locations. If resistance value is incorrect, check wiring con- tinuity between ECM connector and the CTS.
Page 280 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) FUEL TANK AND FUEL PUMP (450) SERVICE TOOLS Description Part Number Page 529 035 868 ......... 499 FLUKE 115 MULTIMETER ............529 036 023 ......... 493 FUEL HOSE ADAPTER..............529 035 899 .........
Page 281 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) = Component must be replaced when removed. To engine EUROPE vmr2015-073-100_a vmr2015-074...
Page 282 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) 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. WARNING Always disconnect battery prior to working on the fuel system.
Page 283 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) Fuel Pump Pressure Regulator The fuel pressure regulator is integral to the fuel pump module. The pressure regulator maintains proper fuel pressure for the EFI system. INSPECTION FUEL TANK LEAK TEST WARNING Always carry out a fuel tank leak test when- ever the fuel tank shows signs of wear or...
Page 284 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) TIME WITHOUT PRESSURE PRESSURE DROP 14 kPa (2 PSI) 3 minutes If pressure drops, locate fuel leak(s) and repair or replace leaking component(s). To locate a leak, check for a fuel smell or leaking fuel.
Page 285 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) 14. Remove test equipment and reconnect fuel hose to injector fuel rail by proceeding in the same manner as for its installation. Test Conclusion The fuel pressure should be within specification in static or dynamic tests.
Page 286 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) 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 287 When replacing fuel hoses, be sure to use hoses – Muffler assembly and clamps as available from BRP parts depart- – Muffler/exhaust pipe heat shield. ment. This will ensure continued proper and safe 7. Reinstall fuel tank cap to prevent foreign ob- operation.
Page 288 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) NOTE: It is not necessary to remove the wiring harness or other components from the battery support. 11. Flip the battery support over towards the RH side of the vehicle for access to the rear frame extension.
Page 289 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) 18. Remove nuts and screws securing trailer hitch and rear frame support to rear final drive. vmr2015-043-012_a Fuel Tank Inspection Inspect fuel tank for any damages or cracks which vmr2015-043-009_a may result in fuel leaks.
Page 290 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) – Fuel pump pressure hose – Electrical connectors. Refuel tank and ensure there are no leaks by performing a FUEL TANK LEAK TEST and a FUEL PUMP PRESSURE TEST as described in this sub- section.
Page 291 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) – Fuel pump relay input voltage (control and If test failed at pump connector, replace fuel power circuits) pump. – Fuel pump relay control circuit continuity to If test succeeded at pump connector, check ECM-J1 wiring and connectors from: –...
Page 292 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) WARNING Fuel vapors are flammable and explosive un- der certain conditions. Use only non-spark- ing tools. CAUTION Replace fuel pump gasket whenever fuel pump retaining nut is loosened. REQUIRED TOOL FUEL PUMP NUT TOOL (P/N 529 035 899)
Page 293 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) WARNING Fuel vapors are flammable and explosive un- der certain conditions. Use only non-spark- ing tools. Ensure pump locking ring is fully engaged. 7. Install fuel pressure hose on fuel pump using a NEW Oetiker clamp.
Page 294 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) 6. Lubricate assembly area of new strainer and fuel pump with O-ring lubricant or clean oil vmr2015-043-028_a vmr2015-043-031_a 4. Remove push nut securing strainer to fuel pump. Be careful not to break the assembly 7.
Page 295 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) 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 ±...
Page 296 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) Pressure Relief Valve Test 1. Install the small hose pincher between the inlet check valve and the fuel pump vent inlet fitting. vmr2015-043-019_a 1. Pressure relief valve 2. Fuel pump vent inlet 4.
Page 297 Section 05 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP (450)) Fuel Tank Vent Valve Installation Inlet Check Valve Installation Ensure white portion of inlet check valve is to- wards the vent breather filter. vmr2015-043-019_d 1. Vent breather filter 2.
Page 298 Section 06 ELECTRICAL SYSTEM Subsection 01 (POWER DISTRIBUTION AND GROUNDS) POWER DISTRIBUTION AND GROUNDS SERVICE TOOLS Description Part Number Page 529 035 868 ......... 527 FLUKE 115 MULTIMETER ............vmr2015-044...
Page 299 Section 06 ELECTRICAL SYSTEM Subsection 01 (POWER DISTRIBUTION AND GROUNDS) GENERAL POWER DISTRIBUTION DIAGRAM FUSE BOX 1 (PF1) 4WD SW (BD) LIGHT SW (MG2) ECM (ECM3) 12 V DC OUTLET (DC) FUSE BOX 2 (PF2) REGULATOR/ RECTIFIER IGNITION (CC) (RD) FLASHER MODULE (ce models only) (DPS1, DPS2, DPS3)
Page 300 Section 06 ELECTRICAL SYSTEM Subsection 01 (POWER DISTRIBUTION AND GROUNDS) FUSE BOX 1 vmr2015-044-006_a vmr2015-044-005_a FUSE IDENTIFICATION RATING 10 A Speedo / Relay Injector(s) / Ignition / Fuel Pump 10 A 10 A Fuse Key Switch / Starter Solenoid Cooling Fan 20 A DC Out.
Page 301 Section 06 ELECTRICAL SYSTEM Subsection 01 (POWER DISTRIBUTION AND GROUNDS) FUSE BOX 3 (PF3) 4. Connect battery as shown and probe relay again as follows. TERMINAL RESISTANCE max. (continuity) vmr2015-044-004_a FUSE IDENTIFICATION Fuse 40 A GROUNDS smr2007-027-060_a If relay failed any test, replace it. All grounds are grouped at the same location on RH side of frame.
Page 302 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) WIRING HARNESS AND CONNECTORS SERVICE TOOLS Description Part Number Page 529 035 730 ......... 541 CRIMPING TOOL (HEAVY GAUGE WIRE) ........529 036 166 ......... 539 ECM ADAPTER TOOL..............529 036 175 ......... 539 ECM TERMINAL REMOVER 2.25..........
Page 303 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) GENERAL ABBREVIATION DESCRIPTION The illustrations in this subsection are typical. Starter positive terminal Several variants of the connector types, such as Turn light relay different number of pin cavities, are used on the Turn light relay vehicle.
Page 304 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) WIRING HARNESS ARRANGEMENT HIC1 HIC2 DPS3 DPS2 DPS1 vmr2015-045-012_a vmr2015-045...
Page 305 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) CE models MC2 MC1 HICa CAG2 CAG1 vmr2015-045-001_b vmr2015-045...
Page 306 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) DIODE AND JOINT TERMINAL LOCATIONS JT BU JT GN JT RD/BK JT BK3 JT OR/GN JT BE JT VI/BU JT VI/GY JT RD/BE JT RD/OR JT RD/JY JT WH/BK JT RD/GY JT WH/BE JT RD/BK vmr2015-045-010_a...
Page 307 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) CE models JT BE JT BK JT RD/BK JT BN JT GY vmr2015-045-011_a vmr2015-045...
Page 308 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) PROCEDURES DEUTSCH CONNECTORS Deutsch Connector Application A variety of Deutsch connectors are used on var- ious systems: – Diagnostic connector – Vehicle speed sensor (VSS) connector. The following procedures may be used on each as they are similar in construction.
Page 309 Section 06 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 V01G0QA TYPICAL — FEMALE CONNECTOR 1. Retaining tabs Terminal Insertion 1. For insertion of a terminal, ensure the sec- ondary plastic lock is removed.
Page 310 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) A33Z01A TYPICAL 1. Retainer 2. Tab (one on each side) vmr2006-032-001_a Open housing by lifting 4 tabs. A33Z02A TYPICAL 1. Tabs (2 on each side) Lift the top plastic lock of the female terminal to be removed and hold in position.
Page 311 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) vmr2008-022-014_a A32E3XA Pull out connector. TYPICAL 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- tem: –...
Page 312 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) Rotate connector lock until it snaps locked. vmr2008-139-016_a 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 313 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) 529036175 1. Remove rear protector from connector. 2. Pull out the connector lock. smr2009-045-027_a NOTICE Before installing wire terminals in the connector, ensure all terminals are prop- erly crimped on wires. After installation of wire terminals in the connectors, ensure they are properly locked by gently pulling on them as if to extract them.
Page 314 Section 06 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) A32E2QA A. 10 mm (3/8 in) smr2010-050-022_a Step 2: Insert GM terminal extractor tool (P/N 12094430) NOTE: Make sure not to cut wire strands while stripping the wire. 3. Gently pull on the wire to extract the pin out the back of the connector.
Page 315 Section 06 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 316 Section 06 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM (450)) IGNITION SYSTEM (450) SERVICE TOOLS Description Part Number Page 529 036 085 ......... 548 ECM ADAPTER TOOL (ONE CONNECTOR)......... 529 035 868 ......... 544–548 FLUKE 115 MULTIMETER ............GENERAL No Multifunction Gauge and Taillight If the multifunction gauge and taillight do not func- IGNITION SYSTEM OPERATION tion, the ECM may not be powered.
Page 317 Section 06 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM (450)) tection. Always check for these problems before which then waits for the START switch signal to replacing expensive components and apply the engage the starter, and control ignition timing for protective grease as specified in the procedures. proper engine operation.
Page 318 Section 06 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM (450)) 2. Engine stop switch 3. Wiring and connectors. Ignition Switch Continuity Test Set the FLUKE 115 MULTIMETER (P/N 529 035 868) Measure the resistance through the ignition switch between the following pins. NOTE: Connector pins “B”...
Page 319 Section 06 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM (450)) Set the FLUKE 115 MULTIMETER (P/N 529 035 868) Measure the resistance through the stop switch (steering harness side) as per following table. ENGINE STOP SWITCH CONTINUITY TEST POSITION Connector RESISTANCE MG2 pin 3 MG1 pin 3 max.
Page 320 Section 06 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM (450)) vmr2008-138-006_b IGNITION COIL LOCATION When troubleshooting an ignition coil problem, vmr2008-137-005_a first carry out a spark occurrence test, refer to 1. Remove plastic pin lock SPARK PLUG in this subsection. Set the FLUKE 115 MULTIMETER (P/N 529 035 868) If there is no spark, carry out the Ignition Coil Input to Vdc.
Page 321 Section 06 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM (450)) If the measure is out of specification, verify the coil ground wire and connection. Ignition Coil Ground Circuit Continuity Test Disconnect ignition coil input connector. Disconnect ECM connector. vmr2008-137-006_b COIL GROUND CIRCUIT CONTINUITY TEST 1.
Page 322 Section 06 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM (450)) Spark Plug Cable Resistance Test If the starter rotates the engine and there is no spark indicated by the tester, follow the ignition Disconnect the spark plug cable from the spark system troubleshooting sequence as indicated.
Page 323 Section 06 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM (450)) the spark plug at prescribed intervals, examining the plug face (i.e. the part of the plug projecting into the combustion chamber). vmr2015-046...
Page 324 Section 06 ELECTRICAL SYSTEM Subsection 05 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page 380941 ......... 558 EXTECH INDUCTIVE AMMETER ..........95260 ......... 558–560 NAPA ULTRA PRO BATTERY LOAD TESTER ....... GENERAL – Fuse 3 30A –...
Page 325 Section 06 ELECTRICAL SYSTEM Subsection 05 (CHARGING SYSTEM) BATTERY REGULARLY DISCHARGED OR If battery voltage drops below specification dur- WEAK CHARG- ing test, replace battery and perform a ING SYSTEM LOAD TEST 1. Loose or corroded battery cable connections. - Tighten or repair battery cable connections. CHARGING SYSTEM LOAD TEST 2.
Page 326 Section 06 ELECTRICAL SYSTEM Subsection 05 (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 Base models (no-DPS, 35 ± 5 Amps not CE) DPS models 41 ±...
Page 327 Section 06 ELECTRICAL SYSTEM Subsection 05 (CHARGING SYSTEM) Voltage Regulator Ground Test 1. Check ground at RD1-3. TEST CONDITIONS RD1-3 Permanent ground BACKPROBE PROBE SPECIFICATION RD1-3 BAT1 (+) Battery voltage 2. Connect a battery load tester such as the NAPA ULTRA PRO BATTERY LOAD TESTER (P/N 95260) 3.
Page 328 Section 06 ELECTRICAL SYSTEM Subsection 05 (CHARGING SYSTEM) WARNING TIGHTENING TORQUE Ensure battery is stored in a safe place, out of Battery retaining plate 4.5 N•m ± 0.5 N•m reach for children. screws (40 lbf•in ± 4 lbf•in) New Battery Activation Refer to the instructions provided with the battery.
Page 329 Section 06 ELECTRICAL SYSTEM Subsection 06 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 085 ......... 565 ECM ADAPTER TOOL (ONE CONNECTOR)......... 529 035 868 ......... 567 FLUKE 115 MULTIMETER ............GENERAL ENGINE TURNS Starting system is OK. STARTING SYSTEM OPERATION 1.
Page 330 Section 06 ELECTRICAL SYSTEM Subsection 06 (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 331 Section 06 ELECTRICAL SYSTEM Subsection 06 (STARTING SYSTEM) TEST CONDITION Pressed Start button Engine Cranking ‡ Will prevent engine from starting 1. Measure voltage drop. vmr2008-139-003_a MG2 STEERING HARNESS CONNECTOR PIN-OUT TEST CONDITION Engine stop switch Ignition switch PROBE PROBE SPECIFICATION vmr2015-048-008_a MG2-1...
Page 332 Section 06 ELECTRICAL SYSTEM Subsection 06 (STARTING SYSTEM) vmr2008-139-016_a 1. ECM connector vmr2015-048-012_a 2. ECM adapter tool 1. SS1 PROBE PROBE SPECIFICATION ECM-L3 Close to 0 If resistance is not as specified, repair or replace wiring/connections. If solenoid power control circuit and ground con- trol circuit both test good, test ECM ground ELECTRONIC FUEL INJECTION circuits.
Page 333 Section 06 ELECTRICAL SYSTEM Subsection 06 (STARTING SYSTEM) Use the FLUKE 115 MULTIMETER (P/N 529 035 868) and set it to the diode symbol as shown. vmr2015-048-009_a SS1 IS ON THE RIGHT PROBE PROBE SPECIFICATION Terminal to Close to 0 starter motor If resistance is not as per specification, replace the vmr2006-020-005...
Page 334 Section 06 ELECTRICAL SYSTEM Subsection 06 (STARTING SYSTEM) WIRING If test failed, replace diode. Refer to HARNESS AND CONNECTORS for diode loca- tion. NOTE: The diode is integrated in the harness near the starter solenoid. vmr2015-048...
Page 335 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) LIGHTS, GAUGE AND ACCESSORIES SERVICE TOOLS Description Part Number Page 529 035 868 ......... 576, 578 FLUKE 115 MULTIMETER ............SERVICE PRODUCTS Description Part Number Page 293 550 004 ......... 572 DIELECTRIC GREASE ..............
Page 336 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) When this indicator is ON, it indicates an engine fault code, look for a message in the main screen display. When this indicator blinks, it indicates that LIMP HOME mode is activated. 8) Fuel Level Display Bar gauge continuously indicates the level of fuel vdd2008-001-085_a...
Page 337 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Navigating the LCD Gauge WARNING Never adjust or set functions on the multi- function gauge while riding the vehicle. Default Display Mode After vehicle startup, the default display mode is either: vsi2009-018-031 –...
Page 338 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Check for signs of moisture, corrosion or dullness. Clean pins properly and coat them with DIELEC- or other appropriate TRIC GREASE (P/N 293 550 004) lubricant when reassembling them, except if oth- erwise specified such as for the ECM connector.
Page 339 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) DIAGNOSTIC GUIDELINES 6. Defective flasher module. (LIGHTS) - Replace flasher module, refer to FLASHER MOD- ULE in this subsection. BRAKE LIGHTS WILL NOT COME ON HAZARD LIGHTS COME ON WITHOUT WHEN BRAKES APPLIED BEING SELECTED (CE MODELS ONLY) 1.
Page 340 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Multifunction Gauge Wire HORN WILL NOT FUNCTION (CE MODELS ONLY) Identification 1. Burnt Clock/Hazard fuse (F4) FUNCTION COLOR - Check fuse 12 volt input from fuse F4 17 OR/GN 2. Defective horn. 12 volt input from fuse F8 - Test horn by applying 12 Vdc and ground jumper (Clock)
Page 341 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) 4. If the 12-hour format was selected, choose Am Clock Setting (A) or Pm (P) by pressing button. In B.U.D.S., select the: 5. Choose hour first digit by pressing button. –...
Page 342 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Multifunction Gauge CAN Resistor Test 1. Disconnect DPS1 connector (control) from the DPS module, refer to STEERING SYSTEM sub- section. 2. Remove seat to access diagnostic link connec- tor (DB). 3.
Page 343 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) New Multifunction Gauge Registration TEST RESULT (coding) READING POSSIBLE CAUSE Whenever the multifunction gauge is replaced, Approximately ECM and CLUSTER CAN wires and B.U.D.S. must be used to register it in the ECM. resistors good Simply click Yes when the following message CAN wire to CLUSTER open...
Page 344 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) HEADLIGHTS SWITCH WIRE COLOR VOLTAGE POSITION Headlight Wire Identification Battery LO beam GREEN ACCESSORY RELAY (R3) voltage (Low beam FUNCTION COLOR connector) HI beam BLACK No voltage 12 volt input from fuse RD/GN Lo beam BLUE...
Page 345 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) 3. Trace a line on the test surface parallel to the ground at each measured height (one for high beam and one for low beam). Low beam aiming is correct when the crest of the low beam is below the applicable horizontal cen- ter line traced on the test surface as per specifi- cation.
Page 346 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Taillight Circuit Protection FLASHER MODULE CONDITION CIRCUIT PROTECTION FUNCTION COLOR Supplied when main Fuse 4 of fuse block 1 Output to multifunction relay R2 activated (from main relay R2) gauge (turn signal MC2-4 indicator) Taillight/Brake Light Bulb Replacement...
Page 347 Section 06 ELECTRICAL SYSTEM Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) vmr2012-035-012_a 1. Flasher module location HORN (CE MODELS ONLY) Horn Wire Identification HORN SWITCH (IN MULTIFUNCTION SWITCH) FUNCTION COLOR 12 volt input from MG3-3 fuse F8 12 volt output to horn MG3-4 BE/BK HORN...
Page 348 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) FRONT DRIVE (450) SERVICE TOOLS Description Part Number Page 529 035 665 ......... 589 BACKLASH MEASUREMENT TOOL..........529 036 120 ......... 587 CV BOOT CLAMP PLIER .............. 529 036 005 ......... 587 CV JOINT EXTRACTOR..............
Page 349 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) 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) Hi-temp bearing (M10) grease NLGI-2 STEERING or equivalent SYSTEM Synthetic grease...
Page 350 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) 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 351 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) 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 352 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) 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 353 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) 529036005 vmr2015-074-002_a FROM LH SIDE 4. Remove screw securing the propeller shaft to the front differential. 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 354 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) vmr2015-074-005_a vmr2006-023-015_a NOTICE Be careful not to knock or to bend 1. Tab of backlash measurement tool vent hose fitting while removing front differen- 2. Mark on tab A. 25.4 mm (1 in) tial.
Page 355 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) 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 356 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) 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 357 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) 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 358 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) 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 359 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) Refill front differential with recommended oil. Re- TIGHTENING TORQUE PERIODIC MAINTENANCE PROCEDURES fer to 75 N•m ± 5 N•m subsection. (55 lbf•ft ± 4 lbf•ft) Propeller shaft screws FRONT PROPELLER SHAFT LOCTITE 648 (GREEN) (P/N 413 711 400) Front Propeller Shaft Removal...
Page 360 Section 07 DRIVE SYSTEM Subsection 01 (FRONT DRIVE (450)) NOTE: Position propeller shaft U-joint as shown for proper grease fitting location. V01H10A Install bearing caps. Use a vise to push bearing caps. V01H11A Using a suitable pusher, fully seat bearing cap on one side.
Page 361 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) REAR DRIVE SERVICE TOOLS Description Part Number Page 529 035 665 ......... 620 BACKLASH MEASUREMENT TOOL..........529 036 120 ......... 616 CV BOOT CLAMP PLIER .............. 529 036 005 ......... 617 CV JOINT EXTRACTOR..............529 035 649 .........
Page 362 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) MODELS WITH 500 ENGINE XPS Synthetic grease MAX models XPS Synthetic Short models grease XPS Synthetic 205 ± 15 N•m grease (151 ± 11 lbf•ft) 90 ± 5 N•m (66 ± 4 lbf•ft) XPS Synthetic grease Synthetic...
Page 363 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) MODELS WITH 450 ENGINE XPS Synthetic grease MAX models XPS Synthetic Short models grease XPS Synthetic 205 ± 15 N•m grease (151 ± 11 lbf•ft) 90 ± 5 N•m (66 ± 4 lbf•ft) XPS Synthetic grease Synthetic...
Page 364 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) XPS synthetic grease For preload adjustment 32 ± 3 N•m (24 ± 2 lbf•ft) For backlash adjustment 22.5 ± 2.5 N•m (17 ± 2 lbf•ft) 180 ± 15 N•m (133 ± 11 lbf•ft) LH threads 5 ±...
Page 365 Section 07 DRIVE SYSTEM Subsection 03 (REAR 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 366 Section 07 DRIVE SYSTEM Subsection 03 (REAR 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 ± 11 lbf•ft) Refer to DRIVE SHAFT BOOT NOTE: If required, tighten castellated nut further...
Page 367 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) PROPELLER SHAFT Remove and discard the circlip. A new one is in- cluded in the boot kit. Propeller Shaft Removal With the Special Tool Place drive shaft in vice with the joint downward. Install the CV JOINT EXTRACTOR (P/N 529 036 005) on bearing.
Page 368 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) 7. Remove rear final drive retaining bolts. Refer to REAR FINAL DRIVE in this subsection. 8. Remove bolts from rear retaining plate. Refer REAR FINAL DRIVE in this subsection. 9. Move the rear final drive rearward to allow dis- lodging the propeller shaft.
Page 369 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) Support U-joint in vice and drive inner yoke down PARTS TORQUE to remove remaining bearing caps. 75 N•m ± 5 N•m Remove U-joint cross. (55 lbf•ft ± 4 lbf•ft) Propeller shaft screw (rear final drive side) Propeller Shaft U-Joint Installation LOCTITE 648 (GREEN)
Page 370 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) V01H12A vmr2015-052-003_a Unplug the vent hose from final drive. Install snap ring. Complete installation for the other bearing caps. PERIODIC MAINTE- Grease U-joint. Refer to NANCE PROCEDURES subsection. REAR FINAL DRIVE Rear Final Drive Removal PERIODIC MAINTENANCE Drain oil.
Page 371 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) BACKLASH ADJUSTMENT GUIDELINE BACKLASH WHAT TO DO MEASUREMENT Add shim(s) and recheck Below 0.1 mm (.004 in) backlash Remove shim(s) and Above 0.35 mm (.014 in) recheck backlash vmr2006-023-015_a 1. Tab of backlash measurement tool 2.
Page 372 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) vmr2015-052-006_a PRELOAD SPECIFICATION vmr2015-052-007_a 0.06 N•m (.5 lbf•in) to 0.50 N•m (4 lbf•in) Split final drive housings. NOTE: Be careful to keep track of shims on ring If preload is out of specification, split final drive gear.
Page 373 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) Unscrew the pinion nut. Use the SPANNER SOCKET (P/N 529 035 649) 529035649 vmr2015-052-011_a 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: PART Pipe: 83 mm (3-1/4 in) diameter x 127 mm...
Page 374 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) RECOMMENDED SHIM THICKNESS See procedure for pinion gear PINION GEAR shim thickness BACKLASH 0.5 mm (.02 in) (as a preliminary adjustment) PRELOAD Procedure for pinion gear shim thickness: 1. Remove the old pinion gear and install the new one without the ball bearing.
Page 375 Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) – Check backlash. Install the shim(s) then a NEW ball bearing. – Check preload. install a NEW O-ring. Apply to pinion nut. Ring Gear LOCTITE 277 (P/N 293 800 073) Install and tighten the pinion nut as per specifica- The installation is the reverse of the removal pro- tion.
Page 376 Section 08 CHASSIS Subsection 01 (WHEELS AND TIRES) WHEELS AND TIRES SERVICE PRODUCTS Description Part Number Page 293 800 070 ......... 627 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 377 Section 08 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 378 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) STEERING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 059 ......... 632 STEERING ALIGNMENT TOOL............. SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page 16 ga ......... 633 SMOOTHFLOW™ TAPERED TIP..........#511 rtt-b SERVICE PRODUCTS Description Part Number...
Page 379 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) Without DPS Loctite Europe Loctite Synthetic grease 31.5 ± 3.5 N•m (23 ± 3 lbf•ft) Loctite 72.5 ± 7.5 N•m (53 ± 6 lbf•ft) Loctite 767 72.5 ± 7.5 N•m (53 ± 6 lbf•ft) 57.5 ±...
Page 380 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) With DPS Europe Loctite Loctite Synthetic grease 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 ± 7.5 N•m (53 ±...
Page 381 Section 08 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 382 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) PROCEDURES HANDLEBAR GRIP Handlebar Grip Removal 1. Loosen the screw at the end of handlebar grip. 2. Remove the handlebar grip cap. 3. Cut and remove the handlebar grip. Handlebar Grip Installation vmr2008-068-009 1.
Page 383 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) vmr2015-054-003_a vmr2012-033-001_a Handlebar Inspection 1. Dash board support Inspect the handlebar for damage, cracks or bend- Steering Connector Identification ing. Replace if any of these problems is detected. Handlebar Installation The installation is the reverse of the removal pro- cedure.
Page 384 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) vmr2012-039-006_a TYPICAL - MULTIFUNCTION SWITCH 2. Separate multifunction switch from handlebar. 3. Disconnect multifunction switch steering con- STEERING CONNECTOR nectors, refer to IDENTIFICATION in this subsection: – MG1 – MG2 – MG3. V07I0FA TYPICAL - THROTTLE LEVER HOUSING 4.
Page 385 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) BRAKES 2. Disconnect brake hose, refer to sub- section. Brake Lever Removal (At Handlebar) 1. Remove brake lever retaining screws. V07I0HA vmr2008-068-004_a 1. Inner housing protector TYPICAL 1. Remove these retaining screws 7. Slide cable in clip slot and remove the end of the cable from clip.
Page 386 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) vmr2012-033-001_a 1. Dash board support vmr2015-054-005_a 1. Lower retainer mounting screws (2) AIR IN- 4. Remove the air intake silencer. Refer to 2. Lower half bushing retainer 3. Steering column TAKE SYSTEM subsection. 4.
Page 387 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) vmr2012-039-011_a vmr2012-033-001_a SOME PARTS REMOVED FOR CLARITY 1. Dash board support 1. Steering column 2. Steering column lower pinch screw and nut AIR IN- 4. Remove the air intake silencer. Refer to 3. DPS unit TAKE SYSTEM subsection.
Page 388 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) Models Without a DPS PRODUCT 4. Check if steering column lower ball bearing O-rings, half XPS SYNTHETIC GREASE turns freely and smoothly. Replace if neces- bushings and DPS (P/N 293 550 010) sary. input shaft splines DPS output shaft LOCTITE 767 (ANTISEIZE...
Page 389 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) WARNING Maximum tie-rod unengaged length must not exceed specification. Both tie-rod ends must be engaged equally. tmr2011-034-107_a MAXIMUM TIE-ROD UNENGAGED LENGTH vmr2015-054-004_a A. 32 mm (1-1/4 in) TIE ROD AT PITMAN ARM 1. Steering column Install NEW cotter pins.
Page 390 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) vmr2015-054-006 V07I0SA 6. Detach upper suspension arm from knuckle, re- TYPICAL 1. Circlip FRONT SUSPENSION fer to 3. Install knuckle on a press. 7. Detach lower suspension arm from knuckle, re- FRONT SUSPENSION fer to 4.
Page 391 Section 08 CHASSIS Subsection 02 (STEERING SYSTEM) PITMAN ARM (WITHOUT A DPS) Pitman Arm Removal 1. Remove tie rod ends from pitman arm. Refer TIE ROD in this subsection. 2. Remove and discard cotter pin. vmr2015-054-009_a Pitman Arm Inspection Inspect pitman arm for cracks or other damages. Replace if necessary.
Page 392 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) DYNAMIC POWER STEERING (DPS) SERVICE TOOLS Description Part Number Page 529 035 868 ......... 652 FLUKE 115 MULTIMETER ............529 036 225 ......... 663, 665 PITMAN ARM JIG ................. 529 036 227 ......... 664 PITMAN ARM PULLER ..............
Page 393 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 394 Section 08 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 395 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) DPS ASSIST MODE Here is the list of provided flow charts: – Flow chart A: No Assistance From DPS 1. To view the active DPS ASSIST mode, momen- – Flow chart B: DPS Intermittent Assistance tarily press and release the OVERRIDE/DPS –...
Page 396 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart A vbs2014-009-001_aen vmr2015-055...
Page 397 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart B vbs2014-009-002_aen vmr2015-055...
Page 398 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart C vbs2014-009-003_aen vmr2015-055...
Page 399 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart D vbs2014-009-004_aen vmr2015-055...
Page 400 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart E vbs2014-009-006_aen vmr2015-055...
Page 401 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) PROCEDURES 2. Test for 12 Vdc DPS motor power at DPS2-A and DPS2-B as per following table. DPS UNIT MULTIMETER PROBE POSITIONS VOLTAGE DPS Unit Fuse Test DPS2 power connector pin A A 40 A DPS fuse located in a fuse holder, on the Battery ground RH side of the frame, under the battery support,...
Page 402 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) 4. Test for 12 Vdc power to the DPS module at MULTIMETER PROBE READING DPS1-A as per following table. POSITIONS MULTIMETER PROBE DPS GDN VOLTAGE POSITIONS connector pin A Continuity Battery ground (close to 0 DPS control connector (pin A) DPS GDN...
Page 403 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) If resistance measured is out of specification, check wires and connector pins. Carry out re- pairs as required and reset fault codes using B.U.D.S software. If resistance measured is good, replace the DPS unit and reset fault codes using B.U.D.S software.
Page 404 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) 5. With the vehicle engine running in PARK, turn the handlebar side to side, momentarily against each stop and observe the indications on the B.U.D.S. DPS Monitoring page. The DPS Torque Sensor Nm increase with torque applied to handlebar.
Page 405 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) – Steering column shim adjustment at half bush- 6. Remove the steering column pinch bolt and re- DPS UNIT INSTALLA- ings as described in the taining nut. Discard the retaining nut. TION procedure detailed in this section.
Page 406 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2012-039-014_a DPS REMOVAL - RH SIDE vmr2010-003-023 1. DPS TYPICAL - TIE ROD ENDS (HARDWARE REMOVED) 2. RH DPS support bracket 3. Remove these screws (2) 9. Pull up on the steering column to partly disen- NOTE: Discard the conical spring washers on the gage it from the DPS unit.
Page 407 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2012-039-035_a 1. DPS heat shield vmr2012-039-016_a 2. Retaining screws to hold steady (2 not visible) TYPICAL - LH DPS SUPPORT BRACKET 3. Retaining nuts to remove 1. DPS unit 2. DPS support bracket 3.
Page 408 Section 08 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 409 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-031 vmr2010-003-023_a TYPICAL - STEERING COLUMN INDEXED TO DPS SHAFT TYPICAL SPLINES 1. Pitman arm 2. Tie rod ends inserted in pitman arm 7. Ensure the following are properly positioned 3. Hardened steel washer on tie rod end on the lower steering shaft and lower steering 9.
Page 410 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2012-039-102_a DPS AND STEERING TORQUE SEQUENCE (3 OF 3) 12. Install the second hardened steel washer and nut on each tie-rod end. Tighten retaining nuts vmr2012-039-100_a as specified. DPS AND STEERING TORQUE SEQUENCE (1 OF 3) TIGHTENING TORQUE 72.5 N•m ±...
Page 411 Section 08 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 412 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) REQUIRED TOOLS PITMAN ARM JIG (P/N 529 036 225) 4. Insert the DPS input shaft in the Pitman arm jig receptacle with the Pitman arm facing up. vmr2010-003-040 DPS SOFTWARE UPDATE 4.
Page 413 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) REQUIRED TOOL POSITIONING ADAPTOR (P/N 529 036 230) vmr2012-039-026_b 1. Extractor nut 2. No space here 8. Install the universal Pitman arm puller over the Pitman arm and the extractor thrust bearing. REQUIRED TOOL vmr2012-039-024_a 1.
Page 414 Section 08 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 DPS output LOCTITE 767 (ANTISEIZE vbs2011-015-008_a shaft splines LUBRICANT) (P/N 293 800 070)
Page 415 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2012-039-032_a vmr2012-039-030_a 1. Spline keyway alignment here 5. Turn the jig positioning screw until the align- ment point makes proper contact with the Pit- man arm. NOTE: Ensure positioning screw is centered in Pitman arm tube.
Page 416 Section 08 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) 9. Carry out a steering alignment as described in this subsection. vmr2015-055...
Page 417 Section 08 CHASSIS Subsection 04 (FRONT SUSPENSION) FRONT SUSPENSION SERVICE TOOLS Description Part Number Page 529 036 310 ......... 675 BALL JOINT REMOVAL TOOL............vmr2015-056...
Page 418 Section 08 CHASSIS Subsection 04 (FRONT SUSPENSION) UPPER SUSPENSION ARMS AND COMPONENTS 61 ± 9 N•m (45 ± 7 lbf•ft) 73 ± 7 N•m (54 ± 5 lbf•ft) Suspension Grease 3.0 ± 0.5 N•m 90° from arm axis (27 ± 4 lbf•in) Suspension Grease 3.0 ±...
Page 419 Section 08 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 420 Section 08 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 421 Section 08 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 422 Section 08 CHASSIS Subsection 04 (FRONT SUSPENSION) 5. Remove ball joint nut and washer. vmr2015-056-006_a 9. Remove screws and nuts securing suspension vmr2015-056-005_a arm to frame. 6. Carefully move brake hose aside. 7. Using a plastic hammer, carefully hit on the knuckle side to separate ball joint from knuckle.
Page 423 Section 08 CHASSIS Subsection 04 (FRONT SUSPENSION) Perform steering alignment procedure. Refer to 2. Remove circlip from ball joint. STEERING ALIGNMENT subsection. SUSPENSION ARM BUSHINGS Suspension Arm Bushings Removal 1. Remove wear plates, bushings and sleeves from suspension arm. vmr2015-056-010 LOWER BALL JOINT vmr2015-056-009_a LOWER SUSPENSION ARM...
Page 424 Section 08 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 425 Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) REAR SUSPENSION SERVICE TOOLS Description Part Number Page 529 036 184 ......... 681 SPRING COMPRESSOR ............... SERVICE PRODUCTS Description Part Number Page 293 550 033 ......... 684 SUSPENSION GREASE ..............vmr2015-057...
Page 426 Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) TRAILING ARMS AND SWAY BAR 255 ± 10 N•m (188 ± 7 lbf•ft) 3.0 ± 0.5 N•m (27 ± 4 lbf•in) Suspension Grease 90° from arm axis Suspension Grease Suspension Grease 3.0 ± 0.5 N•m (27 ±...
Page 427 Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) SHOCK ABSORBERS 61 ± 9 N•m (45 ± 7 lbf•ft) = Components must be replaced when removed vmr2015-057-101 vmr2015-057...
Page 428 Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) GENERAL Check the following conditions that will denote a defective shock: The procedure described below is the same for – A skip or a hang back when reversing stroke at the RH and LH sides, unless otherwise instructed. mid travel –...
Page 429 Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) vmr2015-057-018_a tmr2011-036-020 CAP OPENING AT 180° TYPICAL SWAY BAR 5. Install a NEW bushing as the reverse of re- moval. Sway Bar Removal 6. Install shock absorber on vehicle. 1. Safely lift and support the vehicle off the ground.
Page 430 Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) PERIODIC MAINTE- Lubricate sway bar. Refer to NANCE PROCEDURES subsection. TRAILING ARM Trailing Arm Removal 1. Safely lift and support the vehicle off the ground. REAR DRIVE 2. Remove wheel hub, refer to sub- section.
Page 431 Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) 4. Remove drive shaft bearing from trailing arm. Link Arm Inner Bushing Removal Remove both bushings and sleeve from trailing arm. vmr2015-057-008 6. Firmly hold trailing arm then remove: – Shock absorber lower screw –...
Page 432 Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) Trailing Arm Inspection Check trailing arms for: – Cracks – Bending. Check seals condition. Check inner race of each pivot bearing with your finger. Bearings should turn smoothly and quietly. Replace all damaged parts. Trailing Arm Assembly and Installation The installation is the reverse of the removal pro- vmr2015-057-017_a...
Page 433 Section 08 CHASSIS Subsection 06 (BRAKES) BRAKES SERVICE TOOLS Description Part Number Page 529 036 166 ......... 692 ECM ADAPTER TOOL..............SERVICE PRODUCTS Description Part Number Page 219 701 705 ......... 695 XPS BRAKES AND PARTS CLEANER (USA) ......... 219 701 776 ......... 695 XPS BRAKES AND PARTS CLEANER ...........
Page 434 Section 08 CHASSIS Subsection 06 (BRAKES) OUTLANDER L (FRONT CIRCUIT) All Except CE Models 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 450 engine only To rear circuit 5.5 ± 1.5 N•m (49 ± 13 lbf•in) 28.5 ± 1.5 N•m (21 ±...
Page 435 Section 08 CHASSIS Subsection 06 (BRAKES) OUTLANDER L (REAR CIRCUIT) All Except CE Models 33.5 ± 3.5 N•m (25 ± 3 lbf•ft) 61 ± 9 N•m (45 ± 7 lbf•ft) MAX models 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 0.7 ±...
Page 436 Section 08 CHASSIS Subsection 06 (BRAKES) OUTLANDER L (FRONT CIRCUIT) CE Models 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 450 engine only 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) To rear circuit 5.5 ± 1.5 N•m (49 ± 13 lbf•in) 28.5 ±...
Page 437 Section 08 CHASSIS Subsection 06 (BRAKES) OUTLANDER L (REAR CIRCUIT) CE Models 33.5 ± 3.5 N•m (25 ± 3 lbf•ft) 61 ± 9 N•m MAX models (45 ± 7 lbf•ft) 0.7 ± 0.1 N•m 28.5 ± 1.5 N•m (6 ± 1 lbf•in) (21 ±...
Page 438 Section 08 CHASSIS Subsection 06 (BRAKES) CALIPERS AND BRAKE LEVERS All Models 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 1.3 ±...
Page 439 Section 08 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. NOTE: Sealing washers must be discarded and replaced with new ones every time a Banjo bolt is unscrewed.
Page 440 Section 08 CHASSIS Subsection 06 (BRAKES) PROCEDURES 6. If load reading is not in accordance with the specification: BRAKE LIGHT SWITCHES 6.1 Perform a brake system inspection and cleaning. Brake Light Switch Location 6.2 Bleed brake system. The brake light switch is located on the brake PERIODIC MAINTENANCE NOTE: Refer to pedal master cylinder.
Page 441 Section 08 CHASSIS Subsection 06 (BRAKES) Brake Light Switch Replacement 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. Install NEW sealing washers. 5.
Page 442 Section 08 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) Install NEW sealing washers. PERIODIC Refill and bleed brake system, refer to MAINTENANCE PROCEDURES subsection.
Page 443 Section 08 CHASSIS Subsection 06 (BRAKES) vmr2015-058-002_a vmr2015-058-003_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 444 Section 08 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 445 Section 08 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 446 Section 08 CHASSIS Subsection 07 (BODY (450)) BODY (450) SERVICE TOOLS Description Part Number Page 295 000 070 ......... 709 OETIKER PLIERS................vmr2015-059...
Page 447 Section 08 CHASSIS Subsection 07 (BODY (450)) BODY PARTS NOMENCLATURE (SHORT MODEL) vmr2015-059-100_a 1. Gauge support 8. Footrest panel 2. Console 9. Side panel extension 3. Seat 10. Side panel 4. Rear fender 11. Inner fender panel 5. Rear rack 12.
Page 448 Section 08 CHASSIS Subsection 07 (BODY (450)) BODY PARTS NOMENCLATURE (MAX MODEL) vmr2015-059-101_a 1. Gauge support 9. Footrest panel 2. Console 10. Rear side panel extension 3. Seat 11. Side panel extension 4. Passenger seat 12. Side panel 5. Rear rack 13.
Page 449 Section 08 CHASSIS Subsection 07 (BODY (450)) FRONT AND REAR BODY MODULES (SHORT MODEL) vmr2015-059-102_a 1. Front body module 2. Rear body module vmr2015-059...
Page 450 Section 08 CHASSIS Subsection 07 (BODY (450)) FRONT AND REAR BODY MODULES (MAX MODEL) vmr2015-059-103_a 1. Front body module 2. Rear body module vmr2015-059...
Page 451 Section 08 CHASSIS Subsection 07 (BODY (450)) BODY PARTS (SHORT MODEL) Please note that unless indicated, the procedure is the same for both sides. CE Models vmr2015-059-104_a vmr2015-059...
Page 452 Section 08 CHASSIS Subsection 07 (BODY (450)) BODY PARTS (SHORT MODEL) 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) CE models 4.5 ± 0.5 N•m (40 ±...
Page 453 Section 08 CHASSIS Subsection 07 (BODY (450)) BODY PARTS (MAX MODEL) 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) vmr2015-059-108_a vmr2015-059...
Page 454 Section 08 CHASSIS Subsection 07 (BODY (450)) RACKS AND BODY PARTS 4.5 ± 0.5 N•m (40 ± 4 lbf•in) CE Models 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 15 ± 2 N•m (133 ± 18 lbf•in) 15 ± 2 N•m (133 ±...
Page 455 Section 08 CHASSIS Subsection 07 (BODY (450)) PASSENGER SEAT 25 ± 3 N•m (18 ± 2 lbf•ft) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) vmr2015-059-109_a vmr2015-059...
Page 456 Section 08 CHASSIS Subsection 07 (BODY (450)) PROCEDURES FRONT BODY MODULE Front Body Module Removal PLASTIC RIVET NOTE: Unless indicated, RH side shown on illus- Plastic rivets are used in the riveting of the vari- trations. ous body parts. Plastic rivets can be reused many 1.
Page 457 Section 08 CHASSIS Subsection 07 (BODY (450)) vmr2015-059-003_a vmr2015-059-006_a 1. Locking tie 2. Headlight connectors 6. Remove screw securing front fender to footrest panel (on both sides). vmr2015-059-007_a LH SIDE 9. Remove screws securing front rack to frame. vmr2015-059-004_a 7. Detach front fender from footrest panel by re- leasing retaining tabs (on both sides).
Page 458 Section 08 CHASSIS Subsection 07 (BODY (450)) Front Body Module Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Tighten front fender screws to specification. TIGHTENING TORQUE 4.5 N•m ± 0.5 N•m Screws securing footrest panels to front fender (40 lbf•in ±...
Page 459 Section 08 CHASSIS Subsection 07 (BODY (450)) vmr2015-059-012_a LH SIDE SHOWN vmr2015-059-017_a SHORT MODEL SHOWN 8. Remove rear rack lower retaining screws and nuts. 11. Remove fuel tank cap. 12. Place a clean rag into fuel tank filler tube. 13. With the assistance of a person, pull rear body module rearward.
Page 460 Section 08 CHASSIS Subsection 07 (BODY (450)) INNER FENDER PANELS TIGHTENING TORQUE Inner Fender Removal and Installation Rear storage 4.5 N•m ± 0.5 N•m compartment screws (40 lbf•in ± 4 lbf•in) Remove plastic rivets from inner fender panels. CONSOLE Console Removal 1.
Page 461 Section 08 CHASSIS Subsection 07 (BODY (450)) 6. Lift rear portion of side panel assembly then pull it towards outside. vmr2015-059-022_a 4. Remove plastic rivet securing side panel to air filter housing. vmr2015-059-023_a MAX Models 7. Remove plastic rivet securing rear side panel extension to rear fender.
Page 462 Section 08 CHASSIS Subsection 07 (BODY (450)) BACK OF PANEL SHOWN 5. Remove panel extension. Panel Extension Installation vmr2015-059-024_a FRAME AND ENGINE REMOVED FOR CLARITY Installation is the reverse of removal. 10. Lift rear portion of side panel assembly then PASSENGER SEAT HOLDER pull it towards outside.
Page 463 Section 08 CHASSIS Subsection 07 (BODY (450)) TIGHTENING TORQUE Passenger seat holder 4.5 N•m ± 0.5 N•m retaining screws (40 lbf•in ± 4 lbf•in) REAR SIDE PANEL EXTENSIONS (MAX MODEL) Rear Side Panel Extension Removal 1. Remove driver and passenger seats. 2.
Page 464 Section 08 CHASSIS Subsection 07 (BODY (450)) TIGHTENING TORQUE Rear storage 4.5 N•m ± 0.5 N•m compartment retaining (40 lbf•in ± 4 lbf•in) screws FOOTREST PANELS Footrest Panel Removal Short Models 1. Remove footrest panel retaining screws. 3. Remove both plastic rivet securing inner fender panel to footrest panel.
Page 465 Section 08 CHASSIS Subsection 07 (BODY (450)) Footrest Panel Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Tighten footrest panel screws to specification. TIGHTENING TORQUE Footrest panel retaining 4.5 N•m ± 0.5 N•m screws (40 lbf•in ±...
Page 466 Section 08 CHASSIS Subsection 07 (BODY (450)) TIGHTENING TORQUE 4.5 N•m ± 0.5 N•m Screws securing fender to front rack (40 lbf•in ± 4 lbf•in) Rear Rack Removal 1. Remove screws securing rear fenders and stor- age compartment to rack. vmr2015-059-033_a BOTTOM UP VIEW 2.
Page 467 Section 08 CHASSIS Subsection 07 (BODY (450)) 4. Remove rack from vehicle. Rear Rack Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following: Tighten rear rack retaining screws to specification. TIGHTENING TORQUE Screws securing rear 4.5 N•m ±...
Page 468 Section 08 CHASSIS Subsection 09 (FRAME) FRAME SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page model 9600 ......... 744 BLIND THREADED INSERT INSTALLER........Models Rear frame 24.5 ± 3.5 N•m extension (18 ± 3 lbf•ft) 61 ± 9 N•m (45 ±...
Page 469 Replace frame as neces- sary. Frame Welding No welding should be done on frame except if mentioned or required on an approved BRP Bul- letin. vmr2015-060-001_a INSERT FOR M6 BOLT SHOWN A. 9 mm ± 0.5 mm (.354 in ± .02 in)
Page 470 Section 08 CHASSIS Subsection 09 (FRAME) vsi2014-017-003 REPLACEMENT KIT TIGHTENING TORQUE 24.5 N•m ± 3.5 N•m Footrest bracket nuts (18 lbf•ft ± 3 lbf•ft) vmr2015-060...
Page 471 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER L 450) OUTLANDER L 450 ENGINE ROTAX 450, 4-stroke, Single Over Head Engine type Camshaft (SOHC), liquid cooled Number of cylinder Number of valves 4 valves (mechanical adjustment) Bore 94 mm (3.7 in) Stroke 61.5 mm (2.42 in) Displacement...
Page 472 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER L 450) ENGINE Upper compression ring 0.20 mm to 0.35 mm (.008 in to .014 in) Lower compression ring 0.35 mm to 0.55 mm (.014 in to .022 in) Oil scraper ring 0.20 mm to 0.70 mm (.008 in to .028 in) Piston ring end gap Upper compression ring 0.60 mm (.024 in)
Page 473 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER L 450) ENGINE 42.016 mm to 42.040 mm (1.6542 in to 1.6551 in) Crankshaft main journal MAG/PTO side diameter Service limit 42.000 mm (1.6535 in) Crankcase plain bearing MAG/PTO side Service limit 42.100 mm (1.6575 in) diameter Crankshaft radial play MAG/PTO side...
Page 474 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER L 450) TRANSMISSION Type CVT (Continuously Variable Transmission) Engagement RPM 2000 ± 100 RPM Drive belt width Service limit 30.00 mm (1.181 in) 13.80 mm to 14.00 mm (.543 in to .551 in) Governor cup roller outer diameter Service limit 13.20 mm (.52 in)
Page 475 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER L 450) GEARBOX 5.00 mm to 5.10 mm (.197 in to .201 in) Gear groove width Service limit 5.20 mm (.205 in) MAG side 17.990 mm (.708 in) Counter shaft Service limit PTO side 24.950 mm (.982 in) Bevel gear shaft PTO side...
Page 476 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER L 450) ELECTRICAL SYSTEM - Speedo 10 A - Relay - Ignition coil - Fuel injector 10 A - Fuel pump Fuses (PF1) - Key switch 10 A - Starter solenoid - Cooling fan 20 A -DC out / lights / Acc.
Page 477 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER L 450) DRIVE SYSTEM Drive system type Selectable 2WD/4WD Front 500 ml (17 U.S. oz) Capacity Rear 250 ml (8.5 U.S. oz) XPS synthetic gear oil Front (75W 90) (P/N 93 600 043) Front differential oil/ OR synthetic oil 75W 90 API GL5) rear final drive oil...
Page 478 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER L 450) REAR SUSPENSION 1 UP 315.6 mm (12.43 in) Spring free length 2 UP 325.6 mm (12.82 in) Preload adjustment type 5 position cam BRAKES Dual 214 mm cross drilled Front brakes Type disc brakes with hydraulic twin-piston calipers...
Page 479 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER L 450) TIRES Minimum tire thread depth 3 mm (.118 in) Front 635 x 203 x 305 mm (25 x 8 x 12 (in)) Tire size Rear 635 x 279 x 305 mm (25 x 10 x 12 (in)) WHEELS Base Steel...
Page 480 Section 10 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) WIRING DIAGRAM INFORMATION GENERAL XX/XX-18 2- BF -A WIRING DIAGRAM INFORMATION V06G1JA NOTE: The wiring diagrams are in the manual THE SHADED PART INDICATES A CONNECTOR IDENTIFICATION back cover pocket. Terminal Location in Connector The wiring diagrams use the following codes.
Page 481 OUTLANDER L 2015 "CE" HARNESS ONLY GENERAL SYSTEM WINCH OPTION RD/BK (-C-6) RD/BK FROM ACC RELAY (HOT AT KEY ON) PF_ACC PF_MAIN ACC_RELAY MAIN RELAY BRK_RELAY RD/GN-16 (-B-2) FROM F8 (HOT ALL TIME) (-D-10) (-A-8) JT RD/GY (-A-5) OR/GN TO CLUSTER FLASHER SIGNAL RD/GY RD/GY-14 RD/GY...
Page 482 OUTLANDER L 2015 - CE SYSTEM MAIN HARNESS SIDE CE HARNESS SIDE INTERCONNECT JT RD/BK FROM ACC RELAY/HOT AT KEY ON RD/BK MG3-3 JT BE HORN FLASHER HAZARD HANDLEBAR SW RD/BK BE/RD HORN KX2- FROM MAIN/HOT ALL TIME MC2-1 FLASHER UNIT TO CLUSTER, FLASHER SIGNAL MC2-4 KX1-...
Page 483 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME DESCRIPTION NO LABOR INVOLVED AUCUNE MAIN D’OEUVRE REMOVE AND REPLACE ENGINE (ASS’Y) REMPLACEMENT DU MOTEUR (COMPLET) OIL PRESSURE SWITCH INTERRUPTEUR DE PRESSION D’HUILE HEAT SHIELD AND/OR RUBBER MOUNT DÉFLECTEUR DE CHALEUR ET/OU BUTÉE DE CAOUTCHOUC FAN AND/OR FAN SUPPORT VENTILATEUR ET/OU SUPPORT DE VENTILATEUR CYLINDERS AND/OR GASKETS (ALL)
Page 484 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME DESCRIPTION COOLANT HOSE (ENGINE TO TANK) BOYAU DU SYSTÈME DE REFROIDISSEMENT (RÉSERVOIR AU MOTEUR) EXHAUST MANIFOLD (FRONT) CONNECTEUR D'ÉCHAPPEMENT (AVANT) TUNE PIPE HEAT SHIELD (1) DÉFLECTEUR DE CHALEUR TUYAU D'ÉCHAPPEMENT (1) TUNE PIPE HEAT SHIELD (2) DÉFLECTEUR DE CHALEUR TUYAU D'ÉCHAPPEMENT (2) TUNE PIPE HEAT SHIELD (3) DÉFLECTEUR DE CHALEUR TUYAU D'ÉCHAPPEMENT (3)
Page 485 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME DESCRIPTION OIL PUMP GEAR ENGRENAGE DE LA POMPE À HUILE CAMSHAFT ARBRE À CAME OIL PUMP COVER AND/OR SHAFT AND/OR ROTOR COUVERCLE DE LA POMPE À HUILE ET/OU ARBRE ET/OU ROTOR CRANKCASE RESEAL OR GASKET RECELLEMENT DU CARTER ET/OU JOINT D’ÉTANCHÉITÉ...
Page 486 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME DESCRIPTION ENGINE BRACKET AND/OR RUBBER MOUNT ATTACHE MOTEUR ET/OU TAMPON D'ANCRAGE MAIN DRIVE GEAR AND/OR PIN ROUAGE D'ENTRAÎNEMENT PRINCIPALE ET/OU GOUPILLE INTERMEDIATE GEAR AND/OR PIN AND/OR THRUST WASHER ROUAGE INTERMEDIAIRE ET/OU GOUPILLE ET/OU RONDELLE D'APPUI FRONT OUTPUT SHAFT SEAL ANNEAU ÉTANCHÉITÉ...
Page 487 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME DESCRIPTION CYLINDER HEAD GASKET (1) JOINT D’ÉTANCHÉITÉ DE LA CULASSE (1) CYLINDER HEAD GASKETS (2) JOINTS D’ÉTANCHÉITÉ DE LA CULASSE (2) INJECTOR (1) INJECTEUR(1) INJECTOR (2) INJECTEUR(2) COOLANT HOSE (ENGINE INLET) BOYAU DE REFROIDISSEMENT (ENTRÉE DU MOTEUR) PLUG SCREW BOUCHON FILETÉ...
Page 488 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 01109 01113 01111 01179 01116 01255 01154 01191 01114 01308 01113 01134 01116 01255 01117 0158 0159 450 EFI 01192 vtf2015-001_a Volume 1- Can-Am 2015...
Page 489 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 01117 01101 450 EFI 01276 01140 01101 01276 01140 vtf2015-002_a Can-Am - Volume 1 2015...
Page 490 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 01205 01153 450 EFI 01122 01172 vtf2015-003_a Volume 1- Can-Am 2015...
Page 491 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 450 EFI 01264 01138 01139 01210 01209 vtf2015-004_a Can-Am - Volume 1 2015...
Page 492 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 01215 450 EFI 0190 0103 01220 01137 01132 0196 vtf2015-005_a Volume 1- Can-Am 2015...
Page 493 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 01119 450 EFI 0138 01301 01246 0119 0118 01200 vtf2015-006_a Can-Am - Volume 1 2015...
Page 494 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME FRONT/REAR AVANT/ARRIÈRE 01109 01307 01113 0119 01111 01192 01191 01304 01116 01255 01154 01256 01261 01303 01134 01179 01305 01249 01114 0158 0159 01113 01116 01255 01256 01116 01255 01256 01308 01309 V07C2RY Volume 1- Can-Am 2015...
Page 495 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 01117 01101 01102 01101 01102 01117 0150 V07C2SS Can-Am - Volume 1 2015...
Page 496 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 01247 0156 0157 01139 01245 V07C2TS Volume 1- Can-Am 2015...
Page 497 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 01119 01301 0138 01246 01200 V07C2VV Can-Am - Volume 1 2015...
Page 498 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 0103 01215 0190 01248 0196 01220 01137 01132 V07C2WS Volume 1- Can-Am 2015...
Page 499 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 01205 01152 01223 vtf2009-001-001_a Can-Am - Volume 1 2015...
Page 500 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 01216 01100 0198 0179 0146 0108 0108 0137 vtf2012-002-001_a Volume 1- Can-Am 2015...
Page 501 ENGINE SYSTEM SYSTÈME MOTEUR SYSTEM/SYSTÈME 01196 0183 0183 Outlander MAX 450 EFI Engine/Moteur 500 EFI 01196 0173 0186 0184 Outlander STD 500 EFI 0183 0170 0173 Outlander STD 450 EFI Outlander MAX Outlander MAX 500 EFI 0185 0186 0170 Outlander STD vtf2015-007_a Can-Am - Volume 1 2015...
Page 502 CARBURETOR AND FUEL SYSTEM CARBURATEUR ET SYSTÈME D’ALIMENTATION D’ESSENCE SYSTEM/SYSTÈME DESCRIPTION NO LABOR INVOLVED AUCUNE MAIN D’OEUVRE AIR INTAKE SILENCER (ASS’Y) SILENCIEUX D’ADMISSION D’AIR (COMPLET) THROTTLE CABLE CÂBLE D’ACCÉLÉRATEUR INTAKE ADAPTOR ADAPTATEUR D’ADMISSION AIR INTAKE TUBE TUYAU D’ADMISSION D’AIR REAR AIR INTAKE TUBE AND/OR SLEEVE TUYAU D’ADMISSION D’AIR ARRIÈRE ET/OU DOUILLE AIR TEMPERATURE SENSOR CAPTEUR DE TEMPÉRATURE D’AIR...
Page 503 CARBURETOR AND FUEL SYSTEM CARBURATEUR ET SYSTÈME D’ALIMENTATION D’ESSENCE SYSTEM/SYSTÈME 0289 0294 0262 0258 vtf2012-002-004_a Can-Am - Volume 1 2015...
Page 504 CARBURETOR AND FUEL SYSTEM CARBURATEUR ET SYSTÈME D’ALIMENTATION D’ESSENCE SYSTEM/SYSTÈME 0219 0201 0269 0223 vtf2012-002-005_a Volume 1- Can-Am 2015...
Page 505 IGNITION SYSTEM SYSTÈME D’ALLUMAGE SYSTEM/SYSTÈME DESCRIPTION NO LABOR INVOLVED AUCUNE MAIN D’OEUVRE MAGNETO (ASS’Y) MAGNÉTO (COMPLET) IGNITION COIL (EACH) BOBINE D’ALLUMAGE (CHAQUE) IGNITION CABLE CÂBLE D’ALLUMAGE STATOR (ASS’Y) STATOR (COMPLET) MAGNETO COVER COUVERCLE DE MAGNÉTO MAGNETO COVER GASKET JOINT D’ÉTANCHÉITÉ COUVERCLE DE MAGNÉTO Can-Am - Volume 1 2015...
Page 506 IGNITION SYSTEM SYSTÈME D’ALLUMAGE SYSTEM/SYSTÈME 450 EFI 0327 0302 0332 vtf2015-008_a Volume 1- Can-Am 2015...
Page 507 IGNITION SYSTEM SYSTÈME D’ALLUMAGE SYSTEM/SYSTÈME 0332 0333 0327 0302 V07G29T Can-Am - Volume 1 2015...
Page 508 STARTER SYSTEM SYSTÈME DE DÉMARREUR SYSTEM/SYSTÈME DESCRIPTION NO LABOUR INVOLVED AUCUNE MAIN-D’OEUVRE ELECTRIC STARTER (ASS’Y) DÉMARREUR (COMPLET) STARTER RELAY SOLÉNOÏDE DE DÉMARRAGE STARTER DRIVE LANCEUR DÉMARREUR Volume 1- Can-Am 2015...
Page 509 TRANSMISSION AND LINKAGE SYSTEM SYSTÈME DE TRANSMISSION ET DE TRINGLERIE SYSTEM/SYSTÈME DESCRIPTION NO LABOR INVOLVED AUCUNE MAIN-D’OEUVRE IMPLIQUÉE DRIVEN PULLEY SLIDING HALF DEMI-POULIE MENÉE COULISSANTE BELT COURROIE LEVER BUTTON BOUTON DE LEVIER LEVER (ASS’Y) AND/OR LEVER SPRING LEVIER (COMPLET) ET/OU RESSORT DE LEVIER SPEED SENSOR CAPTEUR DE VITESSE LEVER...
Page 510 TRANSMISSION AND LINKAGE SYSTEM SYSTÈME DE TRANSMISSION ET DE TRINGLERIE SYSTEM/SYSTÈME DESCRIPTION FLEXIBLE ADAPTOR ADAPTATEUR FLEXIBLE CAM, PLATE, DRIVEN SHAFT, SPRING CAME, PLAQUE, ARBRE POULIE MENÉE, RESSORT OUTPUT SHAFT ARBRE DE SORTIE REAR OUTPUT SHAFT SEALS ANNEAUX ÉTANCHÉITÉ DE L’ARBRE DE SORTIE ARRIÈRE GEARS KIT/MAIN SHAFT ENSEMBLE D'ENGRENAGES/ARBRE PRINCIPAL SHIFT SHAFT (ASS'Y )
Page 511 TRANSMISSION AND LINKAGE SYSTEM SYSTÈME DE TRANSMISSION ET DE TRINGLERIE SYSTEM/SYSTÈME 0598 0584 0512 0519 0583 0581 0580 0585 450 EFI 0586 0578 0579 vtf2015-009_a Can-Am - Volume 1 2015...
Page 512 TRANSMISSION AND LINKAGE SYSTEM SYSTÈME DE TRANSMISSION ET DE TRINGLERIE SYSTEM/SYSTÈME 05115 0598 0512 0584 0519 0583 0581 0579 0578 0582 0585 0580 0586 V07K15S Volume 1- Can-Am 2015...
Page 513 TRANSMISSION AND LINKAGE SYSTEM SYSTÈME DE TRANSMISSION ET DE TRINGLERIE SYSTEM/SYSTÈME V500/650/800 05111 05100 05100 05114 05113 05112 05109 0599 05102 05110 05108 05101 05103 05104 0591 05106 05101 05105 05106 05107 V07K16S Can-Am - Volume 1 2015...
Page 514 BRAKE SYSTEM SYSTÈME DE FREIN SYSTEM/SYSTÈME DESCRIPTION NO LABOR INVOLVED AUCUNE MAIN-D’OEUVRE MASTER CYLINDRE MAÎTRE-CYLINDRE FRONT CALIPER (RH OR LH) ÉTRIER AVANT (DROIT OU GAUCHE) FRONT BRAKE PAD (RH OR LH) PLAQUETTE DE FREIN AVANT (DROIT OU GAUCHE) FRONT BRAKE DISC (RH OR LH) DISQUE DE FREIN AVANT (DROIT OU GAUCHE) FRONT FLEXIBLE BRAKE HOSE BOYAU FLEXIBLE DE FREIN AVANT...
Page 515 BRAKE SYSTEM SYSTÈME DE FREIN SYSTEM/SYSTÈME Europe vtf2013-002-003_a Can-Am - Volume 1 2015...
Page 516 STEERING - FRONT DRIVE SYSTEM AND SUSPENSION DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION SYSTEM/SYSTÈME DESCRIPTION NO LABOR INVOLVED AUCUNE MAIN-D’OEUVRE ARM PROTECTOR (RH OR LH) PROTECTEUR DE BRAS (DROIT OU GAUCHE) STEERING CLAMP AND/OR STEERING COVER SUPPORT BRIDE DE DIRECTION ET/OU SUPPORT DU COUVRE-GUIDON INTERNAL BALL JOINT (RH OR LH) JOINT À...
Page 517 STEERING - FRONT DRIVE SYSTEM AND SUSPENSION DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION SYSTEM/SYSTÈME DESCRIPTION FRONT RIM AND/OR TIRE JANTE AVANT ET/OU PNEU THROTTLE HANDLE MANETTE D’ACCÉLÉRATEUR PITMAN ARM LEVIER DE DIRECTION INTERNAL BUSHING AND/OR CUSHION (LOWER AND/OR UPPER ARM) (RH OR LH) DOUILLE INTERNE ET/OU COUSSIN (BRAS INFÉRIEUR ET/OU SUPÉRIEUR) (DROIT OU GAUCHE) BALL JOINTS REPLACEMENT (2)
Page 518 STEERING - FRONT DRIVE SYSTEM AND SUSPENSION DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION SYSTEM/SYSTÈME 0726 0727 0724 0728 0725 0765 0735 0724 0726 0799 0713 0719 0765 0729 vtf2015-010_a Volume 1- Can-Am 2015...
Page 519 STEERING - FRONT DRIVE SYSTEM AND SUSPENSION DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION SYSTEM/SYSTÈME 0737 0733 0733 0733 0796 0733 0732 0732 0732 0704 0732 vtf2012-002-009_a Can-Am - Volume 1 2015...
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Page 521 REAR DRIVE SYSTEM AND SUSPENSION SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION SYSTEM/SYSTÈME DESCRIPTION NO LABOR INVOLVED AUCUNE MAIN D’OEUVRE REAR WHEEL HUB (RH) MOYEU DE ROUE ARRIÈRE (DROIT) REAR DIFFERENTIAL (ASS’Y) DIFFÉRENTIEL ARRIÈRE (COMPLET) REAR PROPELLER SHAFT (ASS’Y) ARBRE DE PROPULSION ARRIÈRE (COMPLET) SWING ARM BRAS OSCILLANT LH PROTECTOR...
Page 522 REAR DRIVE SYSTEM AND SUSPENSION SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION SYSTEM/SYSTÈME DESCRIPTION DIFFERENTIAL SEAL (1) JOINT D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (1) DIFFERENTIAL OIL SEAL ANNEAU D'ÉTANCHÉITÉ DU DIFFÉRENTIEL DIFFERENTIAL SEALS (2) JOINTS D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (2) AXIAL PIVOT AXE DE PIVOT Volume 1- Can-Am 2015...
Page 523 REAR DRIVE SYSTEM AND SUSPENSION SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION SYSTEM/SYSTÈME 08124 08122 08124 08134 08135 08123 08125 08126 08120 08120 08114 0826 0805 08109 08127 vtf2012-002-011_b Can-Am - Volume 1 2015...
Page 524 REAR DRIVE SYSTEM AND SUSPENSION SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION SYSTEM/SYSTÈME 08127 08121 08149 08121 0862 0862 0862 08127 08101 08111 08127 08102 vtf2015-011_a Volume 1- Can-Am 2015...
Page 525 BODY AND ACCESSORIES CARROSSERIE ET ACCESSOIRES SYSTEM/SYSTÈME DESCRIPTION NO LABOR INVOLVED AUCUNE MAIN D’OEUVRE IMPLIQUÉE LUGGAGE RACK KIT (FRONT OR REAR) ENSEMBLE DE PORTE-BAGAGES (AVANT OU ARRIÈRE) CONSOLE CONSOLE SEAT SIÈGE FRONT FASCIA FASCIA AVANT REAR FASCIA FASCIA ARRIÈRE REAR HANDLE (RH OR LH) POIGNÉE ARRIÈRE (GAUCHE OU DROITE) FOOTREST (RH OR LH) MARCHEPIED (DROIT OU GAUCHE)
Page 526 BODY AND ACCESSORIES CARROSSERIE ET ACCESSOIRES SYSTEM/SYSTÈME DESCRIPTION REAR BOX COFFRE ARRIÈRE BOX DOOR PORTE DE COFFRE REAR SUPPORT SUPPORT ARRIÈRE INNER FENDER (RH OR LH) FAUSSE AILE (DROIT OU GAUCHE) HITCH ATTACHE CENTRAL SKID PLAT PLAQUE DE PROTECTION CENTRALE LOCK VERROU FRONT FENDER...
Page 527 BODY AND ACCESSORIES CARROSSERIE ET ACCESSOIRES SYSTEM/SYSTÈME 0913 0956 0913 09367 0991 0917 09284 0929 09152 0956 0991 09283 09244 0948 09149 09149 0991 09158 09305 09305 09438 0991 09336 0948 0928 vtf2015-012_a Can-Am - Volume 1 2015...
Page 528 BODY AND ACCESSORIES CARROSSERIE ET ACCESSOIRES SYSTEM/SYSTÈME 09200 0949 0974 09304 09316 vtf2015-013_a Volume 1- Can-Am 2015...
Page 529 BODY AND ACCESSORIES CARROSSERIE ET ACCESSOIRES SYSTEM/SYSTÈME 0921 09198 0945 0945 09108 09199 vtf2015-014_a Can-Am - Volume 1 2015...
Page 530 ELECTRICAL SYSTEM SYSTÈME ÉLECTRIQUE SYSTEM/SYSTÈME DESCRIPTION NO LABOR INVOLVED AUCUNE MAIN-D’OEUVRE IGNITION SWITCH INTERRUPTEUR D’ALLUMAGE HEADLAMP AND/OR HEADLAMP SUPPORT (ASS’Y) (RH OR LH) PHARE AVANT ET/OU SUPPORT (COMPLET) (DROIT OU GAUCHE) VOLTAGE REGULATOR RÉGULATEUR DE TENSION BATTERY BATTERIE MULTIFUNCTION SWITCH INTERRUPTEUR MULTIFONCTION SPEEDOMETER/TACHOMETER INDICATEUR DE VITESSE/COMPTE-TOURS...
Page 531 ELECTRICAL SYSTEM SYSTÈME ÉLECTRIQUE SYSTEM/SYSTÈME DESCRIPTION BATTERY SUPPORT SUPPORT DE BATTERIE Can-Am - Volume 1 2015...
Page 532 ELECTRICAL SYSTEM SYSTÈME ÉLECTRIQUE SYSTEM/SYSTÈME 1061 1065 1021 1061 1009 1028 1062 1009 1021 Europe 1051 1001 1062 1010 1013 10122 1029 vtf2015-015_a Volume 1- Can-Am 2015...
Page 533 ELECTRICAL SYSTEM SYSTÈME ÉLECTRIQUE SYSTEM/SYSTÈME Can-Am - Volume 1 2015...
Page 534 2015 ATV / VTT COOLING SYSTEM/ MODEL/ ENGINE TYPE/ TABLE DESCRIPTION SYSTEME DE MODÈLE TYPE DE MOTEUR REFROIDISSEMENT 5AFA/5AFB OUTLANDER 450 5AEC/5AFD Liquid cooled/ 5AFE 450 CVT Refroidi par liquide 2WFA/2WFB OUTLANDER DPS 450 2WFC/2WFD 5CFA/5CFB OUTLANDER MAX 450 5CFC Liquid cooled/ 450 CVT Refroidi par liquide...

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