BRP Can-Am Outlander 2015 Series Manual

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2015 Can-Am Outlander/Renegade Series

Here is combined the 2013 base manual with the 2014-2015 & XMR supplement

manual into one manual.

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Summary of Contents for BRP Can-Am Outlander 2015 Series

Page 1 2015 Can-Am Outlander/Renegade Series Here is combined the 2013 base manual with the 2014-2015 & XMR supplement manual into one manual.
Page 2 We strongly recommend that any services be car- act replicas of the parts. ried out and/or verified by a highly skilled profes- The use of BRP parts is most strongly recom- sional mechanic. mended when considering replacement of any It is understood that this manual may be trans- component.
Page 3 INTRODUCTION INTRODUCTION BRP reserves the right at any time to discontinue or change specifications, designs, features, mod- els or equipment without incurring obligation. VEHICLE INFORMATION VEHICLE IDENTIFICATION NUMBER (V.I.N.) vmr2012-002-002_a TYPICAL 1. V.I.N. (Vehicle Identification Number) location The V.I.N. (Vehicle Identification Number) decal is located under the seat.
Page 4 EPA EMISSION REGULATIONS Vehicles manufactured by BRP are certified to the EPA standards as conforming to the requirements of the regulations for the control of air pollution emitted from new vehicle engines. This certifica-...
Page 5 INTRODUCTION A number of procedures throughout the book re- quire the use of special tools. Before starting any procedure, be sure that you have on hand all re- quired tools, or their approved equivalents. The use of RIGHT and LEFT indications in the text are always referenced to the driving position (sit- ting on the vehicle).
Page 6 INTRODUCTION TYPICAL PAGE Page heading Section 06 ENGINE indicates section Subsection 01 (MAGNETO) and subsection. MAGNETO Subsection title Indicates applicable Models models. Drop represents a Loctite 243 service product Exploded view assists to be applied. Model you in identifying parts and their related Dotted box contains positions.
Page 7 INTRODUCTION TYPICAL PAGE Section 03 ENGINE Section 03 ENGINE Subsection 09 (MAGNETO SYSTEM) Subsection 09 (MAGNETO SYSTEM) Tittle in bold indicates category GENERAL GENERAL of information to be carried out. NOTE: The following procedures can be done NOTE: The following procedures can be done without removing the engine.
Page 8 INTRODUCTION TIGHTENING TORQUE Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When a torque is not specified, refer to the following table. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices must be replaced when removed (e.g.: locking tabs, elastic stop nuts, self-lock- ing fasteners, cotter pins, etc.).
Page 9 INTRODUCTION FASTENER INFORMATION Threadlocker Application for Uncovered Holes (Bolts and Nuts) NOTICE Most components in the vehicles are built with parts dimensioned in the metric system. Most fasteners are metric and must not be replaced by customary fasteners or vice-versa. Mismatched or incorrect fasteners could cause damage to the vehicle or possible personal injury.
Page 10 INTRODUCTION Threadlocker Application for 4. Apply several drops along the threaded hole Pre-Assembled Parts and at the bottom of the hole. 5. Apply several drops on bolt threads. 6. Tighten as required. Threadlocker Application for Stud Installation in Blind Holes A00A3OA 1.
Page 11 INTRODUCTION Gasket Compound Application NOTE: If it is difficult to readjust, heat screw with a soldering iron (232°C (450°F)). Application for Stripped Thread Repair A00A3QA 1. Release agent 2. Stripped threads 3. Form-A-Thread lmr2007-040-006_a 4. Tape 5. Cleaned bolt 1. Proper strength Loctite 6.
Page 12 INTRODUCTION Threadlocker Application for Mounting 2. Spray housing and gasket with LOCTITE PRIMER on a Shaft N (P/N 293 800 041) 3. Apply a strip of proper strength Loctite on lead- Mounting with a Press ing edge of outer metallic gasket diameter. NOTE: Any Loctite product can be used here.
Page 13 2013-2015 Shop Manual Supplement Outlander ™ X mr 650/1000...
Page 15: Table Of Contents
TABLE OF CONTENTS SAFETY NOTICE ......................V INTRODUCTION .
Page 16 TABLE OF CONTENTS 02 ENGINE AND CVT (cont’d) (cont’d) 11 – CONTINUOUSLY VARIABLE TRANSMISSION (CVT) PROCEDURES....................60 .
Page 17 TABLE OF CONTENTS 07 CHASSIS (cont’d) 05 – REAR SUSPENSION ..................131 GENERAL .
Page 18 TABLE OF CONTENTS 07 CHASSIS (cont’d) (cont’d) 08 – BODY (OUTLANDER X mr) (cont’d) PROCEDURES ..................... 199 RACK .
Page 19: Safety Notice
We strongly recommend that any services be car- act replicas of the parts. ried out and/or verified by a highly skilled profes- The use of BRP parts is most strongly recom- sional mechanic. mended when considering replacement of any It is understood that this manual may be trans- component.
Page 20: Introduction
Due to late changes, there may be some differ- ences between the manufactured product and the description and/or specifications in this document. BRP reserves the right at any time to discontinue or change specifications, designs, features, mod- els or equipment without incurring obligation.
Page 21: Manual Information
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- tion is contingent on certain adjustments being set to factory standards.
Page 22 INTRODUCTION NOTICE Most fasteners are metric, and most components are built with parts dimensioned using the metric system. Consult the appropri- PARTS CATALOG to obtain and use the cor- rect parts and fasteners. Mismatched or incor- rect fasteners could cause damage to the vehi- cle.
Page 23 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 24 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 25 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 26: Fastener Information
INTRODUCTION FASTENER INFORMATION Threadlocker Application for Uncovered Holes (Bolts and Nuts) NOTICE Most components in the vehicles are built with parts dimensioned in the metric system. Most fasteners are metric and must not be replaced by customary fasteners or vice-versa. Mismatched or incorrect fasteners could cause damage to the vehicle or possible personal injury.
Page 27 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 28 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 29 INTRODUCTION Threadlocker Application for Mounting 2. Spray housing and gasket with LOCTITE PRIMER on a Shaft N (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 30 vmr2013-054...
Page 31 SERVICE TOOLS INDEX BLIND HOLE PULLER KIT FLUKE 115 MULTIMETER PITMAN ARM PULLER (P/N 529 036 056) (P/N 529 035 868) (P/N 529 036 227) Page: 43, 107, 109, 149, 152–155, 158–159 Page: 120 Page: 52 HANDLE POSITIONING ADAPTOR (P/N 420 877 650) CLUTCH HOLDER (P/N 529 036 230) (P/N 529 036 238)
Page 32 SERVICE TOOLS INDEX SPRING COMPRESSOR (P/N 529 036 184) Page: 135 SPRING REMOVER (P/N 529 036 007) Page: 161 STEERING ALIGNMENT TOOL (P/N 529 036 059) Page: 88 TEST CAP (P/N 529 035 991) Page: 15 VACUUM/PRESSURE PUMP (P/N 529 021 800) Page: 15, 29...
Page 33 Subsection XX (BREAK-IN INSPECTION) BREAK-IN INSPECTION This vehicle should be serviced by an authorized Can-Am dealer after the first 10 hours or 300 km (200 mi) of operation, whichever comes first. The break-in inspection is very important and must not be neglected. The following message will appear in the cluster as a reminder of when the break-in inspection is due: MAINTENANCE SOON.
Page 34: Periodic Maintenance Schedule
Subsection XX (PERIODIC MAINTENANCE SCHEDULE) PERIODIC MAINTENANCE SCHEDULE GENERAL MAINTENANCE SCHEDULE Maintenance is very important for keeping the ve- EVERY 750 KM (500 MI) OR 25 HOURS OF hicle in a safe operating condition. Proper main- OPERATION (whichever comes first) tenance is the owner's responsibility.
Page 35 Subsection XX (PERIODIC MAINTENANCE SCHEDULE) EVERY 3 000 KM (2,000 MI) OR 100 HOURS OF OPERATION OR 1 YEAR (whichever comes first) Replace engine oil and filter. Inspect and adjust valve clearance. Inspect and clean muffler spark arrester. Check engine coolant strength. Inspect and clean throttle body.
Page 36 Subsection 02 (PERIODIC MAINTENANCE SCHEDULE) PERIODIC MAINTENANCE SCHEDULE GENERAL Maintenance is very important for keeping the ve- hicle in a safe operating condition. Proper main- tenance is the owner's responsibility. This vehicle should be serviced as per the maintenance sched- ule.
Page 37: Maintenance Schedule
Subsection 02 (PERIODIC MAINTENANCE SCHEDULE) MAINTENANCE SCHEDULE Follow the appropriate maintenance intervals according to the environment where the vehicle is used: normal environment or extreme environment (mud, water, dust). EVERY 750 KM (500 MI) OR 25 HOURS OF OPERATION IN A NORMAL ENVIRONMENT (whichever comes first) EVERY 375 KM (250 MI) OR 12.5 HOURS OF OPERATION IN AN EXTREME ENVIRONMENT (whichever comes first) Inspect and clean (or replace if necessary) engine air filter and foam filter.
Page 38 Subsection 02 (PERIODIC MAINTENANCE SCHEDULE) EVERY 3 000 KM (2,000 MI) OR 100 HOURS OF OPERATION OR 1 YEAR IN A NORMAL ENVIRONMENT (whichever comes first) EVERY 1 500 KM (1,000 MI) OR 50 HOURS OF OPERATION IN AN EXTREME ENVIRONMENT OR 6 MONTHS (whichever comes first) Replace engine oil and filter.
Page 39 Subsection 02 (PERIODIC MAINTENANCE SCHEDULE) EVERY 6 000 KM (4,000 MI) OR 200 HOURS OF OPERATION OR 2 YEARS IN A NORMAL ENVIRONMENT (whichever comes first) EVERY 3 000 KM (2,000 MI) OR 100 HOURS OF OPERATION IN AN EXTREME ENVIRONMENT OR 1 YEAR (whichever comes first) Clean vehicle speed sensor.
Page 40: Periodic Maintenance Procedures
219 700 340 ..........3 AIR FILTER OIL ................293 600 131 ........... 22 BRAKE FLUID................219 700 362 ..........8 BRP PREMIXED COOLANT ............293 600 041 ........... 14 CABLE LUBRICANT ..............293 800 060 ........... 11 LOCTITE 243 (BLUE)..............
Page 41 Subsection XX (PERIODIC MAINTENANCE PROCEDURES) 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. – If any debris or water are found, clean air fil- ter chamber using a vacuum cleaner.
Page 42 Subsection XX (PERIODIC MAINTENANCE PROCEDURES) NOTICE It is not recommended to blow com- pressed air on the paper filter; this could dam- age the paper fibers and reduce its filtration ability when used in dusty environments. NOTICE Do not wash the paper filter with any cleaning solution.
Page 43: Engine (Exhaust System)
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) Engine Air Filter Installation Reinstall oiled foam filter on paper air filter. Slightly grease O-ring seal and plastic body of air AIR INTAKE SYSTEM filter. Refer to exploded view. Install air filter as the reverse of removal. Ensure air filter cover is properly locked onto the air filter housing.
Page 44: Engine (Lubrication System)
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) vmr2012-0005-051_a tmo2011-001-043_a TYPICAL — ALL MODELS 1. Clean spark arrester 1. Screws 2. Tail pipe 5. Inspect mesh of spark arrester for any damage. Replace as required. 3. Remove exhaust tail pipe, gasket (discard) and spark arrester.
Page 45 Subsection XX (PERIODIC MAINTENANCE PROCEDURES) 2. Stop engine. 3. Ensure vehicle is on a level surface. 4. Remove dipstick. 5. Place a drain pan under the engine drain plug area. 6. Clean the drain plug area. 7. Unscrew drain plug and discard the gasket ring. CAUTION The engine oil can be very hot.
Page 46 Subsection XX (PERIODIC MAINTENANCE PROCEDURES) 16. Stop engine. 17. Wait a while to allow oil to flow down to crankcase, then check oil level again. 18. Dispose oil and filter as per your local environ- mental regulations. Engine Oil Filter Replacement Engine Oil Filter Access To reach oil filter, refer to BODY...
Page 47: Engine (Cooling System)
Do not remove the coolant reservoir cap if en- Recommended Engine Coolant gine is hot. COOLANT 4. Use a funnel to avoid spillage. Do not overfill. BRP PREMIXED COOLANT RECOMMENDED 5. Properly reinstall and tighten reservoir cap. (P/N 219 700 362) PRODUCT 6.
Page 48 Subsection XX (PERIODIC MAINTENANCE PROCEDURES) 3. Test the pressure cap using a cooling system tester. 4. Replace the cap if it does not hold the pressure, or if it opens at a relief pressure that is too low or too high. PRESSURE CAP RELIEF PRESSURE Approximately 110 kPa (16 PSI) Engine Cooling System Leak Test...
Page 49 Subsection XX (PERIODIC MAINTENANCE PROCEDURES) 8. Fill cooling system with recommended coolant, COOLING SYSTEM FILLING AND refer to BLEEDING procedure. Engine Cooling System Filling and Bleeding 1. Remove cooling system pressure cap. BODY 2. Remove RH side panel. Refer to subsec- tion.
Page 50: Engine (Cylinder Head)
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) All Engines VALVE CLEARANCE 6. Install bleed screws using NEW gasket rings. 0.11 mm to 0.19 mm EXHAUST (.0043 in to .0075 in) 7. Tighten bleed screws to specification. 0.06 mm to 0.14 mm HOLDING STRIP SCREWS INTAKE (.0024 in to .0055 in) Gasket...
Page 51: Gearbox
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) GEARBOX The oil should be level with the bottom of the oil level hole. Recommended Gearbox Oil NOTICE Operating the gearbox with an im- RECOMMENDED proper oil level may severely damage gearbox. ENGINE QUANTITY PRODUCT Gearbox Oil Replacement Approximately 500, 650,...
Page 52: Continuously Variable Transmission (Cvt)
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) OIL LEVEL PLUG 5 N•m ± 0.6 N•m Tightening Torque (44 lbf•in ± 5 lbf•in) Vehicle Speed Sensor (VSS) Cleaning GEARBOX AND 4X4 Remove the VSS. Refer to COUPLING UNIT (500/650/800R) GEARBOX AND 4X4 COUPLING UNIT (1000) subsection.
Page 53: Fuel System
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) Throttle Cable Lubrication CVT Air Filter Cleaning 1. Remove CVT air filter. The throttle cable must be lubricated with CABLE or an equivalent. LUBRICANT (P/N 293 600 041) 2. Inspect filter and replace if damaged. 3.
Page 54 Subsection XX (PERIODIC MAINTENANCE PROCEDURES) vmo2006-007-032_a V07I0HA 1. Throttle body 2. Side cover screws 1. Inner housing protector Insert the needle of the lubricant can in the end of Remove the cable from the throttle lever housing. throttle cable adjuster. NOTE: Slide cable in clip slot and remove the end of cable from clip.
Page 55: Electrical System
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) – Clean fuel tank as required. – Inspect fuel tank vent breather filter. Re- FUEL TANK place as necessary. Refer to VENT BREATHER FILTER REPLACEMENT in this subsection. ELECTRICAL SYSTEM Battery Inspection Visually inspect battery casing for cracks or other damage.
Page 56: Drive System
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) DRIVE SYSTEM Front Differential Oil Level Verification 1. Clean filler plug prior to checking oil level. vmr2012-036-001_a RH SIDE OF VEHICLE 1. Filler plug 2. Drain plug 5. Lift LH side of vehicle to completely drain front vbl2012-007-007_a differential.
Page 57: Chassis (Wheels And Tires)
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) DRAIN PLUG 7.5 N•m ± 0.5 N•m Tightening Torque (66 lbf•in ± 4 lbf•in) 7. Refill the rear final drive. RECOMMENDED OIL QUANTITY XPS SYNTHETIC GEAR OIL (75W 140) 300 ml (P/N 293 600 140) (10 U.S.
Page 58: Chassis (Steering System)
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) Tie-Rod End WHEEL LUG NUTS Check tie-rod end ball joint for: 100 N•m ± 10 N•m Tightening Torque – Damage (74 lbf•ft ± 7 lbf•ft) – Pitting – Abnormal play. Replace if necessary. Steering Column Half Bushing Cleaning and Lubrication Clean, inspect and lubricate upper and lower steering column half bushings and O rings.
Page 59 Subsection XX (PERIODIC MAINTENANCE PROCEDURES) 3. Clean spherical bearing using a shop rag to re- move any dirt and debris. 4. Lubricate spherical bearing as illustrated. SPHERICAL BEARING LUBRICATION SUSPENSION GREASE (P/N 293 550 033) vmr2012-040-013_a TYPICAL 1. Grease fittings Front Suspension Arm Inspection 1.
Page 60: Chassis (Brakes)
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) 4. Check ball joint for: BRAKE PAD MINIMUM THICKNESS – Damage 1 mm (1/32 in) – Pitting – Play. NOTE: The brake pad grooves are wear indica- tors. 5. Check ball joint bellows for: – Damage –...
Page 61 Subsection XX (PERIODIC MAINTENANCE PROCEDURES) – Check cleanliness of master cylinder rod and NOTE: To locate all bleeders according to ve- EXPLODED VIEW boot hicle configuration, refer to BRAKE CIRCUIT CONFIGURATIONS . See – Check master cylinder boot for cracks or BRAKES subsection.
Page 62: Chassis (Body)
Subsection XX (PERIODIC MAINTENANCE PROCEDURES) Brake Fluid Bleeding (Procedure Using a NOTE: Do not release brake pedal and/or lever(s) Vacuum Pump) until bleeder has been closed. NOTE: Brake fluid reservoir must be kept full to 6. Repeat procedure until fluid flows out without prevent air from being pumped into the system.
Page 63 Subsection XX (PERIODIC MAINTENANCE PROCEDURES) Tow Hitch Inspection 1. Ensure tow hitch receptacle module is solidly mounted. 2. Inspect hitch for cracks and other damages. 3. Repair or replace if necessary. vmr2012-005...
Page 64 219 700 340 ..........3 AIR FILTER OIL ................293 600 131 ........... 23 BRAKE FLUID................219 700 362 ..........7 BRP PREMIXED COOLANT ............293 600 041 ........... 14 CABLE LUBRICANT ..............293 550 033 ........20–21 SUSPENSION GREASE ..............
Page 65 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) vmo2012-012-039_a vmr2013-056-001_a 1. Air filter cover TYPICAL - SOME PARTS REMOVED FOR CLARITY 1. Air filter housing inlet drain tube 4. Remove air filter. 2. Check air filter dirty chamber for cleanliness. – If any debris or water are found, clean air fil- ter chamber using a vacuum cleaner.
Page 66 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) NOTE: Paper filter have a limited life span; re- place filter if too dirty or clogged. NOTICE It is not recommended to blow com- pressed air on the paper filter; this could dam- age the paper fibers and reduce its filtration ability when used in dusty environments.
Page 67 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) Slightly grease O-ring seal and plastic body of air 2. Remove and discard the tail pipe retaining AIR INTAKE SYSTEM filter. Refer to exploded screws. view. Install air filter as the reverse of removal. Ensure air filter cover is properly locked onto the air filter housing.
Page 68 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) vmr2013-056-002_a tmo2011-001-043_a TYPICAL - RH SIDE OF ENGINE 1. Dipstick 1. Clean spark arrester With vehicle on a level surface and engine cold, 5. Inspect mesh of spark arrester for any damage. not running, check the oil level as follows: Replace as required.
Page 69 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) Engine Oil Change 15. Ensure oil filter and drain plug areas are not leaking. 1. Start and warm-up engine. 16. Stop engine. 2. Stop engine. 17. Wait a while to allow oil to flow down to 3.
Page 70 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) ENGINE (COOLING SYSTEM) Recommended Engine Coolant COOLANT BRP PREMIXED COOLANT RECOMMENDED (P/N 219 700 362) PRODUCT Distilled water and ALTERNATIVE, antifreeze solution OR IF NOT (50% distilled water, AVAILABLE 50% antifreeze) NOTICE Always ethylene-glycol tmr2011-010-005_a 1.
Page 71 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) WARNING Do not remove the coolant reservoir cap if en- gine is hot. 4. Use a funnel to avoid spillage. Do not overfill. 5. Properly reinstall and tighten reservoir cap. 6. Reinstall service cover. NOTICE Do not store any objects in the front service compartment.
Page 72 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) 3. Test the pressure cap using a cooling system tester. 4. Replace the cap if it does not hold the pressure, or if it opens at a relief pressure that is too low or too high. PRESSURE CAP RELIEF PRESSURE Approximately 110 kPa (16 PSI) Engine Cooling System Leak Test...
Page 73 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) 3. Using a feeler gauge, check the valve clear- ance. VALVE CLEARANCE 0.11 mm to 0.19 mm EXHAUST (.0043 in to .0075 in) 0.06 mm to 0.14 mm INTAKE (.0024 in to .0055 in) If the valve clearance is out of specification, adjust valves as follows.
Page 74 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) GEARBOX Recommended Gearbox Oil RECOMMENDED ENGINE QUANTITY PRODUCT Approximately 400 ml XPS SYNTHETIC (13.53 U.S. oz) GEAR OIL (75W 140) Approximately (P/N 293 600 140) 1000 450 ml (15.22 U.S. oz) vmo2012-012-057_a TYPICAL - 1000 ENGINE 1.
Page 75 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) OIL LEVEL PLUG 5 N•m ± 0.6 N•m Tightening torque (44 lbf•in ± 5 lbf•in) Vehicle Speed Sensor (VSS) Cleaning GEARBOX AND 4X4 Remove the VSS. Refer to COUPLING UNIT (650) GEARBOX AND 4X4 COUPLING UNIT (1000) subsection.
Page 76 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) 219700341 AIR FILTER CLEANER (P/N 219 700 341) vmo2013-009-020_b 1. Unlatch the sides 2. Let stand for 3 minutes. 2. Slide the service cover tabs 3. Service cover 3. As stated on air filter cleaner (UNI) container, rinse filter with plain water.
Page 77 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) 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. Clean inside throttle body if necessary. Refer to ELECTRONIC FUEL INJECTION (EFI) Throttle Cable Lubrication The throttle cable must be lubricated with...
Page 78 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) V07I0GA 1. Cable protector 2. Throttle cable adjuster 3. Lock nut 4. Throttle lever housing V07I0IA Screw in the throttle cable adjuster. Remove the throttle body side cover. Remove inner housing protector. vmo2006-007-032_a V07I0HA 1. Throttle body 2.
Page 79 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) V07I010 1. Throttle lever A. 2 mm (.079 in) With the shift lever on PARK position, start the en- V07I0JA gine. TYPICAL Check if the throttle cable is adjusted correctly by NOTE: Place a rag around the throttle cable ad- turning handlebar fully to the right then fully to the juster to prevent the lubricant from splashing.
Page 80 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) 3. Remove spark plug. WARNING All fuel system leaks must be repaired. Dam- Spark Plug Installation aged, worn or leaking fuel system com- Prior to installation, ensure that contact surfaces ponents should be replaced to ensure fuel of the cylinder head and spark plug are free of system tightness.
Page 81 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) Front Differential Oil Replacement 2. Clean filler plug area. 1. Place vehicle on a level surface. Set transmis- 3. Remove filler plug. sion in park position. 2. Place a drain pan under the front differential. 3.
Page 82 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) Drive Shaft Joint Inspection Turn and move drive shaft back and forth to detect excessive play. Rear Propeller Shaft U-Joint Condition Check yoke U-joints for wear, backlash or axial play. Replace if necessary. Rear Propeller Shaft U-Joint Lubrication PROPELLER SHAFT U-JOINT LUBRICATION Use Hi-temp bearing grease NLGI-2 or an equivalent...
Page 83 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) NOTE: To properly locate play during this inspec- 2. Remove shock sleeves then O-rings from tion, be sure to check other components for wear shock absorber. or looseness (ball joints, suspension pivots, etc). If necessary repair or replace all defective parts before checking the wheel bearing condition.
Page 84 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) Rear Suspension Arm Inspection 1. Check suspension arm for: – Cracks – Pitting – Bending – Distortion. 2. Check suspension arm for abnormal play: – Side to side – Up and down. 3. If any play is detected, inspect: –...
Page 85 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) – Check pistons movement – Check pistons for scratches, rust or other damages. 2. Clean the following components using BRAKES AND PARTS CLEANER (USA) (P/N 219 701 705) – Brake pads – Caliper support and slider –...
Page 86 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) Brake Fluid Replacement Brake Fluid Draining 1. Clean and remove reservoir cover with its di- aphragm. 2. Connect a clear hose onto bleeder. vmo2012-012-035_a TYPICAL - UNDER THE SEAT 1. Brake fluid reservoir NOTE: If applicable, ensure filler cap diaphragm is fully retracted before closing the cap.
Page 87 Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) Rear Cargo Compartment Latch 7. Close then tighten bleeder. Inspection and Operation BLEEDER Ensure cargo compartment latch functions prop- 5.5 N•m ± 1.5 N•m erly and that compartment panel is properly se- Tightening torque (49 lbf•in ± 13 lbf•in) cured when latched.
Page 88 STORAGE PROCEDURE SERVICE PRODUCTS Description Part Number Page 293 110 001 ..........3 BRP HEAVY DUTY CLEANER ............413 408 601 ..........1 XPS FUEL STABILIZER..............293 600 016 ......... 1, 3 XPS LUBE..................219 701 709 ..........3 XPS MULTI-PURPOSE CLEANER ..........
Page 89 Subsection XX (STORAGE PROCEDURE) vmr2012-007-001_a TYPICAL vmr2012-011-007_c 1. CVT cover 2. Exhaust system heat shield TYPICAL - RENEGADE MODEL ILLUSTRATED 3. CVT outlet 1. Muffler 2. Block with rag here 6. Block CVT outlet hose using a rag. ELECTRICAL SYSTEM Battery Removal Remove battery from ATV.
Page 90 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 91 Subsection XX (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 92 Subsection XX (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE PRODUCTS Description Part Number Page 293 600 016 ........... 2 XPS LUBE..................GENERAL WHAT TO DO IF WATER IS IN THE AIR FILTER HOUSING NOTE: Component failures resulting from these events are not warrantable. Inspect the drain reservoir underneath the air filter housing to validate if water is present.
Page 93 Subsection XX (SPECIAL PROCEDURES) – Check rear final drive oil level and refill if neces- Replace the engine oil (without starting the en- sary. gine). – Inspect suspension components and steering Replace gearbox oil. system components. Inspect fuel tank for water intrusion. If in doubt, –...
Page 94 Subsection XX (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number Page 529 036 022 ........... 5 ENGINE LIFTING TOOL ..............Outlander models 13 ± 2 N•m (115 ± 18 lbf•in) 7 ± 1 N•m (62 ± 9 lbf• in ) 4 ±...
Page 95 Subsection XX (ENGINE REMOVAL AND INSTALLATION) PROCEDURES ENGINE REMOVAL 1. Place vehicle on a workstation equipped with an engine-lifting hoist. 2. Disconnect negative (-) cable from battery. 3. Carry out the following operations. Refer to ta- ble. REFERENCES OPERATIONS (SUBSECTION) Safely lift and support vmr2012-009-003_a INTRODUCTION...
Page 96 Subsection XX (ENGINE REMOVAL AND INSTALLATION) 11. Disconnect ignition coil connector. vmr2012-009-004_a TYPICAL 1. Crankcase vent hose vmr2012-009-007_a 8. Disconnect both engine harness connectors TYPICAL - FROM LH SIDE 1. Ignition coil connector (HIC). 12. Remove the following locking ties. vmr2012-009-005_a TYPICAL 1.
Page 97 Subsection XX (ENGINE REMOVAL AND INSTALLATION) 16. Remove magneto harness from its location along vehicle and gather it in a bundle near engine. NOTE: It may be necessary to slightly lift the rear body module to ease magneto harness removal. Refer to BODY subsection.
Page 98 Subsection XX (ENGINE REMOVAL AND INSTALLATION) Engine Lifting 1. Install the ENGINE LIFTING TOOL (P/N 529 036 on engine. 022) 529036022 vmr2012-009-025_a 500/650/800R ENGINES - SOME PARTS REMOVED FOR CLARITY 1. Disconnect the following coolant hoses vmr2012-009-015 TYPICAL 2. Remove upper retaining screws from engine. vmr2012-009-013_a 1000 ENGINE - SOME PARTS REMOVED FOR CLARITY 1.
Page 99 Subsection XX (ENGINE REMOVAL AND INSTALLATION) vmr2012-009-020_a 1. Oetiker clamps vmr2012-009-017_a 7. Move front propeller shaft bellows forward. LH SIDE 1. Rear retaining bolt 4. Remove front retaining bolt from engine. vmr2012-009-021_a 1. Front propeller shaft bellows vmr2012-009-018_a 8. Remove propeller shaft screw from gearbox LH SIDE output shaft.
Page 100 Subsection XX (ENGINE REMOVAL AND INSTALLATION) 10. Move propeller shaft yoke downwards to TORQUE make room. 62.5 N•m ± 7.5 N•m Engine retaining bolts (46 lbf•ft ± 6 lbf•ft) 6. If applicable, fill engine as per specification. Re- LUBRICATION SYSTEM fer to subsection.
Page 101: Air Intake System
Subsection XX (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM AIR FILTER HOUSING 1.6 ± 0.4 N•m Loctite 5150 (14 ± 4 lbf•in) (silicone sealant) 6 ± 1 N•m (53 ± 9 lbf•in) Suspension grease 6 ± 1 N•m (53 ± 9 lbf•in) Loctite 5150 (silicone sealant) 2.5 ±...
Page 102: General
Subsection XX (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 subsection.
Page 103 Subsection XX (AIR INTAKE SYSTEM) 7. Move ECM aside. vmr2012-010-004_a AIR INTAKE TUBE MOVED TO GAIN ACCESS 1. Coolant tank LH retaining screw vmr2012-009-005_a TYPICAL 1. Engine harness connectors (HIC) 8. Remove air intake tube retaining screw. vmr2012-010-005_a 1. Coolant tank RH retaining screw 11.
Page 104 Subsection XX (AIR INTAKE SYSTEM) vmr2012-010-007 vmr2012-010-010_a TYPICAL - OUTLANDER SHOWN TYPICAL 1. Gearbox vent hose 13. Remove the following locking ties. 15. Detach crankcase vent hose from air filter housing. vmr2013-010-001_a TYPICAL - OUTLANDER SHOWN 1. Locking tie to remove - location shown vmr2012-010-011_a TYPICAL 1.
Page 105 Subsection XX (AIR INTAKE SYSTEM) vmr2012-010-013_a vmr2012-010-015_a SCREW LOCATED UNDER COOLANT TANK TYPICAL - OUTLANDER SHOWN 1. Air filter housing retaining screw 1. Throttle body 20. Remove air filter housing by pulling it towards rear. vmr2012-010-014_a SCREW LOCATED ON LH SIDE - ACCESS FROM UNDER SHIFT LEVER vmr2012-010-016_a 1.
Page 106 Subsection 02 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM AIR FILTER HOUSING 2,5 N•m (22 lbf•in) Loctite 5150 (silicone sealant) 6 N•m (53 lbf•in) Suspension grease 6 N•m (53 lbf•in) 6 N•m (53 lbf•in) 6 N•m (53 lbf•in) 2,5 N•m Loctite 5150 (22 lbf•in) (silicone sealant) = Component must be replaced when removed.
Page 107 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 subsection.
Page 108 Subsection 02 (AIR INTAKE SYSTEM) vmr2013-010-001_a vmr2013-057-004_a TYPICAL 1. Locking tie to remove - location shown 1. Air intake tube retaining screw 8. Detach link rod from shift lever. vmr2012-010-009_a TYPICAL 1. Locking ties to remove vmr2012-010-006_a TYPICAL 11. Detach gearbox vent hose from air filter hous- 1.
Page 109 Subsection 02 (AIR INTAKE SYSTEM) vmr2012-010-011_a vmr2012-010-015_a TYPICAL TYPICAL 1. Crankcase vent hose 1. Throttle body 13. Remove air filter housing retaining screws. 17. Remove air filter housing by pulling it towards rear. vmr2013-057-006_a AIR FILTER HOUSING RETAINING SCREWS TO REMOVE vmr2012-010-016_a AIR FILTER HOUSING REMOVAL 18.
Page 110 Subsection XX (EXHAUST SYSTEM) EXHAUST SYSTEM Outlander Max model Loctite Loctite 243 Loctite Outlander series Engine / 13 ± 1 N•m Moteur (155 ± 9 lbf•in) Loctite 13 ± 1 N•m (155 ± 9 lbf•in) Loctite Renegade series = Component must be replaced when removed. vmr2013-011-001 vmr2013-011...
Page 111 Subsection XX (EXHAUST SYSTEM) GENERAL WARNING Never touch exhaust system components im- mediately after the engine has run. PROCEDURES SPARK ARRESTER PERIODIC For spark arrester servicing, refer to MAINTENANCE PROCEDURES subsection. MUFFLER vmr2012-011-002_a LH SIDE — PARTS REMOVED FOR CLARITY 1.
Page 112 Subsection XX (EXHAUST SYSTEM) NOTE: Loosely install all fasteners before tighten- ing. smr2012-011-004_a REAR VIEW 1. Muffler 2. Remove bolts vmr2012-011-007_d 1. Brace BODY 3. Refer to and remove both rear bumper 2. Secure fasteners braces. HEAT SHIELD Heat Shield Removal BODY 1.
Page 113 Subsection XX (EXHAUST SYSTEM) Y-Exhaust Pipe Installation The installation is the reverse of the removal pro- cedure. Install NEW exhaust gaskets. Properly position exhaust pipe before tightening. TORQUE Head pipe nuts 13 N•m ± 1 N•m (rear cylinder) (115 lbf•in ± 9 lbf•in) HEAD PIPE (FRONT CYLINDER) Front Head Pipe Removal vmr2013-011-002_a...
Page 114 Subsection XX (EXHAUST SYSTEM) vmr2012-011-011_a LH SIDE — PARTS REMOVED FOR CLARITY 1. Head pipe NOTE: The space to remove the front head pipe is limited. Remove it without force. Front Head Pipe Inspection Check head pipe for cracks, bending or other dam- ages.
Page 115 Subsection XX (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number Page 529 035 652 ..........4 ADAPTER HOSE ................529 035 714 ..........4 DISCONNECT TOOL ..............529 035 709 ..........4 PRESSURE GAUGE............... SERVICE PRODUCTS Description Part Number Page 293 800 060 ........
Page 116 Subsection XX (LUBRICATION SYSTEM) COMPONENTS 20 ± 2 N•m (15 ± 1.5 lbf•ft) 12 ± 1 N•m (106 ± 9 lbf•in) Loctite 10 ± 1 N•m (89 ± 9 lbf•in) Engine oil 30 ± 2 N•m (22 ± 1.5 lbf•ft) 6 ±...
Page 117 Subsection XX (LUBRICATION SYSTEM) ENGINE LUBRICATION CIRCUIT vmr2007-033-001_a 1. Camshaft bearings 2. Oil pressure switch 3. Oil filter 4. Oil pressure regulator valve 5. Oil strainer 6. Oil pump 7. Crankshaft main bearings 8. Crankshaft support bearing 9. Connecting rod bearings vmr2013-012...
Page 118 Subsection XX (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 119 Subsection XX (LUBRICATION SYSTEM) Oil Cooler Removal 2. Cylinder head or cylinder base gasket leak. - Retighten cylinder head to specified torque, refer Refer to PERIODIC MAINTENANCE PROCE- to TOP END subsection. Replace gasket if tight- DURES subsection to : ening does not solve the problem.
Page 120 Subsection XX (LUBRICATION SYSTEM) PERIODIC MAINTENANCE PROCE- Refer to OIL PRESSURE SWITCH ACTIVATION RANGE DURES subsection and carry out the following: 30 kPa ± 10 kPa (4.35 PSI ± 1.45 PSI) – Refill engine with recommended oil. See GINE OIL CHANGE To check the function of the oil pressure switch, –...
Page 121 Subsection XX (LUBRICATION SYSTEM) Oil Pressure Switch Installation Oil Pressure Regulator Access To reach the pressure regulator (Outlander series), refer to BODY and remove: – RH side panel – RH footboard panel. Oil Pressure Regulator Removal Remove plug screw and pull oil pressure regulator out.
Page 122 Subsection XX (LUBRICATION SYSTEM) OIL PUMP Oil Pump Location The oil pump is located on the engine PTO side (behind PTO cover). vmr2006-042-011_a 1. Retaining screws 2. Oil pump cover 3. Remove oil pump shaft with needle pin and in- ner rotor.
Page 123 Subsection XX (LUBRICATION SYSTEM) vmr2006-042-014_a 1. Outer rotor 2. Inner rotor A. 0.25 mm (.0098 in) vmr2006-042-012_a If clearance of inner and outer rotors exceeds the 1. Oil pump bore tolerance, replace oil pump rotors. Ensure to also 2. Outer rotor 3.
Page 124 Subsection XX (LUBRICATION SYSTEM) ENGINE OIL STRAINER Oil Strainer Location The engine oil strainer is located between both crankcase halves. Oil Strainer Removal Remove engine from vehicle. BOTTOM Separate crankcase halves. Refer to subsection. Remove screws and retaining plate. Pull out engine oil strainer. vmr2006-042-016 OIL PUMP COVER —...
Page 125 Subsection XX (LUBRICATION SYSTEM) REED VALVE The engine is equipped with a reed valve which prevents accumulation of larger oil quantities in the crankcase. The reed valve is fitted into the crankcase. vmr2006-042-018_a 1. Reed valve 2. Stopper 3. Screws Reed Valve Removal Remove: –...
Page 126: Cooling System
Subsection XX (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 056 ........... 17 BLIND HOLE PULLER KIT ............529 035 868 ..........9 FLUKE 115 MULTIMETER ............420 877 650 ........... 18 HANDLE ..................529 035 757 ........... 18 OIL SEAL PUSHER................
Page 127 Subsection XX (COOLING SYSTEM) RADIATOR 500, 650 and 800R Engine 2.5 ± 0.5 N•m (22 ± 4 lbf•in) 10 ± 2 N•m (89 ± 18 lbf•ft) 10 ± 2 N•m (89 ± 18 lbf•ft) Engine = Component must be replaced when removed. vmr2012-013-101_a vmr2013-013...
Page 128 Subsection XX (COOLING SYSTEM) RADIATOR AND THERMOSTAT 1000 Engine 10 ± 2 N•m (89 ± 18 lbf•ft) 2.5 ± 0.5 N•m (22 ± 4 lbf•in) 10 ± 2 N•m (89 ± 18 lbf•ft) Engine = Component must be replaced when removed. vmr2012-013-102_a vmr2013-013...
Page 129 Subsection XX (COOLING SYSTEM) WATER PUMP AND THERMOSTAT 500, 650 and 800R Engine 6 ± 0.7 N•m 5 ± 0.6 N•m 5 ± 0.6 N•m (53 ± 6 lbf•in) (44 ± 5 lbf•in) (44 ± 5 lbf•in) Loctite 6 ± 0.7 N•m (53 ±...
Page 130 Subsection XX (COOLING SYSTEM) WATER PUMP 1000 Engine 5 ± 0.6 N•m (44 ± 5 lbf•in) 6 ± 0.7 N•m (53 ± 6 lbf•in) Loctite 243 16 ± 2 N•m (142 ± 18 lbf•in) 5 ± 0.6 N•m (44 ± 5 lbf•in) CTS, see ELECTRONIC FUEL 6 ±...
Page 131: General
Subsection XX (COOLING SYSTEM) GENERAL Thermostat Removal 500, 650 and 800R Models NOTICE Never start engine without coolant. Some engine parts such as the rotary seal on 1. Drain engine coolant, refer to PERIODIC MAIN- the water pump shaft can be damaged. TENANCE PROCEDURES subsection.
Page 132: Radiator
Subsection XX (COOLING SYSTEM) All Models Refill and bleed cooling system, refer to PERI- ODIC MAINTENANCE PROCEDURES subsec- tion. Check cooling system for leaks. RADIATOR Radiator Inspection Check radiator fins for clogging or damage. Remove insects, mud or other obstructions with compressed air or low pressure water.
Page 133: Coolant Temperature Sensor (Cts)
Subsection XX (COOLING SYSTEM) 7. Remove cooling fan vent hose from vehicle. NOTE: Take note of the rooting of vent hose on vehicle to ease reinstallation. 8. Pull radiator upwards to release it from rubber bushings. Radiator Installation The installation is the reverse of the removal pro- cedure.
Page 134: Radiator Cooling Fan
Subsection XX (COOLING SYSTEM) TERMINAL RESISTANCE max. (continuity) vmr2012-028-006_d R1: RADIATOR COOLING FAN RELAY Relay Operation Test (Radiator Cooling Fan) 1. Remove relay (R1). smr2007-027-060_a WIRING 2. Bypass relay using a jumper. Refer to If relay failed any test, replace it. DIAGRAM to locate proper terminals.
Page 135 Subsection XX (COOLING SYSTEM) Radiator Cooling Fan Troubleshooting Chart COOLING FAN TROUBLESHOOTING CHART Is fan working? Everything is OK Check ECM fuse (F6) Replace fuse Check FAN fuse (F9) Is fan working? Is fuse burnt? vmr2012-028-006_f Bypass fan relay R1 1.
Page 136: Water Pump Housing
Subsection XX (COOLING SYSTEM) tmr2011-011-006_a vmr2012-013-008_a 1. Coolant drain plug 1. Cooling fan retaining screws 2. Sealing ring 3. Screws 3. Remove radiator cooling fan. 4. Water pump housing Radiator Cooling Fan Installation 4. Pull water pump housing to remove it. The installation is the reverse of the removal pro- Water Pump Housing Inspection cedure.
Page 137: Water Pump Impeller
Subsection XX (COOLING SYSTEM) WATER PUMP IMPELLER DEFECTIVE PART ACTION Water Pump Impeller Removal Replace: - Rotary seal WATER PUMP HOUSING RE- Rotary seal 1. Proceed with - Oil seal MOVAL . See procedure in this subsection. (assembled engine) 2. Remove impeller by unscrewing it counter- Replace: clockwise.
Page 138 Subsection XX (COOLING SYSTEM) vbs2008-011-005 TYPICAL - INNER PART OF ROTARY SEAL REMOVED 3. Carefully bend down the outer part of rotary seal lip using a small chisel. tmr2011-011-052_a 1. Screwdrivers NOTICE Be careful not to damage the crankcase while removing outer part of the rotary seal.
Page 139 Subsection XX (COOLING SYSTEM) tmr2011-011-054_a tmr2011-011-056_a 1. Wooden screws Seals Installation 2. Oil seal 1. Apply engine oil on water pump shaft. 7. Remove oil seal from crankcase by pulling screws with pliers. 2. Apply grease on the lips of the oil seal. 3.
Page 140 Subsection XX (COOLING SYSTEM) REQUIRED TOOLS ROTARY SEAL PUSHER PLATE (P/N 529 036 130) 4x M6 x 85 screws (P/N 420 440 347) 4x tubes 70 mm (2.75 in) SEAL PUSHER (P/N 529 035 766) vbs2008-011-035_a TYPICAL 1. Oil seal properly seated 6.
Page 141 Subsection XX (COOLING SYSTEM) NOTE: Make sure pusher bolt has a plane 15. Remove rotary seal installation tools from surface. crankcase. 12.1 Apply a little grease at the end of tool 16. Repeat steps 9 TO 15 until rotary seal is com- pusher bolt.
Page 142 Subsection XX (COOLING SYSTEM) 20. Check cooling system for leaks. Water Pump Shaft and Seals Replacement (Disassembled Engine) Water Pump Shaft and Seals Removal 1. Remove the following parts, see procedure in this subsection: WATER PUMP HOUSING – WATER PUMP IMPELLER –...
Page 143 Subsection XX (COOLING SYSTEM) tmr2011-011-012_a OIL SEAL REMOVAL - VIEW FROM INSIDE CRANKCASE MAG tmr2011-011-014_a SIDE 1. Oil seal 1. Orifices for oil seal removal 2. Installer handle with oil seal pusher Water Pump Shaft and Seals Installation Apply on seal- DOW CORNING 111 (P/N 413 707 000) ing lip of the oil seal.
Page 144: Water Pump Gears
Subsection XX (COOLING SYSTEM) WATER PUMP GEARS Water Pump Gears Identification mmr2009-112-028_a WATER PUMP SHAFT ASSEMBLY 1. Surface where rotary seal is pushed by tool NOTICE Never use a hammer for rotary seal installation. Only use a press to avoid damag- ing the ceramic component.
Page 145 Subsection XX (COOLING SYSTEM) tmr2011-011-009_a CRANKCASE MAG SIDE tmr2011-011-013_a 1. Water pump gear CRANKCASE PTO SIDE 2. Needle pin 1. Water pump intermediate drive gear 3. Thrust washer 2. Circlip 3. Water pump intermediate shaft Water Pump Intermediate Drive Gear 4.
Page 146 Subsection XX (COOLING SYSTEM) – Needle pin Install NEW circlip to retain water pump interme- diate drive gear. – Water pump gear. NOTICE Never use the circlip a second time. NOTICE A missing thrust washer will cause a Always install a NEW one. leaking rotary seal.
Page 147 Subsection 05 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 056 ........... 18 BLIND HOLE PULLER KIT ............529 035 868 ..........9 FLUKE 115 MULTIMETER ............420 877 650 ........... 19 HANDLE ..................529 035 757 ........... 19 OIL SEAL PUSHER................
Page 148 Subsection 05 (COOLING SYSTEM) RADIATOR 650 Engine 10 N•m (89 lbf•in) 10 N•m (89 lbf•in) 10 N•m (89 lbf•in) 10 N•m 10 N•m (89 lbf•in) (89 lbf•in) 7,5 N•m (66 lbf•in) 15 N•m (133 lbf•in) = Component must be replaced when removed. vmr2013-058-100_a vmr2013-058...
Page 149 Subsection 05 (COOLING SYSTEM) RADIATOR AND THERMOSTAT 1000 Engine 10 N•m (89 lbf•in) 10 N•m (89 lbf•in) 10 N•m (89 lbf•in) 10 N•m (89 lbf•in) 7,5 N•m (66 lbf•in) 10 N•m (89 lbf•in) 15 N•m (133 lbf•in) = Component must be replaced when removed. vmr2013-058-101_a vmr2013-058...
Page 150 Subsection 05 (COOLING SYSTEM) WATER PUMP AND THERMOSTAT 650 Engine 6 ± 0.7 N•m 5 ± 0.6 N•m 5 ± 0.6 N•m (53 ± 6 lbf•in) (44 ± 5 lbf•in) (44 ± 5 lbf•in) Loctite 6 ± 0.7 N•m (53 ± 6 lbf•in) Loctite CTS See Electronic Fuel Injection (EFI)
Page 151 Subsection 05 (COOLING SYSTEM) WATER PUMP 1000 Engine 5 ± 0.6 N•m (44 ± 5 lbf•in) 6 ± 0.7 N•m (53 ± 6 lbf•in) Loctite 243 16 ± 2 N•m (142 ± 18 lbf•in) 5 ± 0.6 N•m (44 ± 5 lbf•in) CTS, see ELECTRONIC FUEL 6 ±...
Page 152 Subsection 05 (COOLING SYSTEM) GENERAL Thermostat Removal 650 Models NOTICE Never start engine without coolant. Some engine parts such as the rotary seal on 1. Drain engine coolant, refer to PERIODIC MAIN- the water pump shaft can be damaged. TENANCE PROCEDURES subsection.
Page 153 Subsection 05 (COOLING SYSTEM) RADIATOR Radiator Inspection Check radiator fins for clogging or damage. Remove insects, mud or other obstructions with compressed air or low pressure water. Radiator Removal PERIODIC 1. Drain engine coolant. Refer to MAINTENANCE PROCEDURES subsection. 2. Remove service cover. 3.
Page 154 Subsection 05 (COOLING SYSTEM) vmr2013-058-006_a 8. Remove coolant bottle retaining screw and nut. vmr2013-058-003_a 1. Radiator retaining screws 2. Radiator retaining screws and bolt - Discard bolts 5. Remove retaining screws securing CVT air filter to CVT air inlet support. vmr2013-058-007_a COOLANT BOTTLE RETAINING SCREW AND NUT 9.
Page 155 Subsection 05 (COOLING SYSTEM) PERI- Refill and bleed cooling system, refer to ODIC MAINTENANCE PROCEDURES subsec- tion. Check cooling system for leaks. COOLANT TEMPERATURE SENSOR (CTS) ELECTRONIC FUEL INJECTION (EFI) Refer to subsection. RADIATOR COOLING FAN RELAY vmr2013-058-013_a (R1) RETAINING SCREWS TO REMOVE. Relay Location (Radiator Cooling Fan) 13.
Page 156 Subsection 05 (COOLING SYSTEM) TERMINAL RESISTANCE CHECK ENGINE COOLING GAUGE ENGINE TEMP. MESSAGE Open circuit LIGHT (OL) 95°C Turns ON (203°F) 93°C Turn OFF (199°F) Check 115°C Turns ON engine (239°F) Hi Temp 118°C Limp Flashes (244°F) Home Radiator Cooling Fan Fuse Location The fuse (F9) is located in front fuse box under smr2007-027-050_a gauge support.
Page 157 Subsection 05 (COOLING SYSTEM) Radiator Cooling Fan Troubleshooting 3. Connect cooling fan connector pin A (BK wire) Chart directly to the negative battery post. 4. Check if cooling fan works properly. COOLING FAN TROUBLESHOOTING CHART – If cooling fan does not work, replace it. ...
Page 158 Subsection 05 (COOLING SYSTEM) vmr2013-058-012_a 1. Cooling fan retaining screws tmr2011-011-006_a 1. Coolant drain plug 3. Remove radiator cooling fan. 2. Sealing ring 3. Screws 4. Water pump housing Radiator Cooling Fan Installation 4. Pull water pump housing to remove it. The installation is the reverse of the removal pro- cedure.
Page 159 Subsection 05 (COOLING SYSTEM) WATER PUMP IMPELLER DEFECTIVE PART ACTION Water Pump Impeller Removal Replace: - Rotary seal WATER PUMP HOUSING RE- Rotary seal 1. Proceed with - Oil seal MOVAL . See procedure in this subsection. (assembled engine) 2. Remove impeller by unscrewing it counter- Replace: clockwise.
Page 160 Subsection 05 (COOLING SYSTEM) vbs2008-011-005 TYPICAL - INNER PART OF ROTARY SEAL REMOVED 3. Carefully bend down the outer part of rotary seal lip using a small chisel. tmr2011-011-052_a 1. Screwdrivers NOTICE Be careful not to damage the crankcase while removing outer part of the rotary seal.
Page 161 Subsection 05 (COOLING SYSTEM) tmr2011-011-054_a tmr2011-011-056_a 1. Wooden screws Seals Installation 2. Oil seal 1. Apply engine oil on water pump shaft. 7. Remove oil seal from crankcase by pulling screws with pliers. 2. Apply grease on the lips of the oil seal. 3.
Page 162 Subsection 05 (COOLING SYSTEM) REQUIRED TOOLS ROTARY SEAL PUSHER PLATE (P/N 529 036 130) 4x M6 x 85 screws (P/N 420 440 347) 4x tubes 70 mm (2.75 in) SEAL PUSHER (P/N 529 035 766) vbs2008-011-035_a TYPICAL 1. Oil seal properly seated 6.
Page 163 Subsection 05 (COOLING SYSTEM) 12. Install rotary seal installation tools 14. Ensure that the rotary seal is going straight crankcase as follows. into crankcase. NOTE: Make sure pusher bolt has a plane 15. Remove rotary seal installation tools from surface. crankcase.
Page 164 Subsection 05 (COOLING SYSTEM) 19. Refill and bleed cooling system. Refer to RIODIC MAINTENANCE PROCEDURES sub- section. 20. Check cooling system for leaks. Water Pump Shaft and Seals Replacement (Disassembled Engine) Water Pump Shaft and Seals Removal 1. Remove the following parts, see procedure in this subsection: WATER PUMP HOUSING –...
Page 165 Subsection 05 (COOLING SYSTEM) tmr2011-011-012_a OIL SEAL REMOVAL - VIEW FROM INSIDE CRANKCASE MAG tmr2011-011-014_a SIDE 1. Oil seal 1. Orifices for oil seal removal 2. Installer handle with oil seal pusher Water Pump Shaft and Seals Installation Apply on seal- DOW CORNING 111 (P/N 413 707 000) ing lip of the oil seal.
Page 166 Subsection 05 (COOLING SYSTEM) WATER PUMP GEARS Water Pump Gears Identification mmr2009-112-028_a WATER PUMP SHAFT ASSEMBLY 1. Surface where rotary seal is pushed by tool NOTICE Never use a hammer for rotary seal installation. Only use a press to avoid damag- ing the ceramic component.
Page 167 Subsection 05 (COOLING SYSTEM) tmr2011-011-009_a CRANKCASE MAG SIDE tmr2011-011-013_a 1. Water pump gear CRANKCASE PTO SIDE 2. Needle pin 1. Water pump intermediate drive gear 3. Thrust washer 2. Circlip 3. Water pump intermediate shaft Water Pump Intermediate Drive Gear 4.
Page 168 Subsection 05 (COOLING SYSTEM) NOTICE – Needle pin Never use the circlip a second time. Always install a NEW one. – Water pump gear. Water Pump Drive Gear NOTICE A missing thrust washer will cause a leaking rotary seal. BOTTOM END subsection.
Page 169 Subsection XX (MAGNETO SYSTEM) MAGNETO SYSTEM SERVICE TOOLS Description Part Number Page 529 035 617 ..........6 CRANKSHAFT LOCKING BOLT............. 529 036 034 ..........6 CRANKSHAFT PROTECTOR ............529 035 868 ......... 4–5 FLUKE 115 MULTIMETER ............529 035 748 ..........6 MAGNETO PULLER ..............
Page 170 Subsection XX (MAGNETO SYSTEM) ELECTRONIC FUEL INJECTION (EFI) 10 ± 1 N•m Molykote (89 ± 9 lbf•in) 6 ± 0.7 N•m (53 ± 6 lbf•in) Drei Bond 10 ± 1 N•m sealing compound (89 ± 9 lbf•in) Loctite 243 4 ± 0.5 N•m (35 ±...
Page 171 Subsection XX (MAGNETO SYSTEM) PROCEDURES MAGNETO COVER Magneto Cover Access Outlander Series BODY Refer to and remove: – RH side panel – RH footboard panel. Renegade Series BODY Refer to and remove: – RH engine panel. tmr2011-012-003_a 1. Magneto cover Magneto Cover Removal 2.
Page 172 Subsection XX (MAGNETO SYSTEM) vmr2012-032-003_a TYPICAL 1. Voltage regulator/rectifier location tmr2011-012-006_a 1. Stator cable grommet (apply Drei Bond sealing compound) Tighten screws using the following sequence. vmr2012-014-020_a 1. Voltage regulator/rectifier 2. Three YELLOW wires Stator Static Test: Continuity 1. Disconnect the stator connector on the voltage vmr2006-041-004_a regulator/rectifier.
Page 173 Subsection XX (MAGNETO SYSTEM) 4. If there is a resistance or continuity, the stator coils and/or the wiring is shorted to ground and needs to be repaired or replaced. 5. Re-plug connectors properly. Stator Dynamic Test: AC Voltage REQUIRED TOOL FLUKE 115 MULTIMETER (P/N 529 035 868) 1.
Page 174 Subsection XX (MAGNETO SYSTEM) HOLDING STRIP SCREWS LOCTITE 243 (BLUE) Service Product (P/N 293 800 060) 4 N•m ± 0.5 N•m Tightening Torque (35 lbf•in ± 4 lbf•in) STATOR RETAINING SCREWS 11 N•m ± 1 N•m Tightening Torque (97 lbf•in ± 9 lbf•in) ROTOR Rotor Removal MAGNETO COVER...
Page 175 Subsection XX (MAGNETO SYSTEM) Rotor Installation NOTE: Use grease to place protector on crank- shaft end prior to screw on the magneto puller. For installation, reverse the removal procedure. However, pay attention to the following. PULLEY FLANGE CLEANER (P/N 413 711 809) clean following parts: –...
Page 176 Subsection XX (MAGNETO SYSTEM) Rotate starter double gear counterclockwise to Remove sprag clutch gear. align intermediate gear teeth with sprag clutch Remove sprag clutch housing screws and sprag gear. clutch housing. vmr2006-041-013_a 1. Sprag clutch housing screws vmr2006-041-012_b 2. Rotor 3.
Page 177 Subsection XX (MAGNETO SYSTEM) Apply LOCTITE 648 (GREEN) (P/N 413 711 400) threads of sprag clutch housing screws. Install screws but do not torque yet. Apply engine oil on sprag clutch and sprag clutch gear needle bearing. vmr2006-041-015_a 1. Rotor 2.
Page 178 Subsection XX (MAGNETO SYSTEM) Starter Drive Gear Removal Remove MAGNETO COVER . See procedure in this subsection. Remove location pins, starter double gear and in- termediate gear. vmr2006-041-017_a 1. Intermediate gear 2. Starter double gear 3. Starter gear 4. Location pins Starter Drive Gear Inspection Inspect gears and location pins for wear and dam- age.
Page 179 Subsection XX (INTAKE MANIFOLD) INTAKE MANIFOLD 0.7 ± 0.1 N•m (6 ± 1 lbf•in) 10 ± 1 N•m (89 ± 9 lbf•in) 6 ± 0.7 N•m (53 ± 6 lbf•in) 10 ± 1 N•m (89 ± 9 lbf•in) Loctite ELECTRONIC FUEL INJECTION (EFI) Engine Engine...
Page 180 Subsection XX (INTAKE MANIFOLD) PROCEDURES INTAKE MANIFOLD Intake Manifold Access BODY Refer to and remove the RH side panel. Intake Manifold Removal 1. Release fuel pressure. Refer to FUEL TANK AND FUEL PUMP subsection. 2. Remove shift rod nut. vmr2012-015-005_a 1.
Page 181 Subsection XX (TOP END) TOP END SERVICE TOOLS Description Part Number Page 529 035 617 ........... 20 CRANKSHAFT LOCKING BOLT............. 529 035 661 ........... 6 ENGINE LEAK DOWN TEST KIT ........... 529 035 921 ........... 24 PISTON CIRCLIP INSTALLER............529 036 153 ........... 24 PISTON CIRCLIP INSTALLER............
Page 182 Subsection XX (TOP END) CYLINDER HEAD NO. 1 7 ± 0.8 N•m (62 ± 7 lbf•in) 12 ± 1 N•m (106 ± 9 lbf•in) Engine oil See tightening Engine oil procedure 20 ± 2 N•m 10 ± 1 N•m (15 ± 1.5 lbf•ft) Engine oil (89 ±...
Page 183 Subsection XX (TOP END) CYLINDER HEAD NO. 2 Engine oil 7 ± 0.8 N•m (62 ± 7 lbf•in) 12 ± 1 N•m (106 ± 9 lbf•in) See tightening procedure 20 ± 2 N•m (5 ± 1.5 lbf•ft) Engine oil Ignition System Engine oil 10 ±...
Page 184 Subsection XX (TOP END) CYLINDERS AND PISTONS Engine oil Engine oil Engine oil Engine oil Engine oil Engine vmr2006-043-003_d vmr2013-016...
Page 185 Subsection XX (TOP END) GENERAL WARNING Always respect this order for disassembly; Special reference are made in the text for proce- disconnect BLACK (-) cable first. dures which are different for cylinder no. 1 and cylinder no. 2. Remove radiator cap. WARNING To prevent burning yourself only remove the radiator cap by wearing the appropriate...
Page 186 Subsection XX (TOP END) Set needle of measuring gauge to zero. REQUIRED TOOL NOTE: All testers have specific instructions on TDC DIAL INDICATOR gauge operation and required pressure. (P/N 414 104 700) Install gauge adapter into previously cleaned spark plug hole. Supply combustion chamber with air pressure.
Page 187 Subsection XX (TOP END) Valve Cover Removal – Air/coolant escaping from cylinder/head means damaged gasket(s) and/or loosened screws Remove valve cover screws. – Air escaping into crankcase area means exces- sively worn cylinder and/or broken piston rings – Air/oil escaping from crankcase means dam- aged gasket and/or loosened screws (refer to BOTTOM END subsection).
Page 188 Subsection XX (TOP END) ROCKER ARM Remove rocker arm assembly (exhaust side and intake side) with adjustment screws and lock Rocker Arm Removal nuts. VALVE COVER Remove . See procedure in this Remove thrust washers. susbsection. TIMING CHAIN Refer to subsection and remove following parts: –...
Page 189 Subsection XX (TOP END) ROCKER ARM SHAFT DIAMETER 12.00 mm to 12.018 mm (.4724 in to .4731 in) SERVICE LIMIT 11.990 mm (.472 in) Any area worn excessively will require parts re- placement. Rocker Arm Installation R400motr68A NOTE: Use the same procedure for exhaust and 1.
Page 190 Subsection XX (TOP END) NOTE: For removal rotate camshaft so that intake/exhaust lobe shows to upper side of cylin- der head. tmr2011-013-013_a 1. Intake cam 2. Exhaust cam 3. Camshaft of cylinder 1 4. Camshaft of cylinder 2 5. Flat spot Camshaft Removal tmr2011-013-014_a 1.
Page 191 Subsection XX (TOP END) CAMSHAFT LOBE (EXHAUST) 32.950 mm to 33.150 mm (1.2972 in to 1.3051 in) 800R engine SERVICE 32.930 mm (1.2965 in) LIMIT 32.860 mm to 33.060 mm (1.294 in to 1.302 in) 1000 engine SERVICE 32.840 mm (1.293 in) LIMIT R400motr76A CAMSHAFT LOBE (INTAKE)
Page 192 Subsection XX (TOP END) tmr2011-013-011_a 1. Cylinder head screws M10 2. Cylinder head screws M6 tmr2011-013-014_b 1. Direction of movement Pull up cylinder head. 2. Camshaft retaining plate 3. Slot retaining camshaft Remove timing chain guide (fixed). For other parts, refer to proper installation proce- Remove and discard the cylinder head gasket.
Page 193 Subsection XX (TOP END) For installation, reverse the removal procedure. Pay attention to the following details. Ensure dowel pins are in place. NOTICE Timing chain guide (fixed) has to be fixed between cylinder and cylinder head. R400motr73A 1. Oil port to lubricate camshaft lobes intake/exhaust 2.
Page 194 Subsection XX (TOP END) CYLINDER HEAD SCREW IDENTIFICATION M6 CYLINDER HEAD SCREWS Location no. 10 N•m ± 1 N•m M10 x 140 Tightening Torque (89 lbf•in ± 9 lbf•in) 500/650/800R engines Location no. Check timing chain guide (tensioner side) for M6 x 85 movement.
Page 195 Subsection XX (TOP END) R400motr80A A. Valve spring length VALVE SPRING FREE LENGTH R400motr78A NOMINAL NEW 40.81 mm (1.607 in) 1. Valve spring compressor clamp 2. Valve spring compressor cup SERVICE LIMIT 39.00 mm (1.535 in) 3. Valve cotter Remove tools and withdraw valve spring retainer Replace valve springs if not within specifications.
Page 196 Subsection XX (TOP END) VALVES Valve Stem Seal Always install NEW seals whenever valves are re- Valve Removal moved. VALVE SPRING Remove valve spring, see in this Valve subsection. Inspect valve surface, check for abnormal stem Push valve stem, then pull valves (intake and ex- wear and bending.
Page 197 Subsection XX (TOP END) If valve seat contact width is too wide or has dark VALVE STEM DIAMETER spots, replace the cylinder head. EXHAUST VALVE 4.956 mm to 4.970 mm (.1951 in to .1957 in) 4.930 mm (.1941 in) SERVICE LIMIT INTAKE VALVE 4.966 mm to 4.980 mm (.1955 in to .1961 in)
Page 198 Subsection XX (TOP END) VALVE GUIDES Clean the valve guide bore before reinstalling the valve guide into cylinder head. Valve Guide Inspection Install valve guide. Always replace valve stem seals whenever valve REQUIRED TOOL guides are removed. VALVE GUIDE INSTALLER Measure valve guide in three places using a small (P/N 529 036 140) bore gauge.
Page 199 Subsection XX (TOP END) R400motr89A R400motr90A 1. Valve seat 2. Valve face (contact surface to valve seat) 1. Cylinder 3. Turn valve while pushing against cylinder head 2. Piston assembly A. Valve seat angle 45° 3. Cylinder base gasket 4. Camshaft timing chain NOTE: Ensure to seat valves properly.
Page 200 Subsection XX (TOP END) CYLINDER TAPER SPECIFICATION REQUIRED TOOL NEW (maximum) 0.038 mm (.0015 in) 500/650 PISTON RING COMPRESSOR engines (P/N 529 035 977) SERVICE LIMIT 0.090 mm (.0035 in) 800R/1000 PISTON RING COMPRESSOR Distance between measurements should not ex- engines (P/N 529 035 919) ceed the service limit.
Page 201 Subsection XX (TOP END) NOTE: After both cylinders are installed, turn crankshaft until piston of cylinder 2 is at TDC and CRANKSHAFT lock crankshaft. Refer to in the BOTTOM END subsection. Install cylinder head and the other parts in accor- dance with the proper installation procedures.
Page 202 Subsection XX (TOP END) Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. PISTON/CYLINDER CLEARANCE 0.057 mm to 0.087 mm (.0022 in to .0034 in) 500/650 engines SERVICE 0.130 mm (.0051 in) LIMIT 0.027 mm to 0.057 mm (.0011 in to .0022 in) 800R/1000...
Page 203 Subsection XX (TOP END) Compare measurements to obtain the connecting PISTON PIN DIAMETER rod/piston pin clearance. 17.996 mm to 18.000 mm CONNECTING ROD/ (.7085 in to .7087 in) PISTON PIN CLEARANCE engines SERVICE 17.980 mm (.7079 in) LIMIT SERVICE LIMIT 0.080 mm (.0031 in) 19.996 mm to 20.000 mm Piston Installation...
Page 204 Subsection XX (TOP END) 800R and 1000 engines ENGINE REQUIRED TOOL For each cylinder, install piston with the punched PISTON CIRCLIP INSTALLER arrow on piston dome is pointing toward the rear (P/N 529036058) side of the engine. Front cylinder: Mark on top of piston must show to intake side.
Page 205 Subsection XX (TOP END) RING/PISTON GROOVE CLEARANCE UPPER COMPRESSION RING 0.03 mm to 0.07 mm (.0012 in to .0028 in) 0.150 mm (.0059 in) SERVICE LIMIT LOWER COMPRESSION RING 0.02 mm to 0.06 mm (.0008 in to .0024 in) SERVICE LIMIT 0.150 mm (.0059 in) OIL SCRAPER RING vmr2007-036-008_a...
Page 206 Subsection XX (TOP END) Using a feeler gauge, check ring end gap. Replace ring if gap exceeds specified tolerance. Ring Installation For installation, reverse the removal procedure. Pay attention to the following details. NOTE: First install spring and then rings of oil scraper ring.
Page 207 Subsection XX (TIMING CHAIN) TIMING CHAIN SERVICE TOOLS Description Part Number Page 529 036 231 ..........5 CAMSHAFT TIMING TOOL............529 036 201 ......... 5, 9 CRANKSHAFT TDC POSITION TOOL ........... SERVICE PRODUCTS Description Part Number Page 293 800 060 ........6, 11 LOCTITE 243 (BLUE)..............
Page 208 Subsection XX (TIMING CHAIN) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 0.1 N•m (0.89 lbf•in) 10 ± 1 N•m (89 ± 9 lbf•in) Engine oil Loctite 243 6 ± 0.7 N•m (53 ± 6 lbf•in) Loctite 243 6 ± 0.7 N•m (53 ±...
Page 209 Subsection XX (TIMING CHAIN) TROUBLESHOOTING UNUSUAL ENGINE NOISE OR VIBRATION 1. IMPROPER VALVE CLEARANCE ADJUSTMENT AND/OR WORN OUT ROCKER ARM(S) - Readjust valve clearance and/or replace defective part(s), refer to TOP END subsection. 2. DEFECTIVE CHAIN TENSIONER - Replace chain tensioner. 3.
Page 210 Subsection XX (TIMING CHAIN) Timing Chain Tensioner Installation For installation, reverse the removal procedure. However, pay attention to the following. NOTE: Before installing the chain tensioner, make sure the camshaft timing gear can be moved back and forth. vmr2006-043-004_a 1. Chain tensioner screw plug 2.
Page 211 Subsection XX (TIMING CHAIN) Camshaft Timing Gear Installation 6. Then compress the spring and screw the plug For installation, reverse the removal procedure. NOTE: To avoid overstressing the timing chain, Pay attention to the following details. the chain tensioner screw plug must engage in 1.
Page 212 Subsection XX (TIMING CHAIN) NOTE: Properly align tube of camshaft timing tool with machined radius on cylinder head. vmr2012-016-003_a 1. Timing chain 2. Camshaft timing gear 3. Printed marks on camshaft timing gear 6. Install and adjust timing chain tensioner, refer to vmr2012-016-001_a TIMING CHAIN TENSIONER in this subsection.
Page 213 Subsection XX (TIMING CHAIN) tmr2011-014-031_a tmr2011-045-011_a 1. CPS 2. Screw TYPICAL 1. Cylinder head base 2. Marks on timing gear of the opposite cylinder 5. Set rear piston no. 2 to TDC ignition by turning the crankshaft clockwise. Camshaft Timing Piston No. 2 (rear) REQUIRED TOOL 1.
Page 214 Subsection XX (TIMING CHAIN) 3. To set front piston no. 1 to TDC ignition turn crankshaft 280° counterclockwise. REQUIRED TOOL Allen key 14 mm vmr2007-037-008_b PISTON NO. 2 AT TDC 1. Piston no. 2 identifier 2. Index mark on magneto flywheel 3.
Page 215 Subsection XX (TIMING CHAIN) tmr2011-045-013_a MAGNETO COVER tmr2011-045-003_c 1. Crankshaft TDC position tool installed in CPS bore TYPICAL - PISTON AT TDC IGNITION 1. Printed marks on camshaft timing gear NOTICE Tool must be fully inserted. 2. Cylinder head base 4.
Page 216 Subsection XX (TIMING CHAIN) 3. Refer to following procedures in this subsection and remove following parts: – Chain tensioner – Camshaft timing gear. 4. Remove timing chain guide (tensioner side) and lower timing chain guide. tmr2011-045-015_a 1. Timing chain 2. Lower timing chain guide 3.
Page 217 Subsection XX (TIMING CHAIN) Timing Chain Guide Inspection (Tensioner Side) Check timing chain guide for wear, cracks or de- formation. Replace if necessary. Timing Chain Guide Installation (Tensioner Side) vmr2006-044-018_a 1. Timing chain The installation is the reverse of the removal pro- If chain is excessively worn or damaged, replace cedure.
Page 218 Subsection XX (BOTTOM END) BOTTOM END SERVICE TOOLS Description Part Number Page 529 036 031 ........... 15 CRANKCASE SUPPORT MAG/PTO ..........529 035 617 ........... 18 CRANKSHAFT LOCKING BOLT............. 529 036 028 ......... 7–8 DRIVE SHAFT OIL SEAL INSTALLER ........... 529 036 029 ..........
Page 219 Subsection XX (BOTTOM END) ENGINE DRIVE SHAFT Engine oil 10 ± 1 N•m (89 ± 9 lbf•in) Loctite 767 (antiseize lubricant) Super Lube grease Loctite 5910 Engine oil Loctite 10 ± 1 N•m 5910 (89 ± 9 lbf•in) Loctite Engine oil Super Lube grease tmr2011-014-001_a...
Page 220 Subsection XX (BOTTOM END) CRANKCASE AND PTO COVER Engine oil 25 ± 3 N•m (18 ± 8 lbf•ft) Loctite 243 10 ± 1 N•m Super (89 ± 9 lbf•in) Lube grease 6 ± 0.7 N•m (53 ± 6 lbf•in) Engine 25 ±...
Page 221 Subsection XX (BOTTOM END) CRANKSHAFT See torquing procedure inside Engine See torquing procedure inside Engine oil vmr2013-018-001_a vmr2012-017...
Page 222 Subsection XX (BOTTOM END) PROCEDURES 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. ENGINE DRIVE SHAFT NOTE: The engine drive shaft transmits the power from the gearbox to the front differential...
Page 223 Subsection XX (BOTTOM END) tmr2011-014-009_a 1. Bearing cover 2. Drive shaft bearing Check drive shaft for cracks, bend, pitting or other F12R17A visible damages. Do not apply in excess as it will spread out inside Check drive shaft splines for wear or damages. crankcase.
Page 224 Subsection XX (BOTTOM END) Front Bearing Cover Installation tmr2013-018-005_a 1. Bearing cover 2. Oil seal tmr2011-014-004_a 5. Install drive shaft oil seal using the following FRONT OF ENGINE tool. 1. Water pump cover 2. Oil seal front side 3. Oil cooler REQUIRED TOOL 4.
Page 225 Subsection XX (BOTTOM END) ENGINE 2. Remove rear bearing cover, refer to DRIVE SHAFT REMOVAL/INSTALLATION this subsection. 3. Remove O-ring from bearing cover. vmr2013-018-002_a 1. Bearing cover 2. Oil seal 3. Oil seal installer 6. Install O-ring in rear bearing cover. vmr2013-018-003_a 1.
Page 226 Subsection XX (BOTTOM END) PTO COVER NOTICE Avoid scoring surfaces with tool. PTO Cover Removal CONTINUOUSLY VARIABLE TRANS- 1. Refer to MISSION (CVT) subsection to remove the fol- lowing parts: – CVT cover – Drive pulley – Driven pulley – CVT air guide. 2.
Page 227 Subsection XX (BOTTOM END) Plain Bearing Replacement WARNING (PTO Cover) Always wear skin and eye protection. Chem- icals can cause skin rash, skin burns and se- Plain Bearing Removal vere eye injury. NOTICE Unless otherwise instructed, never use a hammer to install plain bearings. Always 4.
Page 228 Subsection XX (BOTTOM END) Tighten PTO cover screws following the sequence illustrated. vmr2006-044-008_a 1. Mark position of oil bore on PTO cover 2. Mark position of oil bore on plain bearing remover/installer NOTICE Misalignment of plain bearing and PTO cover oil bores will prevent proper oil supply to plain bearings.
Page 229 Subsection XX (BOTTOM END) tmr2011-014-014_a tmr2011-014-016_a 1. Breather gear 1. Thrust washer 2. Intermediate gear 2. Water pump drive gear 3. Water pump drive gear 3. Needle pin 4. Oil pump drive gear Drive Gears Inspection Drive Gears Removal Intermediate Gear/Oil Pump Drive Gear/Water PTO COVER 1.
Page 230 Subsection XX (BOTTOM END) CRANKCASE – Oil cooler – Oil pump drive gear. Crankcase Disassembly NOTE: Oil pump removal from crankcase is not PERIODIC MAINTENANCE PROCE- 1. Refer to necessary, but recommended to see condition of DURES subsection and carry out the following: oil pump.
Page 231 Subsection XX (BOTTOM END) tmr2011-014-023_a 1. Engine oil strainer 2. Retaining plate tmr2011-014-022 3. Screws NOTE: During disassembly, do not damage the Crankcase Cleaning sealing surfaces of the crankcase halves. 15. Pull crankshaft out of crankcase. WARNING 16. Remove the water pump intermediate shaft. Use safety goggles to avoid eye injuries.
Page 232 Subsection XX (BOTTOM END) tmr2011-014-025_a vmr2006-044-025_a PRESS PLAIN BEARINGS OUTSIDE 1. Plain bearing 1. Crankcase half 2. Oil bore 2. Plain bearing remover/installer A. Measure plain bearing inside diameter 3. Crankcase support sleeve (P/N 529 036 031) Plain Bearing Installation (Main) MAIN BEARING INSIDE DIAMETER (PTO/MAG) SERVICE LIMIT 42.100 mm (1.6575 in)
Page 233 Subsection XX (BOTTOM END) tmr2011-014-028_a 1. Plain bearing joint 2. Oil bore tmr2011-014-026_a 3. Crankcase half PTO (inside surface) 1. Oil bore position marked on plain bearing remover/installer 2. Plain bearing oil bore Crankcase Assembly 3. Oil bore position marked on crankcase The assembly of crankcase is essentially the re- NOTICE Misalignment of the plain bearing...
Page 234 Subsection XX (BOTTOM END) CRANKCASE SCREWS 10 N•m ± 1 N•m Tightening Torque - M6 (89 lbf•in ± 9 lbf•in) 25 N•m ± 3 N•m Tightening Torque - M8 (18 lbf•ft ± 2 lbf•ft) CRANKSHAFT vmr2012-017-001_a 1. Plug screw 2. O-ring 3.
Page 235 Subsection XX (BOTTOM END) tmr2011-014-034_a 1. Screwdriver tmr2011-014-033_a 1. Allen key 14 mm 7. Lock crankshaft. NOTE: When the piston no. 2 is at TDC, the num- REQUIRED TOOL ber 2 piston index mark on the magneto flywheel CRANKSHAFT LOCKING and the notch on the magneto cover are aligned.
Page 236 Subsection XX (BOTTOM END) vmr2006-044-036_a 1. Crankshaft timing gears Crankshaft Axial Play NOTE: Axial play must be measured before split- ting the crankcase. Measure axial play on PTO end of crankshaft using vmr2006-044-037_a a dial indicator. 1. Crankshaft 2. Connecting rods CRANKSHAFT AXIAL PLAY 3.
Page 237 Subsection XX (BOTTOM END) 4. Carry out the tightening procedure described in CRANKSHAFT ASSEMBLY in this subsection. vmr2007-037-003_a 1. Connecting rod screws 2. Measure crankpin. Compare to inside diameter of connecting rod big end. vmr2006-044-039_a A. Connecting rod big end plain bearing CONNECTING ROD BIG END DIAMETER 35.150 mm 500 engine...
Page 238 Subsection XX (BOTTOM END) Crankshaft Radial Play (PTO Cover Bearing) Measure crankshaft journal diameter (PTO cover bearing). Compare to plain bearing inside diame- PTO COVER ter (PTO cover). Refer to in this sub- section. vmr2006-044-040_a 1. Micrometer 2. Crankshaft MAG side main bearing journal vmr2006-044-042_a 1.
Page 239 Subsection XX (BOTTOM END) R1004motr20A 1. Half plain bearing of connecting rod big end 2. Mating surface of the connecting rod 3. Joining surface of plain bearing in line with connecting rod groove Oil the plain bearing surface of the connecting rod and crankshaft pin before installation.
Page 240 Subsection XX (BOTTOM END) tmr2011-014-036_a 1. Connecting rod small ends 2. Connecting rod offset 3. Connecting rod screws CONNECTING RODS SCREWS TIGHTENING vmr2006-044-035_a SEQUENCE 1. Crankcase half MAG side Step 1 Tighten to 1/2 of specified torque 2. Connecting rod cylinder 1 3.
Page 241 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) CONTINUOUSLY VARIABLE TRANSMISSION (CVT) SERVICE TOOLS Description Part Number Page 529 036 238 ......6, 14, 20–22 CLUTCH HOLDER................. 529 035 746 ..........6 CLUTCH PULLER ................529 036 098 ......... 5, 20, 22 PULLER/LOCKING TOOL..............
Page 242 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Loctite 767 Isoflex grease Topas NB 52 500/650/800R engine Pulley flange cleaner 1000 engine Loctite 243 10 ± 1 N•m (89 ± 9 lbf•in) Isoflex grease 8 ± 0.8 N•m Topas NB 52 (71 ± 7 lbf•in) 500/650/800R engine See tightening...
Page 243 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Outlander Model Renegade Model 800R 800R 1000 1000 7 N•m 1 N•m (62 lbf•in) (8.9 lbf•in) 1 N•m (8.9 lbf•in) 1 N•m (8.9 lbf•in) vmr2013-019-002 vmr2013-019...
Page 244 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) GENERAL 3. Reinstall drain reservoir. NOTICE NOTE: For a better understanding, the following If an appreciable amount of water or illustrations are taken with engine out of vehicle. any debris entered the CVT cover, CVT must be To perform the following instructions, it is not nec- cleaned and inspected.
Page 245 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Drive Belt Inspection CVT COVER SCREWS For drive belt inspection refer to DRIVE BELT 7 N•m ± 0.8 N•m Tightening Torque INSPECTION in the PERIODIC MAINTENANCE (62 lbf•in ± 7 lbf•in) PROCEDURES subsection. DRIVE BELT Drive Belt Installation For installation, reverse the removal procedure.
Page 246 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) CAUTION Sliding sheave of drive pulley is spring loaded. vmr2006-021-011_a 1. Mark on drive pulley sliding sheave 2. Mark on governor cup 3. Lock the drive pulley. tmr2011-015-004_a Step 1: Push REQUIRED TOOL 1. Thrust washer 2.
Page 247 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Vmr2012-018-009_a 1. Drive pulley puller 2. Fixed sheave R400motr171A 1. Slider shoe Drive Pulley Disassembly 3. Place the governor cup on a vice to push out the Governor Cup roller sleeve in the direction illustrated (against 1.
Page 248 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Fixed Sheave WARNING Always wear safety glasses to remove spring sleeves. Pull and rotate one-way clutch slowly until the spring sleeves are visible. vmr2006-021-016_a 1. Removal direction 2. Assembly direction NOTE: Whenever removing a governor cup which already has two marked boxes, replace it by a new one.
Page 249 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Drive Pulley Cleaning NOTICE Do not use acetone to clean bush- ing. Clean pulley faces and shaft with fine steel wool and a dry cloth. Using a paper towel with the recommended cleaning solvent, clean: –...
Page 250 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) tmr2011-015-007_a 1. Centrifugal lever 2. Bushing A. Bushing inner diameter CENTRIFUGAL LEVER BORE DIAMETER vmr2006-021-014_a 6.035 mm to 6.078 mm 1. Roller 2. Slider shoe (.238 in to .239 in) A. Roller outer diameter 6.200 mm (.244 in) SERVICE LIMIT ROLLER OUTER DIAMETER...
Page 251 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) SLIDING SHEAVE LARGE BUSHING 55.000 mm to 55.040 mm (2.165 in to 2.167 in) SERVICE LIMIT 55.200 mm (2.173 in) vmr2006-021-024_a A. Centrifugal lever pivot bolt bore diameter CENTRIFUGAL LEVER PIVOT BOLT BORE DIAMETER 6.113 mm to 6.171 mm (.241 in to .243 in) SERVICE LIMIT...
Page 252 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Check for any marks on fixed sheave plate. Re- One-Way Clutch place if necessary. Clean parts. Spring Lubricate springs, spring sleeves and between one way clutch bearings using recommended Measure spring free length and squareness. If product.
Page 253 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2006-021-017 vmr2007-051-003_a 1. Friction washer NOTICE Rollers must move easily after in- 2. Collar 3. One way clutch stallation. Sliding Sheave Carefully press slider shoes in the governor cup Install centrifugal levers with their thrust washers. arm so they bottom out evenly in the machined portion of the governor cup arm.
Page 254 3. Thrust washer WARNING Never substitute conical spring washer and/or screw with aftermarket parts. Al- ways use genuine BRP parts. Lock the drive pulley as per removal procedure. Tighten drive pulley screw to specification. NOTICE Never use any type of impact wrench for drive pulley installation.
Page 255 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Vmr2012-018-011_a 1. Driven pulley screw 2. Thrust washer 6. Remove the driven pulley with the spring and vmr2006-021-035_a 1. Retaining ring the cam. 2. Torque gear 3. Fixed sheave of driven pulley NOTE: The following procedure is not necessary except if ball bearing or shaft must be removed.
Page 256 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Using a paper towel with PULLEY FLANGE , clean countershaft CLEANER (P/N 413 711 809) end and shaft bore. NOTICE To avoid damage, make sure cleaner does not contact the countershaft oil seal. R610tran18A 1.
Page 257 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) REQUIRED TOOL BUSHING INNER DIAMETER 30.060 mm to 30.100 mm Dial Bore Gauge (1.183 in to 1.185 in) MEASURING POINT SERVICE LIMIT 30.200 mm (1.189 in) At least 5 mm (1/4 in) from bushing edge Check torque gear for visible damage and cracks.
Page 258 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Driven Pulley Assembly For installation, reverse the removal procedure. Pay attention to following details. Heat ball bearing area up to 100°C (212°F) before ball bearing installation. NOTE: Place new ball bearing in a freezer for 10 minutes before installation.
Page 259 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) NOTICE Cam splines must engage on coun- tershaft splines. REQUIRED PRODUCT Countershaft splines LOCTITE 767 (ANTISEIZE and countershaft LUBRICANT) (P/N 293 800 070) vmr2006-021-035_a 1. Retaining ring 2. Torque gear 3. Fixed sheave of driven pulley Driven Pulley Installation For installation, reverse the removal procedure.
Page 260 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) As you hold the pulley compressed, install a NEW REQUIRED TOOL driven pulley screw and thrust washer. CLUTCH HOLDER NOTICE This assembly uses a stretch screw. (P/N 529 036 238) Always install a NEW screw. NOTE: Tighten the screw with your hand suffi- TIGHTENING SEQUENCE ciently for the cam to remain engaged.
Page 261 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Vmr2012-018-011_a 1. Driven pulley screw 2. Thrust washer Insert a screwdriver of approximately 5 mm Vmr2012-018-017_a 1000 ENGINE (.197 in) diameter in the cam. 1. Cam 2. Spring end NOTE: For clarity of understanding, some parts 3.
Page 262 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) tmr2013-019-008_a tmr2013-019-009_b 1000 ENGINE 1000 ENGINE 1. Fixed sheave 1. Clutch holder 2. Clutch holder 2. Screwdriver 3. Screwdriver A. Cam freedom of movement Turn the screwdriver approximately 20° counter- Install drive belt. Refer to DRIVE BELT in this sub- clockwise until cam engages in the driven pulley...
Page 263 Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) TIGHTENING SEQUENCE (DRIVEN PULLEY SCREW) STEP 1 20 N•m ± 1 N•m (15 lbf•ft ± 1 lbf•ft) STEP 2 180° ± 5° vmr2012-018-020_a 500/650/800R ENGINE 1. CVT air guide 2. O-rings tmr2013-019-007_a 1. Driven pulley screw 2.
Page 264: Continuously Variable Transmission (Cvt)
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) CONTINUOUSLY VARIABLE TRANSMISSION (CVT) SERVICE TOOLS Description Part Number Page 529 036 238 ......6, 14, 20–22 CLUTCH HOLDER................. 529 035 746 ..........6 CLUTCH PULLER ................529 036 098 ......... 5, 20, 22 PULLER/LOCKING TOOL..............
Page 265 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Loctite 767 Isoflex grease Topas NB 52 engine Pulley flange cleaner 1000 engine Loctite 243 10 N•m (89 lbf•in) Isoflex grease 8 N•m (71 lbf•in) Topas NB 52 engine See tightening procedure 120 N•m (89 lbf•ft) 7 N•m (62 lbf•in)
Page 266 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) 2.5 N•m (22 lbf•in) 1 N•m (9 lbf•in) 1 N•m (9 lbf•in) 1 N•m (9 lbf•in) 1 N•m (9 lbf•in) 1 N•m (9 lbf•in) vmr2013-059-101_a vmr2013-059...
Page 267: General
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) GENERAL 3. Reinstall drain reservoir. NOTICE NOTE: For a better understanding, the following If an appreciable amount of water or illustrations are taken with engine out of vehicle. any debris entered the CVT cover, CVT must be To perform the following instructions, it is not nec- cleaned and inspected.
Page 268: Drive Belt
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Drive Belt Inspection CVT COVER SCREWS For drive belt inspection refer to DRIVE BELT 7 N•m ± 0.8 N•m Tightening torque INSPECTION in the PERIODIC MAINTENANCE (62 lbf•in ± 7 lbf•in) PROCEDURES subsection. DRIVE BELT Drive Belt Installation For installation, reverse the removal procedure.
Page 269 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) CAUTION Sliding sheave of drive pulley is spring loaded. vmr2006-021-011_a 1. Mark on drive pulley sliding sheave 2. Mark on governor cup 3. Lock the drive pulley. tmr2011-015-004_a Step 1: Push REQUIRED TOOL 1. Thrust washer 2.
Page 270 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Vmr2012-018-009_a 1. Drive pulley puller 2. Fixed sheave R400motr171A 1. Slider shoe Drive Pulley Disassembly 3. Place the governor cup on a vice to push out the Governor Cup roller sleeve in the direction illustrated (against 1.
Page 271 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Fixed Sheave WARNING Always wear safety glasses to remove spring sleeves. Pull and rotate one-way clutch slowly until the spring sleeves are visible. vmr2006-021-016_a 1. Removal direction 2. Assembly direction NOTE: Whenever removing a governor cup which already has two marked boxes, replace it by a new one.
Page 272 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Drive Pulley Cleaning NOTICE Do not use acetone to clean bush- ing. Clean pulley faces and shaft with fine steel wool and a dry cloth. Using a paper towel with the recommended cleaning solvent, clean: –...
Page 273 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) tmr2011-015-007_a 1. Centrifugal lever 2. Bushing A. Bushing inner diameter CENTRIFUGAL LEVER BORE DIAMETER vmr2006-021-014_a 6.035 mm to 6.078 mm 1. Roller 2. Slider shoe (.238 in to .239 in) A. Roller outer diameter 6.200 mm (.244 in) SERVICE LIMIT ROLLER OUTER DIAMETER...
Page 274 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) SLIDING SHEAVE LARGE BUSHING 55.000 mm to 55.040 mm (2.165 in to 2.167 in) SERVICE LIMIT 55.200 mm (2.173 in) vmr2006-021-024_a A. Centrifugal lever pivot bolt bore diameter CENTRIFUGAL LEVER PIVOT BOLT BORE DIAMETER 6.113 mm to 6.171 mm (.241 in to .243 in) SERVICE LIMIT...
Page 275 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Check for any marks on fixed sheave plate. Re- One-Way Clutch place if necessary. Clean parts. Spring Lubricate springs, spring sleeves and between one way clutch bearings using recommended Measure spring free length and squareness. If product.
Page 276 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2006-021-017 vmr2007-051-003_a 1. Friction washer NOTICE Rollers must move easily after in- 2. Collar 3. One way clutch stallation. Sliding Sheave Carefully press slider shoes in the governor cup Install centrifugal levers with their thrust washers. arm so they bottom out evenly in the machined portion of the governor cup arm.
Page 277: Driven Pulley
3. Thrust washer WARNING Never substitute conical spring washer and/or screw with aftermarket parts. Al- ways use genuine BRP parts. Lock the drive pulley as per removal procedure. Tighten drive pulley screw to specification. NOTICE Never use any type of impact wrench for drive pulley installation.
Page 278 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Vmr2012-018-011_a 1. Driven pulley screw 2. Thrust washer 6. Remove the driven pulley with the spring and vmr2006-021-035_a 1. Retaining ring the cam. 2. Torque gear 3. Fixed sheave of driven pulley NOTE: The following procedure is not necessary except if ball bearing or shaft must be removed.
Page 279 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Using a paper towel with PULLEY FLANGE , clean countershaft CLEANER (P/N 413 711 809) end and shaft bore. NOTICE To avoid damage, make sure cleaner does not contact the countershaft oil seal. R610tran18A 1.
Page 280 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) REQUIRED TOOL BUSHING INNER DIAMETER Dial bore gauge 30.060 mm to 30.100 mm (1.183 in to 1.185 in) MEASURING POINT SERVICE LIMIT 30.200 mm (1.189 in) At least 5 mm (1/4 in) from bushing edge Check torque gear for visible damage and cracks.
Page 281 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Driven Pulley Assembly For installation, reverse the removal procedure. Pay attention to following details. Heat ball bearing area up to 100°C (212°F) before ball bearing installation. NOTE: Place new ball bearing in a freezer for 10 minutes before installation.
Page 282 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) NOTICE Cam splines must engage on coun- tershaft splines. REQUIRED PRODUCT Countershaft splines LOCTITE 767 and countershaft (ANTISEIZE LUBRICANT) (P/N 293 800 070) vmr2006-021-035_a 1. Retaining ring 2. Torque gear 3. Fixed sheave of driven pulley Driven Pulley Installation For installation, reverse the removal procedure.
Page 283 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) As you hold the pulley compressed, install a NEW REQUIRED TOOL driven pulley screw and thrust washer. CLUTCH HOLDER NOTICE This assembly uses a stretch screw. (P/N 529 036 238) Always install a NEW screw. NOTE: Tighten the screw with your hand suffi- TIGHTENING SEQUENCE ciently for the cam to remain engaged.
Page 284 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Vmr2012-018-011_a 1. Driven pulley screw 2. Thrust washer Insert a screwdriver of approximately 5 mm Vmr2012-018-017_a 1000 ENGINE (.197 in) diameter in the cam. 1. Cam 2. Spring end NOTE: For clarity of understanding, some parts 3.
Page 285 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) tmr2013-019-008_a tmr2013-019-009_b 1000 ENGINE 1000 ENGINE 1. Fixed sheave 1. Clutch holder 2. Clutch holder 2. Screwdriver 3. Screwdriver A. Cam freedom of movement Turn the screwdriver approximately 20° counter- Install drive belt. Refer to DRIVE BELT in this sub- clockwise until cam engages in the driven pulley...
Page 286 Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) TIGHTENING SEQUENCE (DRIVEN PULLEY SCREW) STEP 1 20 N•m ± 1 N•m (15 lbf•ft ± 1 lbf•ft) STEP 2 180° ± 5° vmr2012-018-020_a 650 ENGINE 1. CVT air guide 2. O-rings tmr2013-019-007_a 1. Driven pulley screw 2.
Page 287 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) GEARBOX AND 4X4 COUPLING UNIT (500/650/800R) SERVICE TOOLS Description Part Number Page 529 036 030 ........... 11 BACKLASH MEASUREMENT TOOL..........529 035 763 ........... 27 BEARING INSTALLER (GEARBOX) ..........529 035 762 ........... 27 BEARING INSTALLER (GEARBOX) ..........
Page 288 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM Super Lube grease Engine 10 ± 1 N•m (89 ± 9 lbf•in) Engine Loctite 243 25 ± 3 N•m (18 ± 2 lbf•ft) Engine oil Loctite Super Lube grease Engine...
Page 289 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) GEARBOX HOUSING AND 4X4 ACTUATOR UNIT Petamo grease Petamo grease Petamo grease vmr2013-020-002_a vmr2012-019...
Page 290: Procedures
Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) GENERAL 4 WHEEL DRIVE INDICATION FAILS 1. 4WD indicator switch failure. OVERVIEW - Test 4WD indicator switch. Replace as required. - Bad contact. Check for corrosion or loose con- nector. - Damaged wires. Repair as required. 4 WHEEL DRIVE DOES NOT ENGAGE OR DISENGAGE 1.
Page 291 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) vmr2012-019-004_a vmr2012-019-004_b 1. Gearbox position indicator switches 1. Gearbox position indicator switch - position 1 2. BROWN/GREY wire 2. Gearbox position indicator switch - position 2 3. WHITE/RED wire 3. Gearbox position indicator switch - position 3 4.
Page 292 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) If all switches are removed, make sure to put the wires back in the right location. vmr2012-019-005_a 1. 4WD indicator switch 2. BLACK/BEIGE wire for contact to 4WD 3. Actuator vmr2012-019-004_a 4WD Indicator Switch Test 1.
Page 293 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) When replacing an oil seal, take this opportunity NOTE: When oil seal is removed also inspect to inspect the following: O-ring. – Check bearings behind each oil seal for contam- ination and/or metal shavings. –...
Page 294 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) – Console – RH side panel – RH footrest panel – Shift plate from shift shaft (refer to SHIFTER Using a suitable tube with the proper diameter to install the shift shaft oil seal. If gearbox housing is apart, the following tools can be used for shift shaft oil seal installation.
Page 295 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) Actuator Test Check if the 2WD/4WD selector works properly. REQUIRED TOOL FLUKE 115 MULTIMETER (P/N 529 035 868) Unplug actuator connector. Turn ignition key ON. Set emergency engine stop switch to RUN. Measure voltage as follows SWITCH SWITCH WIRE...
Page 296 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) Verify if coupling fork is in 4WD position. The cou- Install all actuator bolts then torque them to spec- pling fork should be positioned toward the front of ification. vehicle. ACTUATOR SCREWS 25 N•m ±...
Page 297 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) vmr2006-022-010_a 1. Bearing cover 2. Oil seal 2. distance sleeve vmr2006-022-012_a 1. Backlash measurement tool 3. O-ring. 2. Mark on tab A. 47 mm (1.85 in) Position the head of the dial indicator, against the tab at a 90°...
Page 298 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) vmr2012-019-009_a vmr2006-022-021 1. Output shaft 2. Coupling sleeve POSITION FOR BIG FLAT SCREWDRIVER 3. Soft hammer Continue removal procedure by removing: 1. Coupling sleeve, O-ring, ball bearing and thrust washer. vmr2006-022-022 vmr2006-022-024_a POSITION FOR BIG FLAT SCREWDRIVER 1.
Page 299 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) Check if the output shaft ball bearings turn freely and smoothly. Replace if necessary, refer to GEARBOX ADJUSTMENT in this subsection. Replace oil seal if brittle, hard or damaged. Replace O-rings if brittle, hard or damaged. Check splines of coupling sleeve for wear or other damages.
Page 300 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) vmr2006-022-032_a 1. Coupling fork 2. Micrometer COUPLING FORK CLAW THICKNESS vmr2012-019-011_a 1. Soft hammer 4.95 to 5.05 mm (.195 to .199 in) Clean the bearing cover location then attach bear- ing cover with oil seal to the housing. SERVICE LIMIT 4.80 mm (.189 in) Temporarily install the right housing with the four...
Page 301 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) F12R17A Do not apply in excess as it will spread out inside housings. vmr2006-022-035_a 1. Coupling fork NOTE: It is recommended to apply this specific 2. Pin 3. Set screw sealant as described here to get a uniform appli- cation without lumps.
Page 302 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) Pull gearbox to separate it from engine. RIGHT HOUSING M8 SCREWS Tightening Gearbox Disassembly Torque Hand tightened NOTE: During gearbox disassembly, inspect the (step 1) condition of each part closely. Tightening OUTPUT Remove the output shaft.
Page 303 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) BEVEL GEAR AXIAL CLEARANCE 0.02 to 0.15 mm (.00079 to .0059 in) SERVICE LIMIT 0.19 mm (.0075 in) Unscrew the left housing screws. Place the left housing on a wood stand, center housing pointing upwards.
Page 304 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) vmr2006-022-058_a vmr2006-022-060_a 1. Bevel gear 1. Thrust washer 2. Low range gear 2. Needle bearing 3. Shim 3. Reverse gear Remove sliding gear with shift fork. Remove shim on CVT side. vmr2006-022-059_a vmr2006-022-061_a 1.
Page 305 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) vmr2006-022-066_a 1. Parking lock lever Remove index lever with washer, step ring and spring. vmr2006-022-062_a 1. Countershaft 2. Low range gear 3. High range gear Insert a flat screwdriver in the slot of index lever. Turn screwdriver clockwise and remove shift drum.
Page 306 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) vmr2006-022-049_a 1. Bevel gear needle bearing vmr2006-022-068_a 2. Punch PRESS SHAFT IN THE DIRECTION AS SHOWN BY THE ARROW 3. Center housing 1. Intermediate gear shaft 2. Left housing To remove ball bearings of bevel gear and needle Bearing Removal in Housing bearing of countershaft, use a blind hole bearing puller.
Page 307 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) Gearbox Inspection SHIFT FORK CLAW THICKNESS (LOW/REVERSE GEAR SHIFTING) Always verify for the following when inspecting gearbox components: 5.10 to 5.20 mm – gear teeth damage (.200 to .205 in) – worn or scoured bearing surfaces SERVICE LIMIT 5.00 mm (.197 in) –...
Page 308 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) Gears NOTE: Replace gears only together with the corresponding meshing gears. Always replace circlips and use special pliers to install them. Measure the width of shift fork engagement groove. vmr2006-022-080_a TYPICAL 1. Micrometer 2.
Page 309 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) Gearbox Adjustment Bevel Gear NOTE: Only necessary if the backlash and axial clearance of the bevel gear is out of specification or if parts are changed (output shaft, bevel gear shaft or housing). vmr2006-022-123_a There are 2 adjustments to perform on the bevel 1.
Page 310 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) D(E) I(J) vmr2006-022-079_a 1. Mating surface — output shaft 2. Mating surface — left housing Bevel Gear Backlash Procedure Use the following course of calculation to deter- mine the theoretical shim thickness D: D = B - C - A The distance between the thrust surface of the bevel gear and the theoretical center of...
Page 311 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) Take the obtained theoretical shim thickness D and choose the corresponding shim number E according to the following table. THEORETICAL SHIM NUMBER SHIM THICKNESS 1.20 mm to 1.29 mm (.0472 to .0508 in) 1.30 mm to 1.39 mm (.0512 to .0547 in) 1.40 mm to 1.49 mm...
Page 312 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) A = 2 mm (.0787 in) nominal thickness of axial needle bearing. The shim number nominal value as found in BEVEL GEAR BACKLASH PROCEDURE For example, shim number 150 represents a value of 1.50 mm (.0591 in). When the measurements are taken, calculate the theoretical shim thickness I using the formula (I = F + G - H - A - E).
Page 313 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) WARNING Clean oil, outside and inside, from housing before heating. Place new bearing in freezer for 10 minutes be- fore installation. Use a suitable installer for installing ball bearings of countershaft and bevel gear. NOTE: Place gearbox housings on a wood stand before installing ball bearings.
Page 314 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) vmr2006-022-066_a 1. Parking lock lever vmr2006-022-052_b Place shim of CVT side on bearing. 1. Intermediate gear shaft Fit support flange in the left housing and install index lever. NOTE: Fit step ring into index lever. vmr2006-022-090_a vmr2006-022-092_a 1.
Page 315 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) vmr2006-022-095_a 1. Bevel gear 2. Sliding gear 3. Shift fork vmr2006-022-093_a 1. Reverse gear Install a new needle bearing and shim. 2. Needle bearing 3. Thrust washer 4. Countershaft bearing screw Install countershaft with low gear and high gear assembly.
Page 316 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) vmr2006-022-097_a vmr2006-022-098_a 1. Index lever 1. Shift shaft assembly 2. Shift drum 2. Isolating washer 3. Neutral position 3. Marks Install shift fork then engage both shift fork pins in their corresponding groove on the shift drum. NOTE: Move sliding gears to facilitate engage- ment of pins inside grooves.
Page 317 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (500/650/800R)) Gearbox housing mating surfaces are best GEAR HOUSING SCREWS cleaned using a combination of LOCTITE CHISEL Tightening and a brass (GASKET REMOVER) (P/N 413 708 500) Torque Hand tightened brush. Brush a first pass in one direction then (step 1) make the final brushing perpendicularly (90°) to Tightening...
Page 318 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) GEARBOX AND 4X4 COUPLING UNIT (1000) SERVICE TOOLS Description Part Number Page 529 036 117 ........... 18 BLIND HOLE BEARING PULLER SET........... 529 036 222 ........... 11 COUNTERSHAFT OIL SEAL PUSHER .......... 529 036 166 ..........
Page 319 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM 10 ± 1 N•m Petramo The shaded parts are not serviceable. (89 ± 9 lbf•in) grease Gearbox replacement is required. 5 ± 0.6 N•m 10 ± 1 N•m (44 ±...
Page 320 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) GENERAL 3. Damaged or worn gears. - Inspect gears for damages or missing teeth. Re- place respective gears. GEARBOX OVERVIEW GEAR INDICATION FAILS 1. Defective gearbox position sensor (GBPS). - Perform a gearbox position sensor test. - Damaged wires.
Page 321 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) REQUIRED TOOL FLUKE 115 MULTIMETER (P/N 529 035 868) 3. Turn ignition switch ON. 4. Set emergency engine stop switch to RUN. 5. Back-probe the VSS connector. REQUIRED TOOL FLUKE RIGID BACK-PROBE (P/N TP88) Tmr2011-016-006_a 1.
Page 322 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) VSS Removal 7. Measure voltage while slowly rotating rear wheels by hand. Remove screw retaining the VSS. VEHICLE SPEED SENSOR SIGNAL TEST RESULT TEST PROBES (WHILE ROTATING WHEELS) Alternate reading PIN B PIN C between battery (WHITE wire)
Page 323 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) GEARBOX POSITION SENSOR (GBPS) GBPS Reset When replacing the gearbox position sensor (GBPS), it is required to reset (re-zero) its values for proper operation. A reset must be carried out each time any of the following parts has been replaced: –...
Page 324 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) Test as follow: If resistance is out of specification, check wires and connectors. Repair and reset fault codes. MULTIMETER PROBE POSITIONS VOLTAGE If resistance is good and the other tests suc- PIN 1 and PIN 3 of the GBPS connector ceeded, replace the GBPS and reset fault codes.
Page 325 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) ACTUATOR GBPS RESET Reset the GBPS. Refer to in this subsection. Actuator Access 4WD INDICATOR SWITCH BODY To access the actuator, refer to and remove the following parts: 4WD Indicator Switch Access –...
Page 326 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) Actuator Installation Apply a small amount of SUPER LUBE GREASE on actuator O-ring. (P/N 293 550 030) vmr2012-037-006_a OUTLANDER ONLY 1. Remove retaining screws from master cylinder support vmr2006-035-002_A 1. Actuator O-ring Ensure coupling fork is in 4WD position (posi- tioned toward the front of vehicle).
Page 327 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) GEARBOX OIL SEALS Gearbox Oil Seal Replacement Replace oil seals if they are brittle, hard or dam- aged. A small flat screwdriver can be used to remove most of these oil seals. NOTICE Avoid scoring parts during oil seal removal.
Page 328 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) Tmr2011-016-013_a 1. Countershaft oil seal 2. Distance sleeve vmr2012-020-005_a 1. Countershaft oil seal 2. Oil seal pusher Shift Shaft Oil Seal The shift shaft oil seal can be removed without removing the gearbox from the vehicle. To replace the shift shaft oil seal, refer to BODY and remove:...
Page 329 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) REAR DRIVE Remove propeller shaft. Refer to REQUIRED TOOL subsection. OIL SEAL INSTALLER (P/N 529 036 204) Flat washer (P/N 250 200 102) M12 x 1.25 x 35 hexagonal screw Tmr2011-016-015_a 1. Shift shaft oil seal 2.
Page 330 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) Tmr2011-016-038_a Tmr2011-016-043_a LH SIDE OF ENGINE 1. 3 screws M6 x 35 1. Nut M8 2. 13 screws M6 x 55 Place the center housing on a wood stand, left cover pointing upwards. Using a big flat screwdriver and a soft hammer to lift the left cover.
Page 331 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) Index Lever and Index Washer Set gearbox to NEUTRAL position. Remove screw retaining the index washer to the shift drum. Tmr2011-016-075_a 1. Washer 2. Index lever 3. Step ring 4. Index spring Tmr2011-016-073_a Main Shaft and Shift Forks 1.
Page 332 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) vmr2012-020-006_a Tmr2011-016-047_a 1. Shifting sleeve (HIGH range gear) 1. Shift fork shaft 2. Shift fork 2. Shift fork 3. Shift drum When required, remove from main shaft assem- bly: Remove main shaft assembly with shift fork. –...
Page 333 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) Tmr2011-016-032 POSITION FOR BIG FLAT SCREWDRIVER vmr2012-020-008_a 1. Snap ring 2. Shifting sleeve (LOW/REVERSE range gear) 3. Snap ring 4. Free pinion (REVERSE range gear) 5. Needle bearing 6. Main shaft assembly Gearbox Right Cover Remove ACTUATOR...
Page 334 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) Tmr2011-016-072_a Tmr2011-016-077_a 1. Screw 1. Shift drum 2. Washer 2. Thrust washer 3. Intermediate gear 4. Dowel pin Output Shaft and 4x4 Coupling Mechanism Remove output shaft from center housing and Remove shift fork shaft. withdraw 4x4 coupling sleeve.
Page 335 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) To remove ball bearings of countershaft (right cover) and main shaft (left cover) use following tool. REQUIRED TOOL BLIND HOLE BEARING PULLER SET (P/N 529 036 117) Remove screw securing the countershaft bearing in the left cover.
Page 336 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) DIAMETER FREE PINION 29.000 mm to 29.013 mm (1.1417 in to 1.1422 in) SERVICE LIMIT 29.015 mm (1.1423 in) Shifting Sleeves Check shifting sleeves for worn inner splines and rounded or damaged engagement dogs. Tmr2011-016-054_a 1.
Page 337 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) WIDTH OF SHIFT FORK ENGAGEMENT GROOVE COUNTERSHAFT BEARING JOURNALS 5.30 mm to 5.40 mm MAG SIDE (.209 in to .213 in) CVT SIDE SERVICE LIMIT 5.50 mm (.217 in) 24.977 mm to 24.990 mm (.983 in to .984 in) Shafts SERVICE LIMIT...
Page 338 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) Output Shaft Check output shaft and its gear for cracks, bend, pitting or other visible damages. Check output shaft splines for wear or other dam- ages. Check if the output shaft bearings turn freely and smoothly.
Page 339 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) vmr2006-022-032_a 1. Coupling fork 2. Micrometer vmr2012-020-011_a COUPLING FORK CLAW THICKNESS 1. Main shaft 2. Free pinion (REVERSE range gear) 4.95 mm to 5.05 mm 3. Snap ring 4. Shifting sleeve (LOW/REVERSE range gear) (.195 in to .199 in) 5.
Page 340 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) Tmr2011-016-075_b vmr2012-020-006_a 1. Index spring 1. Shifting sleeve (HIGH range gear) 2. Step ring 2. Shift fork 3. Index lever 4. Washer Carefully fit main shaft assembly with shift fork 5. Screw (LOW/REVERSE range gear) into inner splines of Install index washer on shift drum.
Page 341 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) Install coupling fork, coupling fork shaft and set Gearbox housing mating surfaces are best screw in right cover before applying sealant to the cleaned using a combination of LOCTITE CHISEL mating surface. and a brass (GASKET REMOVER) (P/N 413 708 500) brush.
Page 342 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) At installation of left cover, engage parking lock lever slot onto index washer pin. Tmr2011-016-067_a COUNTERSHAFT END CVT SIDE 1. O-ring 2. Distance sleeve 3. Countershaft end CVT side Right Cover Tmr2011-016-065_a Apply sealing compound on mating surfaces of 1.
Page 343 Subsection XX (GEARBOX AND 4X4 COUPLING UNIT (1000)) Before gearbox installation check O-ring in bearing cover if brittle, hard or damaged. Replace if nec- essary. Tmr2011-016-040_a 1. Bearing cover 2. O-ring PERI- After installation, refill gearbox oil. Refer to ODIC MAINTENANCE PROCEDURES vmr2012-020...
Page 344 Subsection XX (SHIFTER) SHIFTER Outlander CE models Loctite 243 Loctite 243 1000 Renegade CE models 800R 1000 800R 9N•m (80 lbf•in) vmr2013-022-002 vmr2013-022...
Page 345 Subsection XX (SHIFTER) PROCEDURES SHIFT LEVER Shift Lever Access BODY 1. Refer to subsection and remove the fol- lowing components: – Seat – Console – RH side panel. Shift Lever Removal SHIFT 1. Remove body parts as required. Refer to LEVER ACCESS in this subsection.
Page 346 Subsection XX (SHIFTER) 5. Turn rod adjuster to center shift lever in neutral notch. vmr2012-021-005_a SHIFT LEVER HANDLE ALIGNMENT 1. Handle 2. Ridge A. Handle parallel with ridge Check if shift lever works properly in all positions. vmr2012-021-006_a NOTE: Shift lever must be perfectly centered SHIFT LEVER CENTERED WITHIN NEUTRAL NOTCH with the neutral mark when transmission is en- A.
Page 347 Subsection XX (SHIFTER) – RH footrest panel (Outlander) – RH engine cover (Renegade). 2. Remove shift rod from shift plate. vmr2012-021-008_c TYPICAL — 1000 SHOWN 1. Shift plate nut 5. Remove shift plate. Shift Plate Inspection vmr2012-021-008_a TYPICAL — 1000 SHOWN Check shift plate for: 1.
Page 348 Subsection XX (SHIFTER) vmr2012-021-011_a TYPICAL — 1000 ENGINE SHOWN vmr2012-021-009_a 1. Shift shaft end 2. Shift plate 800R ENGINE — SHIFT PLATE ANGLE FROM THE SHOWN EDGE A. 2.5 mm ± 1 mm (.1 in ± .040 in) 1. "ATV OUT" marking this side A.
Page 349 Subsection XX (ENGINE MANAGEMENT SYSTEM (EMS)) ENGINE MANAGEMENT SYSTEM (EMS) FRONT IDLE BYPASS VALVE MAPTS INJ 2 INJ 1 GBPS IGNITION COIL IGNITION SWITCH RELAYS: OVERRIDE SWITCH - MAIN - FUEL PUMP RUN/STOP SWITCH INPUTS - LIGHTS D.E.S.S. - ACCESSORIES - BRAKE LIGHTS START SWITCH OUTPUTS...
Page 350 Subsection XX (ENGINE MANAGEMENT SYSTEM (EMS)) GENERAL The ECM reads input signals from various switches, controls, and sensors, that it compares to pre-determined parameters, makes computa- SYSTEM DESCRIPTION tions, and provides control signal outputs required A highly advanced engine management system for proper engine management.
Page 351 Subsection XX (CONTROLLER AREA NETWORK (CAN)) CONTROLLER AREA NETWORK (CAN) GENERAL SYSTEM DESCRIPTION The CAN (Controller Area Network) protocol is an ISO standard for serial data communication. The CAN bus links the ECM, multifunction gauge and DPS module together so that they can communi- cate to each other and interact as required.
Page 352 Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.) COMMUNICATION TOOLS AND B.U.D.S. SERVICE TOOLS Description Part Number Page 710 000 851 ..........3 MPI-2 DIAGNOSTIC CABLE............529 036 018 ..........3 MPI-2 INTERFACE CARD .............. SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page ..........
Page 353 Subsection XX (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 354 Subsection XX (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. Be careful not to touch water while working with the VCK.
Page 355 Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.) Electronic Modules (ECU) Updates Always use the latest applicable B.U.D.S. version available on BOSSWeb. NOTICE Failure to strictly follow a procedure to update a module may permanently damage How to Establish Communication the module. Using B.U.D.S.
Page 356 Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.) 2. If the Update option is black, an update file is available for this module. vbl2012-007-010_a mbg2008-022-100_a 1. Greyed out: No update to perform TYPICAL Black: Update file available 1. File description Before applying an update, log onto BOSSWeb Writing Changes (Saving) in a Module and look in Service menu for the Unit history to If the word Modified appears in the vehicle file...
Page 357 Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.) In such a case, turn ignition switch OFF, then wait for the message to disappear before disconnect- ing the MPI. Disconnect MPI and store the vehicle diagnostic connector in its protective cap. vmr2012-023-003_a 1. Diagnostic connector in its storage cap NOTICE Failure to secure the diagnostic con- nector in its protective cap may result in corro-...
Page 358 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) DIAGNOSTIC SYSTEM AND FAULT CODES GENERAL A message may also be displayed to provide ad- ditional information related to the fault that turned MONITORING SYSTEM on the pilot lamp. Refer to the following chart. NOTE: In some cases, the CHECK ENGINE mes- The Engine Management System (EMS) features sage can be displayed along with other messages.
Page 359 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) MULTIFUNCTION GAUGE PILOT LAMP CAUSE MESSAGE DESS KEY NOT RECOGNIZED Module unable to read the key BAD KEY Key not programmed for the vehicle LO BATT VOLT Low system voltage HIGH BATT VOLT High system voltage Low engine oil pressure LOW OIL...
Page 360 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Fault Code States become active or occurred if the monitoring sys- tem detects an applicable fault. These codes can Fault codes have 3 possible states: be viewed in B.U.D.S. – Active – Occurred How to Display Fault Codes in the –...
Page 361 Subsection XX (DIAGNOSTIC SYSTEM 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. Drop down list FAULT INFORMATION STATE...
Page 362 Subsection XX (DIAGNOSTIC SYSTEM 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 To clear all occurred faults in related Occurred ECU(s) Faults button...
Page 363 Subsection XX (DIAGNOSTIC SYSTEM 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. Possible List the possible causes that causes...
Page 364 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Diagnostic Tips To see the last minute of operating conditions, click on the History tab in B.U.D.S. NOTE: The page displays data whatever there is fault code(s) or not. rmr2011-070-003_a 1. History tab 2.
Page 365 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) GENERAL GUIDELINES TO SOLVE FAULT CODES CONDITION ACTION Use B.U.D.S. to: Read fault codes. Display "Active" faults to see components currently not operating normally. Display "Occurred" faults to troubleshoot intermittent problems. Monitor system(s), sensor(s), switches and actual conditions. Troubleshooting vehicle Activate component(s) for troubleshooting.
Page 366 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) GENERAL GUIDELINES TO SOLVE FAULT CODES CONDITION ACTION May have been generated due to a system or component that was momentarily operating outside normal parameters. May be generated when disconnecting and reconnecting a component, replacing a burnt fuse, or may be due to a momentary high or low voltage.
Page 367 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT CODE TABLE ACRONYMS USED IN THE FAULT CODE TABLE USED IN FAULT CODE TABLE MEANING Engine Control Module Dynamic Power Steering Controller Area Network Throttle Position Sensor GBPS Gearbox Position Sensor NOTE: The following fault code table was up to date as of printing. For the latest fault codes, use B.U.D.S.
Page 368 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE 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.
Page 369 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Disconnect the sensor. Measure resistance from connector: ECM-F4 to CTS-1. (Expected value: < 2 ohms). Engine coolant Damaged sensor, wires Measure resistance from temperature P0116 shorted to battery +, connector: ECM-C3 to CTS-2.
Page 370 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Make sure sensor connector is fully inserted. Measure resistance from connector: ECM-A1 to TPS-1. Throttle position Damaged circuit wires, (Expected value: < 2 ohms). P0123 sensor (TPS) shorted damaged sensor or...
Page 371 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Disconnect injector 1. Measure resistance between injector pin 1 and 2. (Expected value = 14 to15 ohms). Blown fuse, damaged Measure resistance from harness or disconnected Cylinder 1 injector connector: INJ1-1 to INJ1-2.
Page 372 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Make sure sensor Damaged CPS, connector is fully inserted. damaged circuit Measure resistance from wires, damaged Crankshaft position connector: ECM-E1 to CPS-1. P0338 connector or damaged (Expected value: <...
Page 373 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Make sure IDLE connector is fully inserted. Measure resistance from connector: ECM-D4 to IDLE-D. (Expected value: < 2 ohms). Damaged IDLE, Measure resistance from damaged circuit wires, Idle air control system connector: ECM-D3 to IDLE-A.
Page 374 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Check DPS fuse. Measure voltage between harness connector DPS1-A and ground. Blown fuse, battery (Expected value = 11 to 13 volts). failure, voltage Measure voltage between regulator failure, harness connector DPS2-A P0562...
Page 375 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE 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 damaged start switch, connector: ECM-L3 to SS2.
Page 376 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Damaged sensor Measure voltage between harness connected to ECM connector ECM-A1 and ground. Sensor reference P0642 voltage supply. (Expected value: 4.8 to 5.1 volts). voltage low Damaged ECM voltage Check sensor connected to ECM...
Page 377 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Check fuse. Disconnect accessory relay and Lights relay and turn key switch (on w/lights). Measure voltage between harness Diagnosis related connector PF1-10E and ground. to accessories (Expected value: 11 to 13 volts).
Page 378 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Check fuse. Disconnect radiator fan relay. Measure voltage between harness Damaged fan relay, connector PF1-3D and ground. damaged circuit wires, (Expected value: 11 to 13 volts). Radiator fan circuit P0692 damaged connector or...
Page 379 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Verify that gear position information change when you change the position of gear on vehicle. Disconnect GBPS. Measure voltage between harness connector GBPS-1 and GBPS-3. Gear position sensor (Expected value: 4.8 to 5.1 volts) P0707...
Page 380 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Check THROTTLE cable adjustment. Wrong throttle body Check idle stop for wear. mechanical position Ensure throttle plate is during reset of against throttle stop. P1619 TPS adaptation failure closed TPS or no...
Page 381 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Open the ECM activation page in B.U.D.S. Perform an ignition coil activation and check if ignition coil is reacting as expected. Damaged ignition coil, Measure resistance from harness damaged circuit wires, Cylinder 1 ignition...
Page 382 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Disconnect MPI2 from DLC connector. Measure resistance between DLC-1 and DLC-2. (Expected value = 50 to 70 ohms). CAN bus off, no Damaged circuit wires U0073 Measure resistance between or damaged DPS pins.
Page 383 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Measure voltage between harness connector CL-17 and ground. (Expected value = 11 to 13 volts). Disconnect MPI2 from DLC connector. Measure resistance between DLC-1 and DLC-2. (Expected Missing CLUSTER value = 50 to 70 ohms).
Page 384 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE MODULE Check for dirty or oxidized key contact. Clean key contact if needed. Check for broke key contact. Lost communication The vehicle immobilizer Ensure sensor connector with vehicle is reporting an is fully inserted.
Page 385 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) DIAGNOSTIC SYSTEM AND FAULT CODES FAULT CODE TABLE P-CODE MODULE DESCRIPTION CAUSE ACTION If pressure threshold Open SCM Activation page in Release Valve not reach after BUDS, performe a combined C2109 Activation delay calibrated time delay test in System self test Exceed...
Page 386 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Open SCM Activation page in If maximum number of Air Leak Plausibility BUDS, performe a combined C21E1 readjustment for rear check Rear suspension test in System self test suspension is reach sequence section If pressure threshold not reach after Open SCM Activation page in...
Page 387 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check fuse. Disconnect HO2S1. Measure voltage between harness connector HO2S1-C and ground (expected value = 11 to 13 volts). Internal fault path Measure resistance between Damaged O2 sensor, number for Max error: HO2S1 pin C and D (expected damaged circuit wires, P0032 power stage of heater...
Page 388 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Make sure sensor connector is fully inserted. Measure voltage between harness connector pins 1 and 4 . (Expected value: 4.8 to 5.1 volts) Measure resistance from connector: ECMA-H3 to MAPTS-2 (Expected Damaged sensor, value: <...
Page 389 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Make sure sensor connector is fully inserted. Measure voltage between harness connector pins 1 and 4 . (Expected value: 4.8 to 5.1 volts) Measure resistance from connector: ECMA-H3 to MAPTS-2 (Expected Damaged sensor, wires value: <...
Page 390 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Disconnect the sensor and check for a change in the fault code. If the fault code stays the same, look for a short circuit on the harness. If the fault code is different, replace the sensor. Engine Coolant Damaged sensor, wires Measure resistance from...
Page 391 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Make sure sensor connector is fully inserted. Measure resistance from connector: ECMB-K1 to TAS-C First Throttle Damaged circuit wires, (Expected value: < 2 ohms) Accelerator Sensor P0123 damaged sensor or damaged Measure resistance from (TAS) shorted to ECM pins.
Page 392 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check fuse. Disconnect HO2S1. Measure voltage between harness connector HO2S1-C and ground (expected value = 11 to 13 volts). ECU int. fault Measure resistance between Damaged O2 sensor, path no.: electrical HO2S1 pin C and D (expected damaged circuit wires, P0132 diagnosis for lambda...
Page 393 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check fuse. Disconnect HO2S2. Measure voltage between harness connector HO2S2-C and ground (expected value = 11 to 13 volts). Measure resistance between ECU int. fault path no.: Damaged O2 sensor, HO2S2 pin C and D (expected electrical diagnosis for damaged circuit wires, P0136...
Page 394 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check fuse. Disconnect HO2S2. Measure voltage between harness connector HO2S2-C and ground (expected value = 11 to 13 volts). ECU int. fault path no.: Measure resistance between Damaged O2 sensor, diagnosis lambda HO2S2 pin C and D (expected damaged circuit wires, P0139 sensor upstream...
Page 395 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Make sure sensor connector is fully inserted. Measure resistance from connector: ECMB-E1 to TAS-A 2nd Throttle Damaged circuit wires, (Expected value: < 2 ohms) P0222 Accelerator Sensor damaged sensor, or Measure resistance from (TAS) shorted to GND damaged ECM pins.
Page 396 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check fuse Disconnect injector 1 Measure resistance between injector pin 1 and 2 (Expected value = 14 to15 ohms). Measure resistance Blown fuse, damaged from harness connector: Cylinder 1 injector or disconnected injector, ECMA-J1 to INJ1-1 P0261 open circuit or shorted...
Page 397 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Disconnect injector 2 Measure resistance between injector pin 1 and 2 (Expected value = 14 to15 ohms). Measure resistance from harness connector: Damaged injector, INJ2-1 to INJ2-2 Cylinder 2 injector damaged circuit wires, P0265 (Expected value: >...
Page 398 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Open the ECM Activation page in BUDS Perform an ignition coil activation and check if ignition coil is reacting as expected Check fuse & HIC connector Measure resistance from harness connector: Damaged ignition coil, ECMA-M2 to BA-3 damaged circuit wires, (Expected value: <...
Page 399 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Open the ECM Activation page in BUDS Perform an ignition coil activation and check if ignition coil is reacting as expected Check fuse & HIC connector Measure resistance from harness connector: Damaged ignition coil, ECMA-M2 to BA-3 Ignition coil damaged circuit wires,...
Page 400 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check if vehicle speed is available in Monitoring page in BUDS. Check fuse Measure voltage between harness connector CV-A Vehicle speed not Vehicle speed correlation and ground. (Expected P0501 plausible check failed value: 11 to 13 volts) Measure resistance from connector: ECMA-E1 to VC-B (Expected value: <...
Page 401 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Measure resistance between harness connector EOP and ground When engine stopped. (Expected value < 2 ohms) Measure resistance between harness connector EOP and Damaged switch, ground When engine running. damaged circuit wires, Engine oil pressure (Expected value = open) P0523 damaged connector,...
Page 402 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Measure battery voltage with engine stopped. (Expected Blown fuse FC, value: 11 to 13 volts) battery failure, voltage Measure battery voltage with regulator failure, engine running. (Expected damaged circuit wires P0562 System voltage low value: 13 to 14.7 volts) or connection, damaged Check connections...
Page 403 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Try updating the ECM calibration Faulty calibration Control Module If the problem P0606 Faulty programming Processor persists, reflash ECM Damaged ECM If the problem persists, replace the ECM. Make sure sensor connector is fully inserted. Measure resistance from connector: ECMB-K1 to TAS-C (Expected value: <...
Page 404 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) External troubleshooting Internal error or damaged MOTOR HIGH P0637 is not possible CURRENT FAULT Replace the DPS. External troubleshooting DPS motor supply P0658 PHASE A_LOW is not possible Damaged DPS Replace the DPS. External troubleshooting DPS motor supply P0659...
Page 405 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check fuse Disconnect Accessory relay and Lights relay & turn key switch (on w/lights) Measure voltage between harness connector PF1-10E and ground. (Expected value: 11 to 13 volts) Measure voltage between harness connector PF1-8D Blown fuse, damaged and ground.
Page 406 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check fuse Disconnect radiator fan relay Measure voltage between harness connector PF1-3D and ground. (Expected Blown fuse, damaged or value: 11 to 13 volts) Radiator fan circuit disconnected fan relay, Measure resistance P0691 shorted to ground or damaged circuit wires, from harness connector:...
Page 407 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check fuse. Disconnect HO2S1. Measure voltage between harness connector HO2S1-C and ground (expected value = 11 to 13 volts). Measure resistance between ECU int. fault path no.: Damaged O2 sensor, HO2S1 pin C and D (expected electrical diagnosis damaged circuit wires, P1130...
Page 408 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check for ECM fault Control Module P1606 Internal ECM problem External troubleshooting Processor not possible Disconnect ETC Measure resistance from Damaged ETC, Electrical Throttle connector: ECMA-L1 to ETC-3 damaged circuit wires, P160E Actuator (ETA) control (Expected value: <...
Page 409 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check throttle mechanical adjustment. Check idle stop for wear. Ensure throttle plate Throttle mechanical is against throttle stop. adjustment TPS position deviation Check throttle angle at idle. P1615 No initialization fault Perform THROTTLE after throttle body/ POSITION SENSOR ECM replacement...
Page 410 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check cable adjustment. Check idle stop for wear. Ensure throttle plate is against throttle stop.. Throttle mechanical stop Check throttle angle at idle. No initialization P1622 TPS adaptation failed Perform THROTTLE after throttle body/ POSITION SENSOR ECM replacement INITIALIZATION in BUDS...
Page 411 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Disconnect main relay Damaged circuit wires, Main relay Measure resistance between damaged connectors or P20EB de-energized too late terminals 85 and 86 on damaged ECM output pins. or sticking relay. (Expected value: 70 Damaged relay to 90 Ohms) Ensure sensor connector...
Page 412 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) If the accelerator pedal and the brake are activated Throttle and break simultaneously for a delay P2299 pedal are used at the time and the vehicle same time is moving faster than Speed-threshold exchanged lambda Wrong O2 sensor position P2416...
Page 413 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Open ECM Monitoring page in BUDS, Verify that gear position information changes with gear selection changes on vehicle. Disconnect GBPS Measure voltage between Damaged circuit harness connector 5-GBPS-1 wires, damaged Gear position sensor and 5-GBPS-3.
Page 414 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) 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 U0073 Measure resistance damaged DPS pins. messages between DB-1 and DPS1-C (Expected value <...
Page 415 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Disconnect MPI2 from DB connector. Measure resistance between DB-1 and DB-2 (Expected Lost communication value = 50 to 70 ohms). Damaged CAN Bus U0100 with ECM (lost of wires to ECM, damaged Measure resistance between CAN ID’s) DPS/ECM pins.
Page 416 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Check for Cluster 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 Missing CAN ID value = 50 to 70 ohms).
Page 417 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Try updating the ECM Variant Coding, variant or calibration Faulty calibration or variant software If the problem U0301 Faulty programming incompatibility persists, reflash ECM Damaged ECM (DFC_MoFVar) If the problem persists, replace ECM. Try updating the ECM Variant Coding, variant or calibration...
Page 418 Subsection XX (DIAGNOSTIC SYSTEM AND FAULT CODES) Invalid Check Sum External troubleshooting U220E is not possible from CLUSTER Check Sum error message Check for communication fault Check fuse Ensure SCM connector Lost of power on SCM Module improper is fully inserted. U3001 Damaged circuit wires or shutdown...
Page 419 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) ELECTRONIC FUEL INJECTION (EFI) SERVICE TOOLS Description Part Number Page 529 014 500 ..........2 DIGITAL INDUCTION TACHOMETER ........... 529 036 166 ....5, 10, 17, 19, 21–23 ECM ADAPTER TOOL..............529 035 868 ... 5–6, 10–11, 17, 21–23 FLUKE 115 MULTIMETER ............
Page 420: Adjustment
Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) ADJUSTMENT IDLE SPEED Idle speed is not adjustable. The ECM controls the idle speed of the engine primarily through con- trol of the throttle plate position. NOTICE Never attempt to adjust the sealed idle stop screw. It is calibrated at the factory. If the screw adjustment is changed, the throt- tle body must be replaced.
Page 421 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) vmr2012-026-150_a VERIFYING ENGINE RPM USING B.U.D.S. vmr2006-014-064_b 1. Monitoring tab 1. Contact here 2. Engine RPM indication 2. Free-play here NOTE: The multifunction gauge and B.U.D.S. use Open throttle approximately one quarter then the same signal to provide the engine RPM indi- quickly release.
Page 422 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) Start engine and make sure it operates normally When probing terminals, pay attention not to de- through its full engine RPM range. If fault codes form the terminals as this could cause a loose or DIAGNOSTIC SYSTEM AND appear, refer to intermittent connection that would be difficult to...
Page 423 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) ECM Connector Continuity Test of ECM Ground Circuits There is one connector connected to the ECM. It links: 1. Disconnect ECM connector. – Engine harness 2. Install the ECM ADAPTER TOOL (P/N 529 036 166) –...
Page 424 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) If 120 ohms is read, isolate the CLUSTER from CAN by disconnecting it and measuring again at the diagnostic link connector. If 120 ohms is still read, the ECM CAN resistor and wires are good. Check for continuity of the CLUS- TER CAN wires, refer to WIRING DIAGRAM If an open circuit is read, the ECM CAN resistor...
Page 425 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) ECM Manual Data Entry There are 2 possible methods to collect the re- quired information. The 1st being the easiest: 1. Use B.U.D.S. to obtain the data from a saved .mpem file on your PC computer. 2.
Page 426 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) smr2009-030-007_a VEHICLE TAB 6. Enter recorded data in ECM as detailed in ENTERING THE COLLECTED INFORMATION mmr2009-118-011 INTO THE ECM SERVICE, UNIT HISTORY 3. Enter the recorded data in the new ECM as de- 2nd Collecting Method: Collect the Information from the Vehicle and BOSSWeb tailed in...
Page 427 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) NOTICE Enter only the appropriate product model number as obtained when gathering the information. tmr2011-022-017_a smr2008-023-100_b ADDING PART IN HISTORY 1. History tab 6. Select the Vehicle tab and enter the informa- 2. Part Replacement tab 3.
Page 428 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) Fuel Injector Input Voltage Test If supply voltage is not good, check fuse and if INJECTOR POWER CIRCUIT good, perform an Remove the RH side panel. Refer to BODY sub- RESISTANCE TEST section. If supply voltage is good, perform a FUEL INJEC- To reach the rear injector, disconnect the fuel line.
Page 429 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) Using a FLUKE 115 MULTIMETER (P/N 529 035 868) FUEL INJECTOR INSTALLATION check resistance value between terminals as fol- O-RINGS Lubricate with engine oil lows. INJECTOR Position the manifold O-ring on injector as in fol- GROUND CIRCUIT lowing illustration.
Page 430 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) FUEL RAIL Fuel Rail Replacement Fuel Rail Removal 1. Disconnect fuel line to reach the rear injector. FUEL TANK AND FUEL PUMP Refer to subsec- tion. 2. Unscrew rail retaining screws. 3. Gently pull rail off by hand. tmr2011-011-017_c TYPICAL 1.
Page 431 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) – Loosen adjuster lock nut/adjuster until it just re- leases lever. – Turn adjuster clockwise until it touches lever again. – From there, tighten adjuster 1/2 turn (to remove strain in cable). – Tighten lock nut. –...
Page 432 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) Throttle Body Access Remove the RH side panel. Refer to BODY sub- section. Throttle Body Inspection Check that the throttle plate moves freely and smoothly when depressing throttle lever. – Check if throttle body idle set screw is loose or worn.
Page 433 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) vmr2006-014-060_b vmr2006-014-064_a 1. Throttle lever 2. Cable barrel Rotate throttle body into position and ensure to index throttle body tab with boot notch. 9. Remove barrel from cable. 10. Pull out throttle cable. 11. Pull out throttle body. Throttle Body Installation Installation of the throttle body is the reverse of the removal procedure.
Page 434 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) Tighten clamps. – Check throttle cable adjustment. Refer to THROTTLE CABLE in this subsection. – If throttle body was replaced, perform the Closed Throttle And Idle Actuator Reset pro- cedure. Refer to CLOSED THROTTLE AND IDLE ACTUATOR RESET in this subsection.
Page 435 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) Using the following tools, check resistance val- CONNECTION VOLTAGE ues. Pin 1 with battery ground 5.0 V REQUIRED TOOL Pin 2 with battery ground ECM ADAPTER TOOL (P/N 529 036 166) Pin 3 with battery 0.5 V ground: idle REQUIRED TOOL...
Page 436 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) vmr2006-012-004_c TYPICAL – THROTTLE BODY vmr2006-014-012_b 1. TPS 2. Screws TYPICAL 1. Idle air control valve Install the new TPS. Check the resistance between pins as shown. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) IDLE AIR CONTROL VALVE MEASUREMENT the TPS retaining screws, then torque to 3 N•m...
Page 437 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) CRANKSHAFT POSITION If the resistance of any winding is not good, re- place the idle air control valve. SENSOR (CPS) If resistance test of valve windings is good, check continuity of circuits C4, D3, D4, E4. If not good, check/repair wiring/connectors.
Page 438 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) CPS INSTALLATION PRODUCT O-RING XPS SYNTHETIC GREASE (P/N 293 550 010) TIGHTENING TORQUE SENSOR 10 N•m ± 1 N•m SCREW (89 lbf•in ± 9 lbf•in) 529036166 MANIFOLD ABSOLUTE Using a multimeter, measure resistance as per ta- PRESSURE AND TEMPERATURE ble.
Page 439 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) is the case, remove sensor and check for oil or 3. Remove electrical connector from MAPTS. dirt on its end and if problem persists, check throt- 4. Using a FLUKE 115 MULTIMETER (P/N 529 035 tle plate condition/position and the wiring harness.
Page 440 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) 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 441 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) CTS Access Remove the LH panel. Refer to BODY subsection. Remove the CVT duct. vmr2012-026-006_a vmr2006-012-004_e 1. Pull out 1. MAPTS 2. Retaining screw CTS Resistance Test Disconnect MAPTS connector and remove the 1. Disconnect the ECM connector. MAPTS.
Page 442 Subsection XX (ELECTRONIC FUEL INJECTION (EFI)) 5. Reinstall remaining removed parts. ECM ADAPTER MEASUREMENT 6. Refill and bleed the cooling system. Refer to RESISTANCE ( ) COOLING SYSTEM subsection. @ 20°C (68°F) 2280 - 2736 If resistance value is incorrect, check wiring con- tinuity between ECM connector and the CTS.
Page 443 Subsection XX (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP SERVICE TOOLS Description Part Number Page 529 035 868 ....... 13, 17–18 FLUKE 115 MULTIMETER ............529 036 023 ..........5 FUEL HOSE ADAPTER..............529 035 899 ........14, 16 FUEL PUMP NUT TOOL ...............
Page 444 Subsection XX (FUEL TANK AND FUEL PUMP) = Component must be replaced when removed. Engine EUROPE vmr2012-028-001_a vmr2013-028...
Page 445 Subsection XX (FUEL TANK AND FUEL PUMP) GENERAL WARNING Fuel is flammable and explosive under cer- tain conditions. Ensure work area is well ven- tilated. Do not smoke or allow open flames or sparks in the vicinity. WARNING Always disconnect battery prior to working on the fuel system.
Page 446 Subsection XX (FUEL TANK AND FUEL PUMP) Fuel Filters The system comprises two levels of filtration: – A replaceable prefilter element attached to the bottom of the fuel pump. – A non-replaceable fine filter element that is in- tegral to the fuel pump module. Fuel Pump Pressure Regulator The fuel pressure regulator is integral to the fuel pump module.
Page 447 Subsection XX (FUEL TANK AND FUEL PUMP) vmr2012-028-006_b 1. Fuel pump relay fuse vmr2012-028-008_a 1. Fuel tank vent inlet hose 6. Release fuel pressure by running engine until it 2. Gauge connector runs out of gas. TIME WITHOUT 7. Carefully disconnect the fuel hose fitting from PRESSURE PRESSURE DROP the injector fuel rail by pressing on the release...
Page 448 Subsection XX (FUEL TANK AND FUEL PUMP) vmr2012-028-010_a PRESSURE GAUGE SETUP 1. Pressure gauge to fuel hose adapter 2. Fuel hose adapter to fuel rail 3. Fuel hose adapter to fuel pump pressure hose 10. Reinstall the fuel pump relay fuse (F15) in the forward fuse box.
Page 449 Subsection XX (FUEL TANK AND FUEL PUMP) TROUBLESHOOTING FUEL SYSTEM DIAGNOSTIC FLOW CHART Fuel pump does not run Activate electric system to enable fuel pump Fuel pump runs for 2 sec. then stops Install fuel pressure gauge Check fuse. on fuel pressure line Check fuel pump operation.
Page 450 PROCEDURES FUEL HOSE AND OETIKER CLAMPS Fuel Hose Replacement When replacing fuel hoses, be sure to use hoses and clamps as available from BRP parts depart- ment. This will ensure continued proper and safe operation. WARNING vmr2012-028-006_b 1. Fuel pump relay fuse...
Page 451 Subsection XX (FUEL TANK AND FUEL PUMP) vmr2012-028-014_a TYPICAL vmr2012-028-012_a 1. Battery support TYPICAL 2. Rear frame extension 1. Starter solenoid 2. Positive (+) battery cable to disconnect 11. Remove the upper mounting bolt from both rear shock absorbers. 9. Remove the 2 screws that secure the front of the battery support.
Page 452 Subsection XX (FUEL TANK AND FUEL PUMP) vmr2012-028-023_a TYPICAL - RENEGADE MODELS vmr2012-028-017_a 1. Muffler 1. Final drive unit 2. Vent tube to remove 16. Remove fuel tank retaining screws (4). NOTE: Note position of washers and bushings on each screw. vmr2012-028-016_a TYPICAL 1.
Page 453 Subsection XX (FUEL TANK AND FUEL PUMP) vmr2012-028-024_a vmr2012-028-018_a 1. Final drive protector TYPICAL 1. Rear frame extension All Models 2. Loosen these 2 nuts 3. Remove these 4 bolts 20. Remove rear frame supports as an assembly. Outlander Models 18.
Page 454 Subsection XX (FUEL TANK AND FUEL PUMP) Be sure to properly connect and route: – Fuel tank vent tube – Fuel pump pressure hose – Electrical connectors. Refuel tank and ensure there are no leaks by FUEL TANK LEAK TEST FUEL performing a and a...
Page 455 Subsection XX (FUEL TANK AND FUEL PUMP) If battery voltage is still not read, check fuel pump: – Fuse (F15) – Fuel pump relay (R4) – Fuel pump relay input voltage (control and power circuits) – Fuel pump relay control circuit continuity to ECM-J1 –...
Page 456 Subsection XX (FUEL TANK AND FUEL PUMP) 3. Disconnect the following from the fuel pump: – Fuel pump electric connector – Fuel system vent hose – Fuel pump pressure hose. vmr2012-028-006_a FUSE BOX COORDINATES If resistance test failed, disconnect fuel pump connector and measure resistance at fuel pump connector.
Page 457 Subsection XX (FUEL TANK AND FUEL PUMP) 2. Place gasket so that it is properly located be- tween fuel pump and fuel pump mounting neck on fuel tank. vmr2012-028-026_a FUEL PUMP REMOVAL 1. Fuel pump retaining nut vmr2012-028-028_a 5. Carefully pull out and rotate fuel pump as re- 1.
Page 458 Subsection XX (FUEL TANK AND FUEL PUMP) FUEL PUMP PREFILTER REQUIRED TOOL (STRAINER) FUEL PUMP NUT TOOL Fuel Pump Prefilter Replacement (P/N 529 035 899) 1. Remove FUEL PUMP , see FUEL PUMP RE- MOVAL in this subsection. TORQUE 2. Unlock 3 tabs on strainer plastic ring. 29 N•m ±...
Page 459 Subsection XX (FUEL TANK AND FUEL PUMP) vmr2008-135-901_a TYPICAL - FUEL PUMP 1. Fuel level sender Fuel Level Sender Resistance Test vmr2008-135-222_a (Fuel Pump Module Installed) 5. Pull strainer off fuel pump. 1. Disconnect multifunction gauge, refer to the LIGHTS/GAUGE/ACCESSORIES subsection.
Page 460 Subsection XX (FUEL TANK AND FUEL PUMP) FUEL TANK VENT VALVES FUEL If readings are out of specification, refer to LEVEL SENDER RESISTANCE TEST (AT FUEL Fuel Tank Vent Valve Test PUMP CONNECTOR) If readings are as specified, refer to FUEL LEVEL Inlet Check Valve Test SENDER INPUT VOLTAGE TEST...
Page 461 Subsection XX (FUEL TANK AND FUEL PUMP) 2. Set vacuum/pressure pump to PRESSURE and activate pump. The gauge should increase in reading. 3. Set vacuum/pressure pump to VACUUM and activate pump. The gauge on the pump should not change in reading. If the test failed, carry out the following: –...
Page 462 Subsection XX (FUEL TANK AND FUEL PUMP) vmr2012-028-029_b 1. Pressure relief valve flow direction arrow vmr2013-028...
Page 463 Subsection XX (POWER DISTRIBUTION AND GROUNDS) POWER DISTRIBUTION AND GROUNDS GENERAL POWER DISTRIBUTION DIAGRAM COMMUNICATION CONNECTOR FUSE BOX 1 MAIN RELAY (R2) GAUGE FUSE BOX 2 - TAILLIGHTS - LICENSE PL IGNITION COIL BRAKE LIGHT RELAY (R8) FUEL INJECTORS VEHICLE SPEED SENSOR ACCESSORIES VOLTAGE...
Page 464 Subsection XX (POWER DISTRIBUTION AND GROUNDS) FUSE BOX 1 vmr2012-028-006_e FUSES FUSE IDENTIFICATION 10 A 20 A (Europe) 25 A Fuse 30 A 15 A 15 A Jumper 1 vmr2012-028-006_d RELAYS vmr2013-029...
Page 465 Subsection XX (POWER DISTRIBUTION AND GROUNDS) RELAY RELAY STATE (ON) RELAY STATE (OFF) IDENTIFICATION COOLING SYSTEM Cooling fan Approximately 30 seconds When ignition key is turned ON after ignition key is turned OFF Main Run/Stop switch is set to RUN Approximately 30 minutes if ignition key is left ON When ignition key is turned OFF Approximately 30 minutes if ignition key is left ON...
Page 466 Subsection XX (WIRING HARNESS AND CONNECTORS) WIRING HARNESS AND CONNECTORS SERVICE TOOLS Description Part Number Page 529 035 730 ........... 27 CRIMPING TOOL (HEAVY GAUGE WIRE) ........529 036 166 ........... 25 ECM ADAPTER TOOL..............529 036 175 ........... 25 ECM TERMINAL REMOVER 2.25..........
Page 467 Subsection XX (WIRING HARNESS AND CONNECTORS) ABBREVIATION DESCRIPTION LH multifunction switch LH multifunction switch RH lower headlight RH upper headlight Front Fuse box Rear fuse holder LH LO beam headlight LH HI beam headlight License plate light RH marker light PPD1 RH marker light PPD2...
Page 468 Subsection XX (WIRING HARNESS AND CONNECTORS) WIRING HARNESS ARRANGEMENT vmr2012-030-001 1. Turn signal harness - Europe (Renegade series) 2. Turn signal harness - Europe (Outlander series) 3. 2WD/4WD switch 4. Multifunction switch 5. Europe models 6. Main harness 7. To rear brake switch - All models 8.
Page 469 Subsection XX (WIRING HARNESS AND CONNECTORS) vmr2013-030-002_a 1. Winch switch 2. Main harness 3. Winch harness - Outlander XT, XT-P and LTD models Front vmr2013-030...
Page 470 Subsection XX (WIRING HARNESS AND CONNECTORS) WIRING HARNESS ROUTING All Models Except CE vmr2013-030-001 vmr2013-030...
Page 471 Subsection XX (WIRING HARNESS AND CONNECTORS) All Models Except CE vmr2012-030-005 vmr2013-030...
Page 472 Subsection XX (WIRING HARNESS AND CONNECTORS) All Models Except CE vmr2012-030-006 vmr2013-030...
Page 473 Subsection XX (WIRING HARNESS AND CONNECTORS) All Models Except CE vmr2012-030-007 vmr2013-030...
Page 474 Subsection XX (WIRING HARNESS AND CONNECTORS) All Models Except CE vmr2012-030-008 To engine harness vmr2013-030...
Page 475 Subsection XX (WIRING HARNESS AND CONNECTORS) All Models Except CE vmr2012-030-009 vmr2013-030...
Page 476 Subsection XX (WIRING HARNESS AND CONNECTORS) All Models Except CE vmr2012-030-010 vmr2013-030...
Page 477 Subsection XX (WIRING HARNESS AND CONNECTORS) CE Models vmr2012-030-012 vmr2013-030...
Page 478 Subsection XX (WIRING HARNESS AND CONNECTORS) CE Models vmr2012-030-013 vmr2013-030...
Page 479 Subsection XX (WIRING HARNESS AND CONNECTORS) CE Models vmr2012-030-014 vmr2013-030...
Page 480 Subsection XX (WIRING HARNESS AND CONNECTORS) WIRING HARNESS SPLICE LOCATION Main Harness (Rear Part) — All Models vmr2012-030-020 vmr2013-030...
Page 481 Subsection XX (WIRING HARNESS AND CONNECTORS) Main Harness (Front Part 1/2) — All Models vmr2012-030-021 vmr2013-030...
Page 482 Subsection XX (WIRING HARNESS AND CONNECTORS) Main Harness (Front Part 2/2) — All Models vmr2012-030-022 vmr2013-030...
Page 483 Subsection XX (WIRING HARNESS AND CONNECTORS) Turn Indicator Light Harness — Outlander CE Models vmr2012-030-018 Resistor 1 vmr2013-030...
Page 484 Subsection XX (WIRING HARNESS AND CONNECTORS) Turn Indicator Light Harness — Renegade CE Models vmr2012-030-019 Resistor 1 vmr2013-030...
Page 485 Subsection XX (WIRING HARNESS AND CONNECTORS) Brake Harness — All Models vmr2012-030-017b vmr2013-030...
Page 486 Subsection XX (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 487 Subsection XX (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 488 Subsection XX (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 489 Subsection XX (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: – ECM Molex Connector Removal Push and hold the locking tab.
Page 490 Subsection XX (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 491 Subsection XX (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 492 Subsection XX (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 493 Subsection XX (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. Heat the heat shrink rubber tube us- ing the heat gun so that it grasps the wire and the terminal.
Page 494 Subsection XX (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page 529 036 166 ........2, 5–6 ECM ADAPTER TOOL..............529 035 868 ..........5 FLUKE 115 MULTIMETER ............GENERAL 3. Defective trigger wheel - Inspect trigger wheel. Refer to MAGNETO SYS- SYSTEM DESCRIPTION TEM subsection.
Page 495 Subsection XX (IGNITION SYSTEM) PROCEDURES FUNCTION WIRE COLOR Ground signal to ECM in IGNITION SWITCH BLACK/WHITE OFF position Ignition Switch Quick Test D.E.S.S. signal ORANGE/RED Turn ignition switch to ON position. 12 Vdc output to ECM (through emergency If multifunction gauge turns on (assuming it engine stop switch) works), the ignition switch is good.
Page 496 Subsection XX (IGNITION SYSTEM) EMERGENCY ENGINE STOP SWITCH TEST AT ECM FUSE BOX FUNCTION RESULT CONTACT ADAPTER Close to position — G2 to K3 Open circuit STOP Close to position — G2 to K3 vmr2012-039-007_a EMERGENCY EN- If switch fails the test, refer to STEERING CONNECTOR IDENTIFICATION GINE STOP SWITCH TEST AT MULTIFUNCTION 1.
Page 497 Subsection XX (IGNITION SYSTEM) IGNITION COIL vmr2012-031-003_a VIEW RH SIDE OF VEHICLE, OUTLANDER XT 1000 MODEL 1. Ignition coil 2. DPS 3. Winch relay 4. Cooling system thermostat (1000 engine) vmr2006-018-100 Remove the LH inner fender panel(s) for access Ignition Coil Access to the ignition coil connector.
Page 498 Subsection XX (IGNITION SYSTEM) tmr2011-026-002_a 1. Ignition coil connector vmr2012-031-005_b 2. Set emergency engine stop switch to RUN. TYPICAL 1. ECM 3. Turn ignition switch to ON. 2. ECM connector cover 4. Read voltage as per following table. REQUIRED TOOLS REQUIRED TOOL ECM ADAPTER TOOL (P/N 529 036 166)
Page 499 Subsection XX (IGNITION SYSTEM) creased fuel consumption. This is due to a loss of compression. Other possible causes are: pro- longed idling or low-speed riding, a clogged air filter, incorrect fuel, defective ignition system, incorrect spark plug gap, lubricating oil entering the combustion chamber, or too cold spark plug.
Page 500 Subsection XX (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS Description Part Number Page 529 035 868 ........... 2 FLUKE 115 MULTIMETER ............SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page 95260 ........... 3 NAPA ULTRA PRO BATTERY LOAD TESTER ....... SERVICE PRODUCTS Description Part Number...
Page 501 Subsection XX (CHARGING SYSTEM) INSPECTION Output Voltage Test Using a Multimeter CHARGING SYSTEM OUTPUT REQUIRED TOOL First ensure that battery is in good condition prior to performing the following tests. FLUKE 115 MULTIMETER (P/N 529 035 868) Output Voltage Test Using B.U.D.S. 1.
Page 502 Subsection XX (CHARGING SYSTEM) PROCEDURES Battery Voltage Test (No Load Applied) NOTE: A voltage test is carried out on a battery VOLTAGE REGULATOR/ without discharging current. It is the simplest and most commonly used. However, be aware that RECTIFIER the voltage test can be good, while the battery Voltage Regulator/Rectifier Static Test does not have enough power to crank the engine.
Page 503 Subsection XX (CHARGING SYSTEM) TIGHTENING TORQUE Battery retaining plate 4 N•m to 5 N•m screws (35 lbf•in to 44 lbf•in) vmr2012-032-002_a TYPICAL 1. Battery retaining plate 2. Retaining plate screws (3) 4. Remove battery. Battery Cleaning Clean the battery support, cables and battery posts using a solution of baking soda and water.
Page 504 Subsection XX (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 166 ..........2 ECM ADAPTER TOOL..............529 035 868 ......... 3, 5 FLUKE 115 MULTIMETER ............SERVICE PRODUCTS Description Part Number Page 293 550 004 ..........8 DIELECTRIC GREASE ..............
Page 505 Subsection XX (STARTING SYSTEM) 3. Defective start button or circuit - Test start button and wiring, see procedure in this subsection. 4. Defective starter solenoid or circuit - Test starter solenoid and wiring, see procedure in this subsection. 5. Defective starter - Test starter and wiring, see procedure in this sub- section.
Page 506 Subsection XX (STARTING SYSTEM) vmr2012-033-002_a vmo2012-012-033_a 1. LH multifunction switch connector (MG2) TYPICAL - OUTLANDER MODELS ILLUSTRATED 1. Gauge support Start Button Wire Identification Outlander Models LH MULTIFUNCTION SWITCH CONNECTOR 3. Remove dashboard support. (MG2) FUNCTION COLOR 12 volt input from emergency engine VIOLET/BEIGE stop switch...
Page 507 Subsection XX (STARTING SYSTEM) vmr2012-033-003_a 1. Cable from starter solenoid to starter vmr2012-023-003_b 2. Battery cable to starter solenoid (not visible) 1. Battery support 3. Fuel tank 2. Starter solenoid 4. RH rear fender 3. Battery cable 4. Tool kit Starter Solenoid Wire Identification Starter Solenoid Access for Electrical WIRE...
Page 508 Subsection XX (STARTING SYSTEM) REQUIRED TOOL STARTER SOLENOID WINDING RESISTANCE TEST RESULT @ FLUKE 115 MULTIMETER TEST PROBES 20°C (68°F) (P/N 529 035 868) Starter Starter solenoid solenoid SS2 Approximately 5 STARTER SOLENOID INPUT VOLTAGE TEST SS1 pin RESULT If measurement is out of specification, replace so- TEST PROBES (START BUTTON lenoid.
Page 509 Subsection XX (STARTING SYSTEM) – Check power cable condition from solenoid to starter. – Replace solenoid. Starter Solenoid Removal 1. Remove the following: – Seat – Tool kit – Battery (refer to CHARGING SYSTEM sub- section). 2. Disconnect starter power cable at starter sole- noid terminal.
Page 510 Subsection XX (STARTING SYSTEM) vmr2006-019-010_a vmr2012-033-003_a TYPICAL - SOME PARTS REMOVED FOR CLARITY PURPOSE 1. Power cable from starter solenoid to starter ONLY 2. Power cable from battery to starter solenoid (not visible) 3. Fuel tank 4. RH rear fender 2.
Page 511 Subsection XX (STARTING SYSTEM) NOTICE When connecting the RED (+) cable to the starter motor, make sure the battery ca- bles are disconnected. STARTER CABLE NUT TIGHTENING TORQUE PRODUCT DIELECTRIC GREASE 6 N•m (53 lbf•in) (P/N 293 550 004) Install remaining removed parts, refer to applica- ble subsections.
Page 512 Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) GENERAL 2. Turn ignition switch to ON using any of the key provided with the vehicle. DO NOT start the SYSTEM DESCRIPTION engine. 3. Click the Read Data button in B.U.D.S. The ignition key contains a ROM chip with a unique digital code that is the equivalent of a unique teeth pattern on a conventional key.
Page 513 Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) KEY TYPE Performance key BLACK key GRAY key Normal key 8. Click on the appropriate Add Key button. tbl2011-001-053_d 1. Add Performance Key button 2. Add Normal Key button NOTE: The Add Work Key button is not used for these vehicles.
Page 514 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) LIGHTS, GAUGE AND ACCESSORIES SERVICE TOOLS Description Part Number Page 529 035 868 ........15, 17 FLUKE 115 MULTIMETER ............SERVICE PRODUCTS Description Part Number Page 293 550 004 ........... 10 DIELECTRIC GREASE ..............GENERAL Speedometer This display will show vehicle speed.
Page 515 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) Transmission Position Display Low fuel level Indicator Lamp This display will show transmission position. When this indicator turns ON, it indicates that there is approximately 5 L (1.3 U.S. gal.) of fuel left in fuel tank. 4WD Indicator Lamp When this indicator is ON, it indicates the 4WD system is activated.
Page 516 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) Multifunction Display Modes WARNING Never adjust or set functions on the multi- function gauge while riding the vehicle. The available modes may be displayed by pressing the selector button. NOTE: An abbreviation of the mode selected will also be displayed in Display 3.
Page 517 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) MULTIFUNCTION GAUGE (ANALOG/DIGITAL) Multifunction Gauge Description The Multifunction Gauge (Analog/digital) is located on the steering column. The Multifunction Gauge (Analog/digital) is comprised of a digital gauge and two analog gauges (speedometer and tachometer). The engine temperature and fuel level bar graphs are comprised in the digital gauge. The indicators lamps are comprised in both analog gauges.
Page 518 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) 1) Analog Speedometer To reset any trip functions, push and hold the MODE (M) button for three seconds. Measures vehicle speed in km/h or mph. 4) Analog Tachometer (RPM) 2) MODE (M) Button Measures engine revolutions per minute (RPM). Pressing the MODE (M) button will scroll through Multiply by 1000 to obtain actual revolutions.
Page 519 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) MESSAGE DESCRIPTION Message displayed when the brakes are applied continuously for 15 BRAKE seconds. PERFORMANCE KEY Displayed at power up when a the performance key is used. Override is displayed when the override switch is pressed and the shift OVERRIDE lever is set to reverse gear.
Page 520 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) 2) Transmission Position Display 3) Main Screen This display will show transmission position. The main screen is used to display numerous functions of the multifunction gauge. MULTIFUNCTION GAUGE MODES Refer to the available display modes. 4) Fuel Level Display Bar gauge continuously indicates the level of fuel in the fuel tank while riding.
Page 521 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) 9) KM/H or MPH Indicator Lamp Combined Mode In this mode, the display shows the speed of the vehicle and the engine RPM. The applicable lamp turns on to indicate the active speedometer unit of display. 10) Turn signal/Hazard lights Indicator Lamp When this indicator is ON, it indicates: –...
Page 522 Subsection XX (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 – Vehicle speed Press and HOLD the selector button for 2 seconds –...
Page 523 Subsection XX (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. Pay attention to ground wires.
Page 524 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) DIAGNOSTIC GUIDELINES HAZARD LIGHTS WILL NOT COME ON WHEN SELECTED (CE MODELS ONLY) (LIGHTS) 1. Clock/Hazard fuse (F10) open circuit. LOW AND HIGH BEAM HEADLIGHTS WILL NOT COME ON SIMULTANEOUSLY - Check fuse, refer to POWER DISTRIBUTION sub- section.
Page 525 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) HAZARD LIGHTS INDICATOR NOT WORKING WITH IGNITION SWITCH OFF (CE MODELS ONLY) 1. Diode D10 open circuit. - Test diode, refer to WIRING DIAGRAM. POSITION LIGHTS WILL NOT COME ON (CE MODELS ONLY) 1. Accessories fuse F7 open circuit. - Test fuse, refer to POWER DISTRIBUTION sub- section.
Page 526 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) Outlander Models NOTE: SET TIME will appear on display 3. Renegade Models NOTE: The display will flash. Outlander and Renegade Models 3. Choose the 12-hour (12H) or 24-hour (24H) for- mat by pressing button. 4.
Page 527 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) Units of Display Selection Wow Test In B.U.D.S., select the: This function is used to check if the indicator lights, display and analog indicators (if applicable) – Setting page tab are functional. – Cluster page tab. NOTE: This function does not test the signals or Select Imperial or Metric in the Cluster Units external circuits.
Page 528 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) This function confirms that the ECM receives the CAN RESISTOR TEST inputs. DIAGNOSTIC LINK Vehicle Parameters Monitoring RESISTANCE CONNECTOR In B.U.D.S., select the: Pins 1 and 2 Approximately 60 – Monitoring page – Cluster tab. NOTE: This tests both the ECM and the Cluster CAN resistors and wires.
Page 529 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) vmr2006-020-058_a IMPORTANT: If a multifunction gauge from an- other vehicle model is installed and is not regis- tered in the ECM through B.U.D.S., engine start- ing will not be allowed until the gauge is reg- istered with the proper coding.
Page 530 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) Headlights Circuit Protection All Models Unplug the connectors of the power outlet. CONDITION CIRCUIT PROTECTION Unscrew the retaining nut. Supplied when Fuse 11 of fuse block 1 headlights relay (R5) Reverse procedure for installation. (from fuse 2 of fuse block 2) activated 12 Volt Power Outlet Wire...
Page 531 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) Headlight Bulb Replacement SPECIFICATION NOTICE Never touch glass portion of a halo- Low beam crest (top 25 mm to 125 mm of low beam) gen bulb with bare fingers, it shortens its oper- (1 in to 5 in) below ating life.
Page 532 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) TAILLIGHTS/BRAKE LIGHTS Brake Light Switch For brake light switch location and testing, refer to BRAKES subsection. vmo2012-012-059_b LOW BEAM 1. Adjustment knobs vmo2012-012-060_a HIGH BEAM 1. Adjustment knobs Beam Aiming Adjustment (Renegade) Turn adjustment knobs to adjust beam height and side orientation to specification.
Page 533 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) Brake Light Wire Identification BRAKE LIGHT RELAY (R8) FUNCTION COLOR 12 volt input from fuse F4 ORANGE/GREEN (brake light power) 12 volt input from F4 (relay ORANGE/GREEN winding input) 12 volt output to LH and WHITE/ORANGE RH brake lights Relay winding ground...
Page 534 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) HORN (CE MODELS ONLY) TURN SIGNAL SWITCH (IN MULTIFUNCTION SWITCH) Horn Wire Identification FUNCTION COLOR HORN SWITCH (IN MULTIFUNCTION SWITCH) 12 volt input from MG3-3 RED/BLACK FUNCTION COLOR fuse F10 12 volt input from RH turn 12 volt output MG3-3 RED/BLACK...
Page 535 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) 2. Remove the hook. WINCH SWITCH 2.1 Remove and discard the cotter pin. FUNCTION COLOR 2.2 Remove the hook pin. 12 volt input from fuse 7 RED/BLACK 12 volt output to relay GREEN/BLUE winding (IN) 12 volt output to relay LIGHT BLUE winding (OUT)
Page 536 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES) 8. Remove winch. Winch Installation For the installation, reverse the removal proce- dure, however pay attention to the following. Connect winch power cables as noted at removal. NOTE: If the winch power cables are not con- nected correctly, the winch motor will operate in the reverse direction of selection.
Page 537 Subsection XX (FRONT DRIVE) FRONT DRIVE SERVICE TOOLS Description Part Number Page 529 035 665 ..........9 BACKLASH MEASUREMENT TOOL..........529 036 120 ..........5 CV BOOT CLAMP PLIER .............. 529 036 005 ..........5 CV JOINT EXTRACTOR..............529 035 649 ..........8 SPANNER SOCKET ...............
Page 538 Subsection XX (FRONT DRIVE) FRONT DRIVE SHAFTS AND FRONT PROPELLER SHAFT 205 ± 15 N•m (151 ± 11 lbf•ft) STEERING SYSTEM 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) (M8) Synthetic grease 22.5 ± 2.5 N•m (17 ± 2 lbf•ft) Loctite 61 ±...
Page 539 Subsection XX (FRONT DRIVE) FRONT DIFFERENTIAL 33 ± 3 N•m (24 ± 2 lbf•ft) 22.5 ± 2.5 N•m (17 ± 2 lbf•ft) 180 ± 15 N•m (133 ± 11 lbf•ft) LH threads Loctite 277 7.5 ± 0.5 N•m (66 ± 4 lbf•in) XPS Synthetic grease = Component must be replaced when removed.
Page 540 Subsection XX (FRONT DRIVE) GENERAL The procedure explained below is the same for the RH and LH sides unless otherwise instructed. SYSTEM DESCRIPTION The Visco-Lok ® system constantly monitors front wheel speed and, if it detects one wheel spinning faster than its mate, it progressively sends more power to the wheel with the better traction.
Page 541 Subsection XX (FRONT DRIVE) FRONT DRIVE SHAFT Front Drive Shaft Removal Lift and support vehicle. BODY Remove inner fender panel(s). Refer to subsection. Remove the KNUCKLE . Refer to STEERING SYS- subsection. Remove shock absorber lower bolt. Lift and attach the following parts to make room. V07H0AA –...
Page 542 Subsection XX (FRONT DRIVE) 529036005 vmr2012-036-003_a FROM LH SIDE 1. Vent hose 4. Remove bolts securing front differential to frame. vmr2007-053-010_a TYPICAL — CV JOINT SHOWN 1. Joint extractor tool With an hammer, hit on the tool to separate joint from shaft.
Page 543 Subsection XX (FRONT DRIVE) vmr2012-036-008_a vmr2012-036-005_a TYPICAL - RETAINING SCREWS FRONT DIFFERENTIAL MOVED REARWARD Separate half housings. 7. Remove front differential by pulling it from LH Remove oil seals no. 12. side. Visco-Lok Carrier/Ring Gear Remove Visco-Lok carrier/ring gear out of half housing.
Page 544 Subsection XX (FRONT DRIVE) RECOMMENDED TOOLS Pipe: 89 mm (3-1/2 in) diameter x 127 mm (5 in) in length Screwed rod: M12 x 1.25, 178 mm (7 in) length M12 x 1.25 nut Flat bar vmr2012-036-010_a TYPICAL 1. Oil seal Unscrew the pinion nut no.
Page 545 Subsection XX (FRONT DRIVE) RECOMMENDED SHIMS 1.67 mm ± 0.04 mm PINION GEAR (.066 in ± .002 in) BACKLASH 0.5 mm (.02 in) (for preliminary adjustment) PRELOAD NOTE: The procedure above sets the pinion shim thickness and should not be modified thereafter. Any changes should be done on the preload and/or backlash side(s).
Page 546 Subsection XX (FRONT DRIVE) Pinion Gear Install a new O-ring no. 13. Install the shims no. 8 then a new ball bearing no. 6. Install a new needle bearing no. 9. Apply to pinion nut LOCTITE 277 (P/N 293 800 073) no.
Page 547 Subsection XX (FRONT DRIVE) 4. Remove bolts securing front differential to 7. Pry front differential upwards to make room. frame. vmr2012-036-004_a vmr2012-036-007_a 1. Bolts securing front differential to frame 1. Pry bar 8. Remove front propeller shaft by pulling it for- 5.
Page 548 Subsection XX (REAR DRIVE) REAR DRIVE SERVICE TOOLS Description Part Number Page 529 035 665 ..........9 BACKLASH MEASUREMENT TOOL..........529 036 120 ..........5 CV BOOT CLAMP PLIER .............. 529 036 005 ..........6 CV JOINT EXTRACTOR..............529 035 649 ........... 11 SPANNER SOCKET ...............
Page 549 Subsection XX (REAR DRIVE) 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 22.5 ± 2.5 N•m grease (17 ±...
Page 550 Subsection XX (REAR DRIVE) For preload adjustment For backlash 32.5 ± 3.5 N•m adjustment (24 ± 3 lbf•ft) 7.5 ± 0.5 N•m (66 ± 4 lbf•in) 180 ± 15 N•m (133 ± 11 lbf•ft) LH threads Loctite 271 XPS Synthetic grease = Component must be replaced when removed.
Page 551 Subsection XX (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 552 Subsection XX (REAR DRIVE) Drive Shaft Inspection PART 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 553 Subsection XX (REAR DRIVE) PROPELLER SHAFT Remove boot from drive shaft. Remove and discard the circlip. A new one is in- Propeller Shaft Removal cluded in the boot kit. 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 554 Subsection XX (REAR DRIVE) vmr2012-037-009_a vmr2012-037-007_a TYPICAL — LH SIDE OF VEHICLE 1. Master cylinder moved apart 1. Remove screw 4. Lift and support vehicle. 7. Remove rear final drive retaining bolts. Refer to REAR FINAL DRIVE in this subsection. 5.
Page 555 Subsection XX (REAR DRIVE) Apply Support U-joint in vice and drive inner yoke down XPS SYNTHETIC GREASE (P/N 293 550 010) splines. to remove remaining bearing caps. Remove U-joint cross. PARTS TORQUE Propeller shaft screw 75 N•m ± 5 N•m Propeller Shaft U-Joint Installation (rear final drive side) (55 lbf•ft ±...
Page 556 Subsection XX (REAR DRIVE) V01H12A vmr2012-037-011_a Install snap ring. 1. Remove bolts Complete installation for the other bearing caps. Unplug the vent hose from final drive. PERIODIC MAINTE- Grease U-joint. Refer to NANCE PROCEDURES subsection. REAR FINAL DRIVE Rear Final Drive Removal Drain oil.
Page 557 Subsection XX (REAR DRIVE) BACKLASH ADJUSTMENT GUIDELINE BACKLASH WHAT TO DO MEASUREMENT Add shim(s) and recheck Below 0.05 mm (.002 in) backlash Remove shim(s) and Above 0.36 mm (.014 in) recheck backlash vmr2006-023-015_a 1. Tab of backlash measurement tool 2. Mark on tab A.
Page 558 Subsection XX (REAR DRIVE) vmr2006-023-012 TYPICAL — FRONT DIFFERENTIAL SHOWN PRELOAD SPECIFICATION tmr2011-032-008_a 1. Housing screws 0.06 N•m (.5 lbf•in) to 0.50 N•m (4 lbf•in) Split final drive housings. If preload is out of specification, split final drive NOTE: Be careful to keep track of shims no. 2 and housing and adjust shim thickness as per follow- no.
Page 559 Subsection XX (REAR DRIVE) – Ring gear – Housing. As a preliminary setup, install shims according to the following table. RECOMMENDED SHIM THICKNESS PINION GEAR 1.67 mm ± 0.04 mm (.066 in ± .002 in) BACKLASH 0.5 mm (.02 in) (as a preliminary adjustment) PRELOAD The pinion gear shim thickness (no.
Page 560 Subsection XX (REAR DRIVE) vmr2012-037-016_c 1. Shim no. 8 Install a new needle bearing no. 9. Apply to pinion nut LOCTITE 277 (P/N 293 800 073) no. 5. NOTE: If a new pinion nut is used, a self-locking product is already applied, do not use Loctite 277. Install and tighten the pinion nut.
Page 561 Subsection XX (WHEELS AND TIRES) WHEELS AND TIRES SERVICE PRODUCTS Description Part Number Page 293 800 070 ......... 2–3 LOCTITE 767 (ANTISEIZE LUBRICANT) ........PROCEDURES WARNING – Replace tires only with the same type and TIRES size as original tires. –...
Page 562 Subsection XX (WHEELS AND TIRES) vmr2012-038-002_a 1. Tire outer bead 2. Beadlock inner ring shoulder 2. Place the beadlock clamp ring on the tire. vmr2012-038-001_a 1. Beadlock clamp ring 3. Apply LOCTITE 767 (ANTISEIZE LUBRICANT) 2. Beadlock screws (16 x) or an equivalent product to (P/N 293 800 070) 6.
Page 563 Subsection XX (WHEELS AND TIRES) vmr2012-038-001_b vmr2012-038-001_c FIRST AND SECOND TIGHTENING SEQUENCE FINAL TIGHTENING SEQUENCE The beadlock clamp ring should be in contact the 7. Inflate tire to seat the inner bead on wheel. Al- beadlock inner ring. ways use safe practices, such as a tire safety cage.
Page 564 Subsection XX (WHEELS AND TIRES) TORQUE 8.5 N•m ± 1.5 N•m Threaded insert (75 lbf•in ± 13 lbf•in) NOTE: The insert must not protrude the wheel surface. tmr2011-033-002_a TYPICAL 1. Direction of rotation Install wheel with the tire in the right direction of rotation.
Page 565 Subsection 01 (WHEELS AND TIRES) WHEELS AND TIRES SERVICE PRODUCTS Description Part Number Page 293 800 070 ........... 2 LOCTITE 767 (ANTISEIZE LUBRICANT) ........100 N•m (74 lbf•ft) vmr2013-060-100_a vmr2013-060...
Page 566 Subsection 01 (WHEELS AND TIRES) PROCEDURES TIRES WARNING – Respect direction of rotation when applica- ble. – On 650 Models, do not rotate tires. The front and rear rims and front and rear tires have different sizes. Tire Pressure vmr2013-060-001_a TYPICAL 1.
Page 567 Subsection 01 (WHEELS AND TIRES) Tighten wheel lug nuts to the specified torque us- ing the illustrated sequence. WHEEL LUG NUTS 100 N•m ± 10 N•m TORQUE (74 lbf•ft ± 7 lbf•ft) vmr2012-038-004_a TIGHTENING SEQUENCE NOTICE Always recommended wheel nuts for the type of wheel. Using a different nut could cause damages to the rim or studs.
Page 568 Subsection XX (STEERING SYSTEM) STEERING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 059 ........... 5 STEERING ALIGNMENT TOOL............. SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page 16 ga ........... 6 SMOOTHFLOW™ TAPERED TIP..........#511 rtt-b SERVICE PRODUCTS Description Part Number Page...
Page 569 Subsection XX (STEERING SYSTEM) Outlander 500/650/800R/1000 and Renegade 800R/1000 (without a DPS) Outlander 500/650/800R/1000 Renegade 800R/1000 Europe 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) Synthetic grease 31.5 ± 3.5 N•m (23 ± 3 lbf•ft) 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) Loctite 24.5 ±...
Page 570 Subsection XX (STEERING SYSTEM) Outlander XT and LTD Models (with a DPS) Europe 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) Synthetic grease 31.5 ± 3.5 N•m (23 ± 3 lbf•ft) 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) 24.5 ± 3.5 N•m (18 ±...
Page 571 Subsection XX (STEERING SYSTEM) Renegade X xc and XT-P 800R/1000 31.5 ± 3.5 N•m (23 ± 3 lbf•ft) Europe 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) Synthetic grease 31.5 ± 3.5 N•m (23 ± 3 lbf•ft) 24.5 ± 3.5 N•m (18 ±...
Page 572: Steering Alignment
Subsection XX (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 573: Procedures
Subsection XX (STEERING SYSTEM) 13. Repeat procedure for other front wheel. 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. vmr2008-068-009 TYPICAL —...
Page 574: Handlebar
Subsection XX (STEERING SYSTEM) vmr2006-025-005_a TYPICAL 1. Plastic U-clamp vmr2012-039-004_a TYPICAL Renegade 1. Stiffeners 2. Handlebar clamps Remove the 4 screws that secure the steering cover and handlebar to the steering head. 3. Remove the handlebar. Renegade X xc Renegade Model Remove the fabric steering cover, then pull the NOTE: Handlebar grips, throttle and brake levers protective foam from the handlebar.
Page 575: Steering Connectors
Subsection XX (STEERING SYSTEM) vmr2012-033-001_a 1. Dash board support vmr2012-039-005_a 1. Socket screws Steering Connector Identification 2. Handlebar clamps Handlebar Inspection Inspect the handlebar for damage, cracks or bend- ing. Replace if any of these problems is detected. Handlebar Installation For the installation, reverse the removal proce- dure.
Page 576: Throttle Lever
Subsection XX (STEERING SYSTEM) vmr2012-039-006_a TYPICAL - MULTIFUNCTION SWITCH 2. Separate multifunction switch from handlebar. 3. Disconnect multifunction switch steering con- nectors, refer to STEERING CONNECTOR IDENTIFICATION in this subsection: V07I0FA – MG1 TYPICAL - THROTTLE LEVER HOUSING 1. Remove retaining screws –...
Page 577: Brake Lever
Subsection XX (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 578 Subsection XX (STEERING SYSTEM) vmr2012-033-001_a vmr2012-039-009_a TYPICAL - OUTLANDER MODELS TYPICAL 1. Dash board support 1. Lower retainer mounting screws (2) 2. Lower half bushing retainer 3. Steering column All Models (Without a DPS) 4. Pitman arm AIR IN- 4. Remove the air intake silencer. Refer to 8.
Page 579 Subsection XX (STEERING SYSTEM) vmr2012-033-001_a vmr2012-039-010_a TYPICAL - OUTLANDER MODELS TYPICAL 1. Dash board support 1. Upper steering column support 2. Half bushings All Models (With a DPS) 3. Half bushing retainer 4. Retainer mounting screws (2) AIR IN- 4. Remove the air intake silencer. Refer to TAKE SYSTEM subsection.
Page 580: Tie-Rod
Subsection XX (STEERING SYSTEM) TIE-ROD Tie-Rod Inspection Inspect tie-rod for straightness, cracks and other NOTE: Use the same procedure for RH and LH damages. Replace as required. side. Inspect tie-rod ends for wear or excessive play. If Tie-Rod Removal excessive, replace the tie-rod end. 1.
Page 581: Knuckle
Subsection XX (STEERING SYSTEM) WHEEL BEARINGS TIGHTENING TORQUE Wheel Bearing Inspection 34 N•m ± 2 N•m Tie-rod lock nut (25 lbf•ft ± 1 lbf•ft) (Maintenance) 72 N•m ± 7 N•m PERIODIC MAINTENANCE PROCE- Refer to Tie rod end retaining nut (53 lbf•ft ±...
Page 582: Pitman Arm (With A Dps)
Subsection XX (STEERING SYSTEM) WARNING Clean all grease from outside and inside of knuckle before heating it. Wheel Bearing Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. To ease wheel bearing installation: –...
Page 583 Subsection 02 (STEERING SYSTEM) STEERING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 059 ........... 4 STEERING ALIGNMENT TOOL............. SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page 16 ga ........... 5 SMOOTHFLOW™ TAPERED TIP..........#511 rtt-b SERVICE PRODUCTS Description Part Number Page...
Page 584 Subsection 02 (STEERING SYSTEM) 650 Model 0,4 N•m 5 N•m (4 lbf•in) (44 lbf•in) 10 N•m (89 lbf•in) Loctite 31,5 N•m (23 lbf•ft) 24,5 N•m (18 lbf•ft) 31,5 N•m (23 lbf•ft) 24,5 N•m (18 lbf•ft) Synthetic grease Loctite 24,5 N•m 24,5 N•m (18 lbf•ft) (18 lbf•ft)
Page 585 Subsection 02 (STEERING SYSTEM) 1000 Model 5 N•m 0,4 N•m (44 lbf•in) (4 lbf•in) 10 N•m (89 lbf•in) 31,5 N•m Loctite (23 lbf•ft) Synthetic grease 24,5 N•m (18 lbf•ft) 24,5 N•m (18 lbf•ft) 24,5 N•m 72,5 N•m (18 lbf•ft) (53 lbf•ft) Loctite 24,5 N•m Synthetic...
Page 586 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. On X mr 1000, put ACS setting to 3. 2. Place vehicle on a level surface. 3.
Page 587 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. Remove all rubber residues of the old grip be- TYPICAL —...
Page 588 Subsection 02 (STEERING SYSTEM) HANDLEBAR Handlebar Removal HANDLE- 1. Remove handlebar cover. Refer to BAR COVER REMOVAL in this subsection. NOTE: Remove handlebar grips, throttle handle, brake handle and multifunction switch only if the handlebar is defective and requires replacement. 2.
Page 589 Subsection 02 (STEERING SYSTEM) Steering Connector Identification Multifunction Switch Installation For installation, reverse the removal procedure. NOTICE Be sure to route and secure the mul- tifunction switch steering harness as noted prior to removal. THROTTLE LEVER Throttle Lever Removal 1. Disconnect HIC1 connector (2/4WD...
Page 590 Subsection 02 (STEERING SYSTEM) V07I0GA 1. Cable protector 2. Throttle cable adjuster 3. Lock nut 4. Throttle lever housing V07I0IA 5. Loosen lock nut and screw in the throttle cable 8. Remove throttle cable from housing. adjuster. 6. Remove inner housing protector. Throttle Lever Installation For installation, reverse the removal procedure.
Page 591 Subsection 02 (STEERING SYSTEM) Brake Lever Installation 6. Remove steering column lower pinch bolt, just above the DPS unit. For installation, reverse the removal procedure however, pay attention to the following. NOTE: Some parts in following illustration not shown for clarity of illustration. TIGHTENING TORQUE Brake lever mounting 9 N•m ±...
Page 592 Subsection 02 (STEERING SYSTEM) Steering Column Installation 3. If completely removing tie-rod from vehicle, re- peat previous step at pitman arm. For the installation, reverse the removal proce- dure however, pay attention to the following. PRODUCT O-rings, half XPS SYNTHETIC GREASE bushings and DPS (P/N 293 550 010) input shaft splines...
Page 593 Subsection 02 (STEERING SYSTEM) WARNING Maximum tie-rod unengaged length must not exceed specification. Both tie-rod ends must be engaged equally. vmr2013-061-025 TYPICAL tmr2011-034-107_a TYPICAL - MAXIMUM TIE-ROD UNENGAGED LENGTH 6. Detach upper suspension arm from knuckle, re- A. 32 mm (1.26 in) FRONT SUSPENSION fer to Install NEW cotter pins.
Page 594 Subsection 02 (STEERING SYSTEM) 5. Remove bearing from knuckle using an appro- priate bearing remover. tmr2011-034-109 TYPICAL V07I0RA NOTE: It may be necessary to heat the knuckle to TYPICAL remove bearing. 3. Remove the circlip. WARNING Clean all grease from outside and inside of knuckle before heating it.
Page 595: Dynamic Power Steering (Dps)
Subsection XX (DYNAMIC POWER STEERING (DPS)) DYNAMIC POWER STEERING (DPS) SERVICE TOOLS Description Part Number Page 529 035 868 ........11, 13 FLUKE 115 MULTIMETER ............529 036 225 ........23, 25 PITMAN ARM JIG ................. 529 036 227 ........... 24 PITMAN ARM PULLER ..............
Page 596: General
1. Dynamic power steering unit (DPS) eration with an approved BRP track kit. The DPS system uses the following parameters to Derating Explanation determine how much steering assist it provides: Derating is an internal protection system inte- –...
Page 597: Dps System Description (Components)
Subsection XX (DYNAMIC POWER STEERING (DPS)) DPS SYSTEM DESCRIPTION Steering Torque Sensor (COMPONENTS) DPS Unit The DPS unit is a self contained unit that includes the steering gear, the DPS module, the DPS mo- tor, and the torque sensor. rmr2008-019-017 vmr2010-003-003 TYPICAL - DPS UNIT The steering column is connected to the shaft on...
Page 598: Dps Assist Mode
Subsection XX (DYNAMIC POWER STEERING (DPS)) DPS ASSIST MODE PART ADJUSTED OR WHAT TO DO REPLACED 1. To view the active DPS ASSIST mode, momentarily press and release the OVER- – DPS unit RIDE/DPS/ACS button on the LH multifunction – Steering column switch assembly.
Page 599: Troubleshooting
Subsection XX (DYNAMIC POWER STEERING (DPS)) RENEGADE GAUGE 1. DPS mode display 2. To change DPS ASSIST mode, press and hold the OVERRIDE/DPS/ACS button for approxi- mately 2 seconds to go to the next setting. The DPS system will toggle to the following avail- able mode.
Page 600 Subsection XX (DYNAMIC POWER STEERING (DPS)) Flow Chart A vbs2011-012-001_aen vmr2013-040...
Page 601 Subsection XX (DYNAMIC POWER STEERING (DPS)) Flow Chart B vbs2011-012-002_aen vmr2013-040...
Page 602 Subsection XX (DYNAMIC POWER STEERING (DPS)) Flow Chart C vbs2011-012-003_aen vmr2013-040...
Page 603 Subsection XX (DYNAMIC POWER STEERING (DPS)) Flow Chart D vbs2011-012-004_aen vmr2013-040...
Page 604 Subsection XX (DYNAMIC POWER STEERING (DPS)) Flow Chart E vbs2011-012-006_aen vmr2013-040...
Page 605: Procedures
Subsection XX (DYNAMIC POWER STEERING (DPS)) PROCEDURES DPS UNIT DPS Unit Fuse Test A 40 A DPS fuse located in the rear fuse box (PF2- F3) under the seat provides power for the DPS motor. vmr2012-029-002_a TYPICAL 1. 30 A Main 2.
Page 606 Subsection XX (DYNAMIC POWER STEERING (DPS)) If battery voltage is measured, carry out the fol- MULTIMETER PROBE POSITIONS VOLTAGE DPS UNIT GROUND CIRCUIT TEST lowing DPS2 power NOTE: This test may also be carried out by con- connector pin A necting a 12 Vdc test light between the DPS con- Battery ground DPS2 power...
Page 607 Subsection XX (DYNAMIC POWER STEERING (DPS)) DPS Unit Communication Link (CAN) REQUIRED TOOL Continuity Test NOTE: DPS unit must receive an RPM signal to FLUKE 115 provide power steering assist. MULTIMETER (P/N 529 1. Disconnect the DPS control connector and the 035 868) diagnostic connector.
Page 608 Subsection XX (DYNAMIC POWER STEERING (DPS)) vmr2010-003-007 If the electrical system cannot sustain at least mmr2009-023-027_e 12 Vdc, check the following: 1. MIN function selected – Battery 7. Turn the handlebar momentarily against the – Battery connections steering frame stops to each side. –...
Page 609 Subsection XX (DYNAMIC POWER STEERING (DPS)) 5. With the vehicle engine running in PARK, turn – Steering column shim adjustment at half bush- DPS UNIT INSTALLA- the handlebar side to side, momentarily against ings as described in the TION each stop and observe the indications on the procedure detailed in this section.
Page 610 Subsection XX (DYNAMIC POWER STEERING (DPS)) 7. Turn the steering to each side and disengage each tie-rod end from the pitman arm. vmr2010-003-016_a TYPICAL 1. Cut this locking tie 2. Steering column bellows 5. Remove the steering column pinch bolt and re- taining nut.
Page 611 Subsection XX (DYNAMIC POWER STEERING (DPS)) vmr2012-039-014_a DPS REMOVAL - RH SIDE 1. DPS vmr2012-039-016_a 2. RH DPS support bracket TYPICAL - LH DPS SUPPORT BRACKET 3. Remove these screws (2) 1. DPS unit 2. DPS support bracket NOTE: Discard the conical spring washers on the 3.
Page 612 Subsection XX (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 613 Subsection XX (DYNAMIC POWER STEERING (DPS)) vmr2012-039-018_a vmr2010-003-031 A. XPS synthetic grease (P/N 293 550 010) here TYPICAL - STEERING COLUMN INDEXED TO DPS SHAFT SPLINES 5. Insert the steering column onto the DPS input shaft 7. Ensure the following are properly positioned on the lower steering shaft and lower steering 6.
Page 614 Subsection XX (DYNAMIC POWER STEERING (DPS)) vmr2010-003-023_a TYPICAL 1. Pitman arm 2. Tie rod ends inserted in pitman arm 3. Hardened steel washer on tie rod end 9. Install the lower half bushing retainer loosely using NEW fasteners. vmr2012-039-100_a DPS AND STEERING TORQUE SEQUENCE (1 OF 3) vmr2012-039-021_a 1.
Page 615 Subsection XX (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 616: Pitman Arm
Subsection XX (DYNAMIC POWER STEERING (DPS)) vmr2010-003-040 DPS SOFTWARE UPDATE 4. Once the correct DPS software file is installed, vmr2010-003-039_a TYPICAL - LH ILLUSTRATED go to the Faults page and clear the fault codes. 1. Pitman arm 2. Contact point with frame stop TORQUE OFFSET RESET 5.
Page 617 Subsection XX (DYNAMIC POWER STEERING (DPS)) REQUIRED TOOLS REQUIRED TOOL POSITIONING ADAPTOR PITMAN ARM JIG (P/N 529 036 230) (P/N 529 036 225) 4. Insert the DPS input shaft in the Pitman arm jig receptacle with the Pitman arm facing up. vmr2012-039-024_a 1.
Page 618 Subsection XX (DYNAMIC POWER STEERING (DPS)) vmr2012-039-026_b vbs2011-015-008_a 1. Extractor nut 1. Jig upper bar 2. No space here 2. Positioning screw 3. Lock nut 8. Install the universal Pitman arm puller over the Pitman arm and the extractor thrust bearing. 10.
Page 619 Subsection XX (DYNAMIC POWER STEERING (DPS)) REQUIRED TOOL PITMAN ARM JIG (P/N 529 036 225) 2. Apply antizeize lubricant on DPS output shaft splines; completely cover all the splines with a light coat. PRODUCT vmr2012-039-030_a LOCTITE 767 1. Spline keyway alignment here (ANTISEIZE DPS output shaft splines 5.
Page 620 Subsection XX (DYNAMIC POWER STEERING (DPS)) 9. Carry out a steering alignment as described in this subsection. vmr2012-039-032_a vmr2012-039-033_a 1. Ensure proper contact here 7. Unscrew positioning screw and remove pusher adapter and pull out DPS unit. 8. Install Pitman arm retaining washer and nut. Tighten nut as specified.
Page 621: Front Suspension
Subsection XX (FRONT SUSPENSION) FRONT SUSPENSION UPPER SUSPENSION ARMS AND COMPONENTS Outlander XT-P Outlander XT Outlander STD Renegade 800R Renegade XXC Outlander LTD Outlander DPS Renegade 1000 Renegade 500 61 ± 9 N•m (45 ± 7 lbf•ft) 61 ± 9 N•m (45 ±...
Page 622 Subsection XX (FRONT SUSPENSION) LOWER SUSPENSION ARMS AND COMPONENTS 48 ± 6 N•m (35 ± 4 lbf•ft) 3.0 ± 0.5 N•m (27 ± 4 lbf•in) Suspension grease 48 ± 6 N•m (35 ± 4 lbf•ft) Suspension grease 90° from arm axis 4.5 ±...
Page 623: General
Subsection XX (FRONT SUSPENSION) GENERAL Extend and compress the piston several times over its entire stroke. Check that it moves The procedure explained below is the same for smoothly and with uniform resistance with its the RH and LH sides unless otherwise noted. rod upward.
Page 624: Upper Suspension Arm
Subsection XX (FRONT SUSPENSION) PERIODIC Lubricate suspension arm. Refer to MAINTENANCE PROCEDURES subsection. Tighten ball joint nut to specification. TORQUE Nut securing ball joint 48 N•m ± 6 N•m to knuckle (35 lbf•ft ± 4 lbf•ft) Perform steering alignment procedure. Refer to STEERING ALIGNMENT subsection.
Page 625 Subsection XX (FRONT SUSPENSION) tmr2011-035-020 vmr2012-040-006_a TYPICAL - CAREFULLY HIT ON KNUCKLE SIDE 1. Ball joint cotter pin 8. Remove bolt and nut securing suspension arm 5. Remove ball joint nut and washer. to shock absorber. vmr2012-040-008_a vmr2012-040-007_a TYPICAL - SOME PARTS REMOVED FOR CLARITY 1.
Page 626: Suspension Arm Bushings
Subsection XX (FRONT SUSPENSION) Upper Suspension Arm Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. PERIODIC Lubricate suspension arm. Refer to MAINTENANCE PROCEDURES subsection. Install a NEW cotter pin to secure ball joint nut. Both end of cotter pin must be folded.
Page 627 Subsection XX (FRONT SUSPENSION) tmr2011-035-019_a TYPICAL - UPPER BALL JOINT 1. Circlip 3. Install suspension arm on a press. 4. Use an appropriate ball joint remover. tmr2011-035-021 TYPICAL 5. Remove ball joint from suspension arm. NOTICE Make sure that suspension arm is properly supported on the press during ball joint removal.
Page 628 Subsection XX (REAR SUSPENSION) REAR SUSPENSION SERVICE TOOLS Description Part Number Page 529 036 184 ........... 5 SPRING COMPRESSOR ............... SERVICE PRODUCTS Description Part Number Page 293 550 033 ........... 9 SUSPENSION GREASE ..............vmr2013-042...
Page 629 Subsection XX (REAR SUSPENSION) TRAILING ARMS AND ANTI-SWAY BAR 255 ± 10 N•m (188 ± 7 lbf•ft) 24.5 ± 3.5 N•m 3.0 ± 0.5 N•m (18 ± 3 lbf•ft) (27 ± 4 lbf•in) 3.0 ± 0.5 N•m Suspension (27 ± 4 lbf•in) grease Suspension Suspension...
Page 630 Subsection XX (REAR SUSPENSION) SHOCK ABSORBERS Outlander STD Renegade 800R STD Outlander XT-P Outlander XT Outlander DPS Renegade 1000 STD Renegade X xc Renegade 500 vmr2013-042-002_a vmr2013-042...
Page 631: General
Subsection XX (REAR SUSPENSION) GENERAL Extend and compress the piston several times over its entire stroke. Check that it moves The procedure described below is the same for smoothly and with uniform resistance with its the RH and LH sides, unless otherwise instructed. rod upward.
Page 632: Springs
Subsection XX (REAR SUSPENSION) 3. Use an appropriate socket to push bushing. vmr2012-041-020_a tmr2011-036-021 TYPICAL TYPICAL 1. Inner bushing 2. Outer bushing 4. Remove bushing from shock absorber. 5. Install NEW bushings as the reverse of re- moval. 6. Install shock absorber on vehicle. SPRINGS Spring Removal 1.
Page 633: Anti-Sway Bar
Subsection XX (REAR SUSPENSION) on applicable models, install spring cap opening at 180° from spring stopper opening. vmr2012-041-004_a SOME PARTS REMOVED FOR CLARITY 1. Bolt securing anti-sway bar 6. Remove bolts and nuts securing anti-sway bar tmr2011-036-013_a CAP OPENING AT 180° to frame (both sides).
Page 634: Trailing Arm
Subsection XX (REAR SUSPENSION) Anti-Sway Bar Inspection Check anti-sway bar for cracks, bending or other damages. Replace if necessary. Anti-Sway Bar Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Install all retaining bolts of anti-sway bar loosely first.
Page 635 Subsection XX (REAR SUSPENSION) 6. Remove lower nut retaining shock absorber. tmr2011-036-014_a TYPICAL 1. Circlip 2. Install trailing arm on a press. vmr2012-041-011_a 1. Lower nut 3. Use an appropriate bearing remover. 7. Firmly hold trailing arm then remove: 4. Remove drive shaft bearing from trailing arm. –...
Page 636 Subsection XX (REAR SUSPENSION) Install the following NEW parts: – Trailing arm pivot nuts – Pivot bearings – Pivot seals – Circlip. Use an appropriate shaft to center trailing arm in- ner spacer during pivot bearings installation. Install pivot bearings and inner spacer as per the following sequence.
Page 637 Subsection XX (REAR SUSPENSION) Tighten trailing arm pivot nuts as per the following sequence. TIGHTENING SEQUENCE Tighten nut until RH side nut it reaches end of Trailing arm threads pivot nuts 255 N•m ± 10 N•m LH side nut (188 lbf•ft ± 7 lbf•ft) Position link arm bolts with their heads towards inside.
Page 638: Air Controlled Suspension (Acs)
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) AIR CONTROLLED SUSPENSION (ACS) SERVICE TOOLS Description Part Number Page 529 035 868 ..... 9, 12–15, 18–19 FLUKE 115 MULTIMETER ............295 000 070 ........... 20 OETIKER PLIERS................529 036 007 ........... 21 SPRING REMOVER ............... SERVICE PRODUCTS Description Part Number...
Page 639 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) ACS solenoid release valve 53 N•m (39 lbf•ft) Loctite (pipe sealant) compressor vmr2013-043-100_a vmr2013-043...
Page 640: General
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) GENERAL Changing ACS Setting To change the ACS setting proceed as follows: Be careful while manipulating nylon hoses, they must not be kinked. Press MODE (M) button to display AIR_SUSP. CAUTION Always wear safety goggles when working with pressurized air system.
Page 641: System Description (Components)
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) NOTE: If the message is not acknowledged, the ACS SYSTEM suspension will automatically return to setting PRESSURE ACS 3 ZONE LINK WITH TRANSDUCER NOTE: If the Mode (M) button in the multifunc- LOCATION tion gauge is pressed while the acknowledge- High-pressure Shock Inside ACS...
Page 642 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) FRONT FUSE BOX PIN RELAY (R5) TERMINAL 1000 LTD vmr2013-043...
Page 643 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) ACS Main Components ACS COMPONENTS MAIN FUNCTION Filter (air intake) To filter air intake of the compressor Compressor To pressurize the system Solenoid release valve To release air from the system Electronic module To control the compressor or the solenoid release valve To split the air hoses and allows to manually release air in the Manifold system...
Page 644: Troubleshooting
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) TROUBLESHOOTING 2. Check fuse (F14). 3. Check ACS module signal continuity. DIAGNOSTIC TIPS 4. Check ACS module input voltage. Error Code (AIR FAULT) Displayed in 5. Check ACS module ground. Gauge Refer to ACS MODULE to see the complete test- ing procedures.
Page 645: Troubleshooting With B.u.d.s
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) TROUBLESHOOTING WITH B.U.D.S. ACS System Leak Test 1. Connect vehicle to B.U.D.S. Refer to COMMU- NICATION TOOLS AND B.U.D.S. SOFTWARE subsection of the appropriate Shop Manual. 2. Select Activation page. 3. Select ACS folder. 4.
Page 646 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) ACS Solenoid Valve Removal 1. Release air pressure, refer to RELEASING AIR PRESSURE IN SYSTEM FOR SERVICING in this subsection. 2. Disconnect the following hoses and connector from solenoid valve air fittings. – Manifold air inlet hose (from manifold) –...
Page 647 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) vmr2013-043-017_c Install air fittings and check valve as follows. vmr2013-043-024_a 1. Retaining screws 5. Unscrew air fittings and check valve. vmr2013-043-017_d RETAINING SCREWS ARE OFFSET TOWARD MODULE FITTING 1. Manifold air inlet fitting (from manifold) 2.
Page 648: Acs Manifold
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) ACS MANIFOLD ACS Manifold Removal RELEASING AIR 1. Release air pressure, refer to PRESSURE IN SYSTEM FOR SERVICING in this subsection. 2. Disconnect pressure transducer connector. vmr2013-043-026_a 1. Inlet hose (from compressor) 2. Solenoid valve hose 3.
Page 649: Acs Module
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) 4. Set the FLUKE 115 MULTIMETER (P/N 529 035 868) 5. Measure resistance as per the following tables. TEST PROBES RESISTANCE Gauge pin 18 (WH/BK) Close to 0 Module pin 5 (WH/BK) TEST PROBES RESISTANCE Gauge pin 19 (WH/BE) Close to 0...
Page 650 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) vmr2013-043-006_b vmr2013-043-004_a 1. Module hose 1. Module connector NOTICE Do not attempt to disconnect hose 3. Set the FLUKE 115 MULTIMETER (P/N 529 035 from module. to Vdc. 868) 3. Disconnect module connector. 4. Place ignition switch to ON position. 5.
Page 651: Acs Compressor Relay (R5)
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) ACS Module Installation TEST PROBES RESISTANCE The installation procedure is the reverse of re- Terminal 30 moval procedure, however pay attention to the Close to 0 Terminal 87 following. If a new ACS module is installed, check diode (D7) If results are not as per the above tables, replace of the solenoid valve to ensure that it is not de- relay.
Page 652: Acs Compressor
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) 3. Set the FLUKE 115 MULTIMETER (P/N 529 035 868) 4. Measure resistance as per the following table. Outlander 1000 LTD TEST PROBES RESISTANCE Module pin 8 (OR/PK) Close to 0 Relay ground wire (OR/PK) ACS COMPRESSOR vmr2013-043-002_a...
Page 653 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) 7. Set suspension mode to ACS 2 using the ACS button. vmr2013-043-007_b 1. Connector of auxiliary line pressure transducer tmo2013-003-001_b 1. AIR_SUSP displayed 2. Actual setting 7. Disconnect compressor connector. 8. Measure voltage between compressor connec- tor terminals as per the following table.
Page 654 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) 9.3 Pull air hose. 10. Remove compressor support rear retaining bolts and nuts. 11. Remove compressor side retaining bolt and nut. vmr2013-043-013_a TYPICAL 1. Compressor front support mounting bolts vmr2013-043-019_a TYPICAL - PARTS REMOVED FOR CLARITY 1.
Page 655: Acs Air Filter
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) PRESSURE TRANSDUCER ACS Compressor Installation The installation procedure is the reverse of re- Pressure Transducer Signal Circuit moval procedure, however pay attention to the Continuity Test following. 1. Remove seats and RH side panel. If fitting or valve is the one previously removed 2.
Page 656 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) vmr2010-004-108 Pressure Transducer Input Voltage Test 1. Remove seats and RH side panel. 2. Disconnect pressure transducer connector. vmr2013-043-007_b 1. Pressure transducer connector 3. Set the FLUKE 115 MULTIMETER (P/N 529 035 to Vdc. 868) 4.
Page 657: Acs Hoses
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) vmr2013-043-014_a 1. Auxiliary line adapter 2. Fitting ring vmr2013-043-011_a 3. Install new adapter. 1. Auxiliary line pressure transducer 2. Connector 4. Secure adapter support using rivets. 3. Oetiker clamp 5. Connect auxiliary line hose into adapter. 5.
Page 658 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) 3. Unscrew air hose from shock absorber as fol- lows: 3.1 Install an appropriate wrench on shock fit- ting to hold it in place. 3.2 Unscrew air hose fitting using another wrench. vmr2013-043-022_b 1. Shock absorber upper bolt 2.
Page 659 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) Replace shock absorber if any faults are present. Shock Absorber Assembly and Installation Assembly and installation are the reverse of dis- assembly and removal procedures, however pay attention to the following. Assemble shock absorber as per the following il- lustrations.
Page 660 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) vmr2013-043-023_a TYPICAL 1. Small sleeve 2. Lower cap 3. Upper cap 4. Large sleeve Torque upper and lower shock absorber bolts to 53 N•m (39 lbf•ft). If the same shock absorber is reused, apply LOC- on air TITE 592 (PIPE SEALANT) (P/N 293 800 018)
Page 661 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) AIR CONTROLLED SUSPENSION (ACS) SERVICE TOOLS Description Part Number Page 529 035 868 ..... 9, 12–15, 18–19 FLUKE 115 MULTIMETER ............295 000 070 ........... 20 OETIKER PLIERS................529 036 007 ........... 21 SPRING REMOVER ............... SERVICE PRODUCTS Description Part Number...
Page 662 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) ACS solenoid release valve 19 N•m (168 lbf•in) Loctite 592 (pipe sealant) Front 6 N•m Loctite 592 (53 lbf•in) (pipe sealant) Loctite 592 (pipe sealant) compressor 53 N•m (39 lbf•ft) vmr2013-065-101_a vmr2013-065...
Page 663 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) 6 N•m (53 lbf•in) 19 N•m (168 lbf•in) 53 N•m (39 lbf•ft) 53 N•m (39 lbf•ft) vmr2013-065-100_a vmr2013-065...
Page 664 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) GENERAL ACS SUSPENSION SETTINGS Be careful while manipulating nylon hoses, they RIDING SETTING RIDING CONDITION COMFORT must not be kinked. ACS 3 Semi-soft CAUTION Always wear safety goggles Trail riding with cargo ACS 4 Semi-firm when working with pressurized air system.
Page 665 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) The requested setting is controlled by the ACS NOTE: The auxiliary line output pressure will vary electronic module. The module is equipped with according to the ACS suspension setting. The ACS 1 a pressure transducer to keep air pressure con- adjustment will provide less pressure than ACS 6 stant in the system.
Page 666 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) ACS Compressor Relay (R5) Compressor relay is located above the ACS mod- ule. Refer to the following table. RELAY (R5) FRONT FUSE BOX PIN TERMINAL ACS Main Components ACS COMPONENTS MAIN FUNCTION Filter (air intake) To filter air intake of the compressor Compressor To pressurize the system...
Page 667 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) TROUBLESHOOTING 2. Check fuse (F14). 3. Check ACS module signal continuity. DIAGNOSTIC TIPS 4. Check ACS module input voltage. Error Code (AIR FAULT) Displayed in 5. Check ACS module ground. Gauge Refer to ACS MODULE to see the complete test- ing procedures.
Page 668 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) TROUBLESHOOTING WITH B.U.D.S. ACS System Leak Test 1. Connect vehicle to B.U.D.S. Refer to COMMU- NICATION TOOLS AND B.U.D.S. SOFTWARE subsection of the appropriate Shop Manual. 2. Select Activation page. 3. Select ACS folder. 4.
Page 669 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) ACS Solenoid Valve Removal 1. Release air pressure, refer to RELEASING AIR PRESSURE IN SYSTEM FOR SERVICING in this subsection. 2. Disconnect the following hoses and connector from solenoid valve air fittings. – Manifold air inlet hose (from manifold) –...
Page 670 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) ACS Solenoid Valve Installation The installation procedure is the reverse of re- moval procedure, however pay attention to the following. If fitting is the one previously removed (old one), apply LOCTITE 592 (PIPE SEALANT) (P/N 293 800 018) on all male fittings.
Page 671 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) 4. To disconnect hoses, proceed as follows: 4.1 Push fitting ring toward manifold. 4.2 Hold ring in place. 4.3 Pull air hose. vmo2010-011-102_a TYPICAL - PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED 1. Fitting 2.
Page 672 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) TEST PROBES RESISTANCE Gauge pin 18 (WH/BK) Close to 0 Module pin 5 (WH/BK) TEST PROBES RESISTANCE Gauge pin 19 (WH/BE) Close to 0 Module pin 6 (WH/BE) ACS Module Input Voltage Test 1. Remove seat and RH side panel. vmr2013-043-028_a 2.
Page 673 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) vmr2013-065-008_a vmr2013-065-008_b 1. Module connector 1. Module hose NOTICE 3. Set the Do not attempt to disconnect hose FLUKE 115 MULTIMETER (P/N 529 035 to Vdc. from module. 868) 4. Place ignition switch to ON position. 3.
Page 674 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) ACS Module Installation TEST PROBES RESISTANCE The installation procedure is the reverse of re- Terminal 30 moval procedure, however pay attention to the Close to 0 Terminal 87 following. If a new ACS module is installed, check diodes If results are not as per the above tables, replace D7, D8, D9 to ensure that it is not defective as relay.
Page 675 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) 3. Set the FLUKE 115 MULTIMETER (P/N 529 035 TEST PROBES RESISTANCE 868) Module pin 8 (OR/PK) 4. Measure resistance as per the following table. Close to 0 Relay ground wire (OR/PK) TEST PROBES RESISTANCE Compressor pin C ACS COMPRESSOR...
Page 676 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) 8. Measure voltage between compressor connec- tor terminals as per the following table. TEST PROBES VOLTAGE Pin C (RD/WH) Battery voltage (± 12 Vdc) Pin A (BK) ACS Compressor Removal RELEASING AIR 1. Release air pressure, refer to PRESSURE IN SYSTEM FOR SERVICING in this subsection.
Page 677 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) vmr2013-043-013_a TYPICAL 1. Compressor front support mounting bolts vmr2013-043-019_a TYPICAL - PARTS REMOVED FOR CLARITY 1. Compressor support rear retaining bolts 2. Compressor support side retaining bolt 12. Remove compressor front retaining screw. vmr2013-043-003_a TYPICAL 1.
Page 678 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) If fitting or valve is a new one, do not apply sealant, it should be already applied on male threads. Ensure that check valve is installed with arrows pointing toward the manifold. vmr2013-065-008_a 1. Module connector 3.
Page 679 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) Pressure Transducer Input Voltage Test 1. Remove seat and RH side panel. 2. Disconnect pressure transducer connector. vmr2013-065-007_a 1. Pressure transducer connector 3. Set the FLUKE 115 MULTIMETER (P/N 529 035 to Vdc. 868) 4.
Page 680: Shock Absorbers Front & Rear
Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) vmr2013-043-014_a TYPICAL 1. Auxiliary line adapter vmr2013-065-012_a 2. Fitting ring 1. Auxiliary line pressure transducer 2. Connector 3. Install new adapter. 3. Oetiker clamp 4. Secure adapter support using rivets. 5. Install a new pressure transducer on hose. 5.
Page 681 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) 2. Install jack stands or blocks under the frame to support the vehicle. 3. Unscrew air hose from shock absorber as fol- lows: 3.1 Install an appropriate wrench on shock fit- ting to hold it in place. 3.2 Unscrew air hose fitting using another wrench.
Page 682 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) Replace shock absorber if any faults are present. Shock Absorber Assembly and Installation Assembly and installation are the reverse of dis- assembly and removal procedures, however pay attention to the following. Assemble shock absorber as per the following il- lustrations.
Page 683 Subsection XX (AIR CONTROLLED SUSPENSION (ACS)) NOTICE Never screw shock absorber air hose by using the air hose fitting only. To avoid damaging the shock fitting threads, in- stall a wrench on the shock fitting to hold it in place while screwing the air hose fitting. vmr2013-043-023_a TYPICAL - REAR SHOCK SHOWN 1.
Page 684: Brakes
Subsection XX (BRAKES) BRAKES SERVICE TOOLS Description Part Number Page 529 036 166 ........... 13 ECM ADAPTER TOOL..............SERVICE PRODUCTS Description Part Number Page 219 701 705 ........... 16 XPS BRAKES AND PARTS CLEANER ........... 293 550 010 ........... 15 XPS SYNTHETIC GREASE.............
Page 685 Subsection XX (BRAKES) OUTLANDER (FRONT CIRCUIT) All Except CE Models 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 61 ± 9 N•m (45 ± 7 lbf•ft) 33.5 ± 3.5 N•m (25 ± 3 lbf•ft) To rear circuit 5.5 ± 1.5 N•m (49 ±...
Page 686 Subsection XX (BRAKES) OUTLANDER (REAR CIRCUIT) All Except CE Models 33.5 ± 3.5 N•m (25 ± 3 lbf•ft) 61 ± 9 N•m (45 ± 7 lbf•ft) 0.7 ± 0.1 N•m (6 ± 1 lbf•in) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 28.5 ±...
Page 687 Subsection XX (BRAKES) OUTLANDER (FRONT CIRCUIT) CE Models 61 ± 9 N•m (45 ± 7 lbf•ft) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 33.5 ± 3.5 N•m (25 ± 3 lbf•ft) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) To rear circuit 5.5 ±...
Page 688 Subsection XX (BRAKES) OUTLANDER (REAR CIRCUIT) CE Models 33.5 ± 3.5 N•m (25 ± 3 lbf•ft) 61 ± 9 N•m (45 ± 7 lbf•ft) 0.7 ± 0.1 N•m (6 ± 1 lbf•in) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 28.5 ±...
Page 689 Subsection XX (BRAKES) RENEGADE (FRONT CIRCUIT) All Except CE Models 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 28.5 ± 1.5 N•m 61 ± 9 N•m (21 ± 1 lbf•ft) (45 ± 7 lbf•ft) 33.5 ± 3.5 N•m (25 ± 3 lbf•ft) To rear circuit 5.5 ±...
Page 690 Subsection XX (BRAKES) RENEGADE (REAR CIRCUIT) All Except CE Models 33.5 ± 3.5 N•m (25 ± 3 lbf•ft) 61 ± 9 N•m (45 ± 7 lbf•ft) 0.7 ± 0.1 N•m (6 ± 1 lbf•in) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 28.5 ±...
Page 691 Subsection XX (BRAKES) RENEGADE (FRONT CIRCUIT) CE Models 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) To rear circuit 33.5 ± 3.5 N•m (25 ± 3 lbf•ft) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) To rear circuit 61 ±...
Page 692 Subsection XX (BRAKES) RENEGADE (REAR CIRCUIT) CE Models To front circuit 61 ± 9 N•m (45 ± 7 lbf•ft) 33.5 ± 3.5 N•m (25 ± 3 lbf•ft) 0.7 ± 0.1 N•m (6 ± 1 lbf•in) To front circuit XPS synthetic grease 27.5 ±...
Page 693 Subsection XX (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 1.4 ± 0.1 N•m (12 ±...
Page 694: General
Subsection XX (BRAKES) GENERAL RENEGADE LH BRAKE RH BRAKE BRAKE WARNING MODELS LEVER LEVER PEDAL Always check brake system operation after Controls removing or servicing a brake component. All except Controls Controls front CE models rear brakes rear brakes brakes NOTICE Avoid spilling brake fluid on plastic, Controls...
Page 695: Procedures
Subsection XX (BRAKES) vmr2012-042-006_a A. Distance from handlebar (refer to table) vmr2012-042-007_a 4. Read load recorded by the force gauge. A. Distance to push (refer to table) 5. Load reading must be as per the following table. 4. Read load recorded by the force gauge. BRAKE LEVER VERIFICATION 5.
Page 696 Subsection XX (BRAKES) vmr2012-035-005_a RH BRAKE LEVER 1. Brake light switch 2. Brake light switch connector vmr2012-035-004_a BRAKE PEDAL MASTER CYLINDER 1. Brake light switch 2. Brake light switch connector Renegade Models BRAKE SWITCH LOCATIONS BRAKE FRONT MODELS PEDAL RH BRAKE BRAKE MASTER LEVER...
Page 697: Brake Pedal
Subsection XX (BRAKES) 529036166 Brake Light Switch Replacement Brake Light Switch Located on Brake Lever vmr2012-042-001_a TYPICAL - SOME PARTS REMOVED FOR CLARITY 1. Disconnect brake light switch connector. 1. Master cylinder support 2. Replace brake light switch by a new one. 5.
Page 698: Master Cylinder
Subsection XX (BRAKES) Install NEW brake pedal O-ring. Lubricate brake pedal pivot. LUBRICATION XPS SYNTHETIC Brake pedal pivot GREASE (P/N 293 550 010) Tighten brake pedal nut as per the following se- quence. TIGHTENING SEQUENCE STEP Brake pedal bolt 10 N•m ± 2 N•m (pivot) (89 lbf•in ±...
Page 699: Brake Pads
Subsection XX (BRAKES) TORQUE 61 N•m ± 9 N•m Caliper retaining screws (45 lbf•ft ± 7 lbf•ft) BRAKE PADS Brake Pads Replacement CALIPER REMOVAL 1. Remove caliper, refer to this subsection. 2. Remove pin retainer securing brake pad pin. tmr2011-037-010_a TYPICAL 1.
Page 700: Brake Disc
Subsection XX (BRAKES) 7. Ensure brake pad spring is properly positioned onto caliper and not damaged. vmr2012-042-014_a 1. Caliper support 13. Install caliper, refer to CALIPER INSTALLA- TION in this subsection. BRAKE DISC vmr2012-042-011_a BRAKE PAD SPRING Brake Disc Inspection 8.
Page 701 Subsection XX (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. TORQUE 33.5 N•m ± 3.5 N•m Brake disc screws (25 lbf•ft ± 3 lbf•ft) 7. Install wheel hub then caliper. 8.
Page 702 Subsection 07 (BRAKES) BRAKES SERVICE TOOLS Description Part Number Page 529 036 166 ........... 8 ECM ADAPTER TOOL..............SERVICE PRODUCTS Description Part Number Page 219 701 705 ........... 11 XPS BRAKES AND PARTS CLEANER (USA) ......... 293 550 010 ........... 9 XPS SYNTHETIC GREASE.............
Page 703 Subsection 07 (BRAKES) OUTLANDER (FRONT CIRCUIT) 28,5 N•m (21 lbf•ft) 4,5 N•m (40 lbf•in) 61 N•m (45 lbf•ft) 33,5 N•m (25 lbf•ft) To rear circuit 5,5 N•m (49 lbf•in) 4,5 N•m (40 lbf•in) 4,5 N•m 28,5 N•m (21 lbf•ft) (40 lbf•in) 4,5 N•m (40 lbf•in) 33,5 N•m...
Page 704 Subsection 07 (BRAKES) OUTLANDER (REAR CIRCUIT) 33,5 N•m (25 lbf•ft) 0,7 N•m (6 lbf•in) 61 N•m (45 lbf•ft) 28,5 N•m (21 lbf•ft) 5 N•m (44 lbf•in) 28,5 N•m (21 lbf•ft) 4,5 N•m (40 lbf•in) To front circuit 4,5 N•m 24,5 N•m (40 lbf•in) (18 lbf•ft) XPS synthetic grease...
Page 705 Subsection 07 (BRAKES) OUTLANDER (FRONT CIRCUIT) 1000 61 N•m (45 lbf•ft) 28,5 N•m (21 lbf•ft) 4,5 N•m 33,5 N•m (40 lbf•in) (25 lbf•ft) 4,5 N•m (40 lbf•in) 28,5 N•m (21 lbf•ft) 4,5 N•m (40 lbf•in) To rear circuit 5,5 N•m (49 lbf•...
Page 706 Subsection 07 (BRAKES) OUTLANDER (REAR CIRCUIT) 1000 33,5 N•m (25 lbf•ft) 61 N•m (45 lbf•ft) 28,5 N•m (21 lbf•ft) 0,7 N•m 4,5 N•m (6 lbf•in) (40 lbf•in) 5 N•m (44 lbf•in) 28,5 N•m (21 lbf•ft) To front circuit 4,5 N•m 24,5 N•m (40 lbf•in) (18 lbf•ft)
Page 707 Subsection 07 (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 1.4 ± 0.1 N•m (12 ±...
Page 708 Subsection 07 (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 709 Subsection 07 (BRAKES) PERIODIC MAINTENANCE NOTE: Refer to PROCEDURES subsection. Brake Pedal Verification NOTE: Do not pump up the brakes repeatedly be- fore doing the validation. 1. Position force gauge perpendicularly on brake pedal edge. 2. Position a ruler perpendicularly to brake pedal. 3.
Page 710 Subsection 07 (BRAKES) Brake Light Switch Located on Master Cylinder or Manifold 1. Disconnect brake light switch connector. 2. Drain brake line. 3. Remove brake light switch. NOTE: Use shop rags to catch any spilled brake fluid. 4. Install NEW sealing washers. 5.
Page 711 Subsection 07 (BRAKES) 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 712 Subsection 07 (BRAKES) vmr2012-042-008_a TYPICAL vmr2012-042-009_a 1. Caliper screws 1. Pin retainer 6. Place caliper assembly onto a support. 3. Remove brake pad pin from caliper. NOTICE Do not let caliper hangs by the hose and do not stretch or twist hose. Caliper Installation The installation is the reverse of the removal pro- cedure.
Page 713 Subsection 07 (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. Check disc surfaces for scratches or grooves on both sides.
Page 714 Subsection 07 (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. TORQUE 33.5 N•m ± 3.5 N•m Brake disc screws (25 lbf•ft ± 3 lbf•ft) 7. Install wheel hub then caliper. 8.
Page 715: Body (Outlander X Mr)
Subsection XX (BODY (OUTLANDER)) BODY (OUTLANDER) SERVICE TOOLS Description Part Number Page 295 000 070 ........... 12 OETIKER PLIERS................vmr2013-045...
Page 716 Subsection XX (BODY (OUTLANDER)) BODY PARTS NOMENCLATURE (SHORT MODEL) vmr2013-045-106_a 1. Gauge support 11. Front bumper 2. Console 12. Hood 3. Seat 13. Front rack 4. Rear top panel (under rear rack) 14. Front fascia 5. Rear rack 15. Rear fascia 6.
Page 717 Subsection XX (BODY (OUTLANDER)) BODY PARTS NOMENCLATURE (MAX MODEL) vmr2013-045-112_a 1. Gauge support 11. Inner fender panels 2. Console 12. Front bumper 3. Seat 13. Hood 4. Passenger seat 14. Front rack 5. Rear top panel (under rear rack) 15. Front fascia 6.
Page 718 Subsection XX (BODY (OUTLANDER)) FRONT AND REAR BODY MODULES (SHORT MODEL) vmr2012-043-100_a 1. Front body module (TYPICAL) 2. Rear body module (TYPICAL) vmr2013-045...
Page 719 Subsection XX (BODY (OUTLANDER)) FRONT AND REAR BODY MODULES (MAX MODEL) vmr2013-045-105 1. Front body module (TYPICAL) 2. Rear body module (TYPICAL) vmr2013-045...
Page 720 Subsection XX (BODY (OUTLANDER)) BODY PARTS (SHORT MODEL) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) See AIR INTAKE SYSTEM See FRAME 4.5 ± 0.5 N•m (40 ± 4 lbf•in) LH side shown, RH side identical vmr2012-043-102_a vmr2013-045...
Page 721 Subsection XX (BODY (OUTLANDER)) BODY PARTS (MAX MODEL) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) LH side shown, RH side identical vmr2013-045-109_a vmr2013-045...
Page 722 Subsection XX (BODY (OUTLANDER)) RACKS AND BODY PARTS 4.5 ± 0.5 N•m 4.5 ± 0.5 N•m (40 ± 4 lbf•in) (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 ±...
Page 723 Subsection XX (BODY (OUTLANDER)) BUMPERS AND BODY PARTS On applicable models CE models 16 ± 2 N•m (142 ± 18 lbf•in) 1.6 ± 0.4 N•m (14 ± 4 lbf•in) See FRAME 16 ± 2 N•m (142 ± 18 lbf•in) 4.5 ± 0.5 N•m (40 ±...
Page 724 Subsection XX (BODY (OUTLANDER)) REAR STORAGE COMPARTMENT CE models 4.5 ± 0.5 N•m (40 ± 4 lbf•in) Outlander MAX CE models 27 ± 2 N•m (20 ± 1 lbf•in) 10 ± 2 N•m 14 ± 1 N•m (89 ± 18 lbf•in) (124 ±...
Page 725 Subsection XX (BODY (OUTLANDER)) PASSENGER SEAT 3.75 ± 0.25 N•m (33± 2 lbf•in) 1.6 ± 0.1 N•m (14± 9 lbf•in) 1.4 ± 0.1 N•m (12 ± 9 lbf•in) 25 ± 3 N•m (18 ± 2 lbf•ft) 10 ± 2 N•m (89±...
Page 726: Procedures
Subsection XX (BODY (OUTLANDER)) PROCEDURES FRONT BODY MODULE Front Body Module Removal PLASTIC RIVET 1. Disconnect battery negative (-) cable. Plastic rivets are used in the riveting of the vari- 2. Remove the following panels, see procedure in ous body parts. Plastic rivets can be reused many this subsection.
Page 727 Subsection XX (BODY (OUTLANDER)) 8. Remove screws securing front body module to frame. vmr2012-043-003_a RH SIDE SHOWN 1. Headlight connectors 6. Remove screw securing front fender to footrest vmr2012-043-006_a RH SIDE panel (on both sides). 1. Front body module retaining screw vmr2012-043-004_a vmr2012-043-007_a TYPICAL...
Page 728 Subsection XX (BODY (OUTLANDER)) 10. With the assistance of a person, pull front body module forward. 11. Install front body module on a stable and clean support. Front Body Module Installation The installation is the reverse of the removal pro- cedure.
Page 729 Subsection XX (BODY (OUTLANDER)) 8. Remove muffler upper retaining bolt. vmr2012-043-016_a vmr2012-043-014_a LH SIDE 1. Muffler upper retaining bolt 1. Rear body module lower retaining bolts 9. Remove rear body module upper retaining bolts. vmr2012-043-017_a RH SIDE - SOME PARTS REMOVED FOR CLARITY 1.
Page 730: Rear Body Module
Subsection XX (BODY (OUTLANDER)) 12. Detach rear fender from footrest panel by re- TIGHTENING TORQUE leasing retaining tabs (on both sides). 4.5 N•m ± 0.5 N•m Rear top panel screws (40 lbf•in ± 4 lbf•in) CONSOLE Console Removal 1. Remove seat. 2.
Page 731: Console
Subsection XX (BODY (OUTLANDER)) GAUGE SUPPORT LIGHTS, GAUGE AND ACCESSORIES Refer to subsection. INNER FENDER PANELS Inner Fender Removal and Installation Remove the following plastic rivets from inner fender panels. vmr2012-043-023_a 1. Plastic rivet securing side panel 3. Remove plastic rivet securing side panel to air filter housing.
Page 732 Subsection XX (BODY (OUTLANDER)) LUGGAGE 5. Remove luggage tray. Refer to TRAY 6. Lift rear portion of side panel assembly then pull it towards outside. NOTE: For Short Models, side panel assembly includes side panel and panel extension. NOTE: For Max Models, side panel assembly in- cludes side panel, panel extension and rear side panel extension.
Page 733 Subsection XX (BODY (OUTLANDER)) 4. Using a screwdriver, unclip retaining tabs secur- ing rear top panel to rear storage compartment. vmr2013-045-010_c vmr2013-045-017_a 1. Retaining screws securing luggage tray to frame PARTS REMOVED FOR CLARITY 2. Rivets securing luggage tray to rear side panel extension 1.
Page 734 Subsection XX (BODY (OUTLANDER)) vmr2012-043-027_a TYPICAL - FOOTREST PANEL RETAINING SCREWS 2. Remove screw securing front fender to footrest vmr2012-043-022_b SOME PARTS REMOVED FOR CLARITY panel. 4. Remove screw securing rear fender to footrest panel. vmr2012-043-004_a TYPICAL 1. Screw securing front fender vmr2012-043-018_a 3.
Page 735 Subsection XX (BODY (OUTLANDER)) vmr2012-043-028_a TYPICAL vmr2012-043-019_a 1. Screw securing footrest panel TYPICAL 1. Rear fender retaining tabs 6. Detach front fender from footrest panel by re- leasing retaining tabs. 8. Remove footrest panel from vehicle. Max Models 1. Remove footrest panel retaining screws. vmr2012-043-005_a TYPICAL 1.
Page 736 Subsection XX (BODY (OUTLANDER)) 2. Remove screw securing rear fender to footrest panel. 3. Remove plastic rivet securing footrest panel to rear side panel extension. 4. Remove plastic rivet securing footrest panel to frame. vmr2013-045-050_a TYPICAL - RH SIDE DOWN 1.
Page 737 Subsection XX (BODY (OUTLANDER)) PASSENGER GRIPS 8. Detach front fender from footrest panel by re- leasing retaining tabs. Passenger Grips Removal 1. Remove retaining screw securing passenger grips and remove passenger grips. vmr2012-043-005_a TYPICAL 1. Front fender retaining tabs 9. Detach rear fender from footrest panel by relea- vsi2013-001-012_a sing retaining tabs.
Page 738 Subsection XX (BODY (OUTLANDER)) vmr2013-045-020_a TYPICAL - PARTS REMOVED FOR CLARITY vmr2013-045-021_a 1. Retaining bolts locations TYPICAL - LH SIDE OF ASSEMBLY SHOWN ON VEHICLE FOR CLARITY 2. Remove rack assembly from vehicle. 1. Retaining bolt securing rack support to rail 3.
Page 739 Subsection XX (BODY (OUTLANDER)) vmr2012-043-030_a TYPICAL vmr2013-045-011_a 1. Retaining nuts and bolts securing rack to frame 3. Install a new rear storage compartment cover 2. Frame 3. Rack assembly as the reverse of removal. 2. Remove rack from vehicle. Rear Storage Compartment 3.
Page 740 Subsection XX (BODY (OUTLANDER)) 7. Remove retaining screw securing RH rear stor- age compartment support to rear storage com- partment. vmr2013-045-030_a 1. Retaining screw securing LH rear storage compartment support to rear storage compartment 2. Retaining screw securing LH support and LH rear storage compartment support to rear storage compartment vmr2013-045-031_a 1.
Page 741: 13. Inner Fender Panels
Subsection 08 (BODY (OUTLANDER X mr)) BODY (OUTLANDER X mr) SERVICE TOOLS Description Part Number Page 295 000 070 ........... 10 OETIKER PLIERS................BODY PARTS NOMENCLATURE (X mr 650) vmr2013-067-101_a 1. Gauge support 11. Panel extension 2. Console 12. Front fender 3.
Page 742 Subsection 08 (BODY (OUTLANDER X mr)) BODY PARTS NOMENCLATURE (X mr 1000) vmr2013-067-100_a 1. Gauge support 13. Rear side panel extension 2. Console 14. Side panel 3. Seat 15. Panel extension 4. Glove box 16. Front fender 5. Rear top panel (under rear rack) 17.
Page 743 Subsection 08 (BODY (OUTLANDER X mr)) FRONT AND REAR BODY MODULES (X mr 650) vmr2013-067-111_a 1. Front body module (TYPICAL) 2. Rear body module (TYPICAL) vmr2013-067...
Page 744 Subsection 08 (BODY (OUTLANDER X mr)) FRONT AND REAR BODY MODULES (X mr 1000) vmr2013-067-110_a 1. Front body module (TYPICAL) 2. Rear body module (TYPICAL) vmr2013-067...
Page 745 Subsection 08 (BODY (OUTLANDER X mr)) BODY PARTS (X mr 650) 4,5 N•m (40 lbf•in) vmr2013-067-107_a vmr2013-067...
Page 746 Subsection 08 (BODY (OUTLANDER X mr)) BODY PARTS (X mr 1000) 4,5 N•m (40 lbf•in) LH side shown, RH side identical = Component must be replaced when removed. vmr2013-067-108_b vmr2013-067...
Page 747 Subsection 08 (BODY (OUTLANDER X mr)) RACKS AND BODY PARTS 4.5 N•m (40 lbf•in) 4.5 N•m (40 lbf•in) 1.6 N•m ( 14 lbf•in) 4.5 N•m (40 lbf•in) 4.5 N•m (40 lbf•in) vmr2013-067-109_a vmr2013-067...
Page 748 Subsection 08 (BODY (OUTLANDER X mr)) BUMPERS AND BODY PARTS 1000 1,6 N•m (14 lbf•in) 1000 See FRAME 16 N•m (142 lbf•in) 4,5 N•m (40 lbf•in) 1,6 N•m (14 lbf•in) vmr2013-067-106_a vmr2013-067...
Page 749 Subsection 08 (BODY (OUTLANDER X mr)) REAR STORAGE COMPARTMENT 45 N•m (40 lbf•in) 27 N•m (20 lbf•in) 10 N•m 14 N•m (89 lbf•in) (124 lbf•in) vmr2013-067-112_b vmr2013-067...
Page 750 Subsection 08 (BODY (OUTLANDER X mr)) PROCEDURES FRONT BODY MODULE Front Body Module Removal PLASTIC RIVET 1. Disconnect battery negative (-) cable. Plastic rivets are used in the riveting of the vari- 2. Remove the following panels, see procedure in ous body parts.
Page 751 Subsection 08 (BODY (OUTLANDER X mr)) 8. Disconnect headlights connectors. vmr2012-043-005_a 1. Front fender retaining tabs 11. Remove screws securing front body module vmr2012-043-003_a to frame. TYPICAL - RH SIDE SHOWN 1. Headlight connectors 9. Remove screw securing front fender to footrest panel (on both sides).
Page 752 Subsection 08 (BODY (OUTLANDER X mr)) vmr2012-043-009_a vmr2012-043-008_a TYPICAL TYPICAL - RH SIDE SHOWN 1. Rear top panel retaining screws 1. Screw securing front fender 4. Disconnect taillights connectors. 13. With the assistance of a person, pull front body module forward. 14.
Page 753 Subsection 08 (BODY (OUTLANDER X mr)) vmr2012-043-013_a vmr2012-043-016_a 1. Voltage regulator rectifier connectors LH SIDE 1. Rear body module lower retaining bolts 7. Remove muffler upper retaining bolt. vmr2012-043-017_a RH SIDE - SOME PARTS REMOVED FOR CLARITY vmr2012-043-014_a 1. Rear body module lower retaining bolts 1.
Page 754 Subsection 08 (BODY (OUTLANDER X mr)) TIGHTENING TORQUE 4.5 N•m ± 0.5 N•m Rear top panel screws (40 lbf•in ± 4 lbf•in) CONSOLE Console Removal 1. Remove seat. 2. Lift rear portion of console upwards. vmr2012-043-019_a TYPICAL 1. Rear fender retaining tabs 12.
Page 755: Side Panels
Subsection 08 (BODY (OUTLANDER X mr)) INNER FENDER PANELS Inner Fender Removal and Installation Remove the following plastic rivets from inner fender panels. vmr2012-043-024_a 1. Plastic rivet securing side panel 4. Remove plastic rivet securing side panel (X mr 650 Models) or rear side panel extension (X mr 1000 Models) to rear fender.
Page 756: Panel Extensions
Subsection 08 (BODY (OUTLANDER X mr)) 6. Remove panel extension. Panel Extension Installation Installation is the reverse of removal. LUGGAGE TRAY (X mr 1000 MODELS) Luggage Tray Removal 1. Remove seat. 2. Remove retaining screws securing luggage tray and rear top panel to frame. vmr2012-043-026_a LIFT REAR PORTION Side Panel Installation...
Page 757: Rear Side Panel Extensions (X Mr 1000 Models)
Subsection 08 (BODY (OUTLANDER X mr)) Luggage Tray Installation 5. Slide rear top panel forward to free it from rear storage compartment retaining tab. Installation is the reverse of removal. However pay attention to the following: TIGHTENING TORQUE Luggage tray retaining 4.5 N•m ±...
Page 758 Subsection 08 (BODY (OUTLANDER X mr)) vmr2013-067-502_a SCREWS TO REMOVE vmr2013-067-501_a 5. Remove screw securing footrest panel to SCREWS TO REMOVE frame. 3. Remove both plastic rivet securing inner fender panel to footrest panel. vmr2012-043-028_a TYPICAL 1. Screw securing footrest panel 6.
Page 759 Subsection 08 (BODY (OUTLANDER X mr)) 7. Detach rear fender from footrest panel by relea- sing retaining tabs. vmr2013-067-301_a LH FOOTREST PANEL RETAINING SCREWS vmr2012-043-019_a TYPICAL 1. Rear fender retaining tabs 8. Remove footrest panel from vehicle. X mr 1000 Models 1.
Page 760: Upper Bumper
Subsection 08 (BODY (OUTLANDER X mr)) 5. Remove plastic rivet securing footrest panel to panel extension. 6. Remove plastic rivet securing footrest panel to frame. 7. Remove screw securing front fender to footrest panel. vmr2012-043-019_a TYPICAL 1. Rear fender retaining tabs 10.
Page 761: Rack
Subsection 08 (BODY (OUTLANDER X mr)) Remove retaining screw securing upper bumper TIGHTENING TORQUE to front fender and frame. 4.5 N•m ± 0.5 N•m Screws and nuts securing rear rack to rail (40 lbf•in ± 4 lbf•in) Screws an nuts securing 4.5 N•m ±...
Page 762 Subsection 08 (BODY (OUTLANDER X mr)) vmr2013-045-028_a vmr2013-045-029_a 1. Retaining screws securing bottom of RH rear storage 1. Retaining screw securing top of RH fender to top of rear storage compartment support compartment 5. Remove retaining screws securing RH rear 10.
Page 763 Subsection 08 (BODY (OUTLANDER X mr)) vmr2013-045-027_a 1. Retaining screws securing LH fender to rear storage compartment 13. Remove rear storage compartment. Rear Storage Compartment Installation Installation is the reverse of removal. However pay attention to the following: TIGHTENING TORQUE 4.5 N•m ±...
Page 764 Subsection XX (BODY (RENEGADE)) BODY (RENEGADE) SERVICE TOOLS Description Part Number Page 295 000 070 ........... 7 OETIKER PLIERS................vmr2013-046...
Page 765 Subsection XX (BODY (RENEGADE)) BODY PARTS NOMENCLATURE REAR body module FRONT body module vmr2012-047-100_a REAR BODY MODULE - FRONT BODY MODULE 1. Gauge support 2. Console 3. Rear fender 4. Side panel 5. Footrest panel 6. Engine panel (RH side only) 7.
Page 766 Subsection XX (BODY (RENEGADE)) BODY PARTS CE model 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 1.6 ± 0.4 N•m (14 ± 4 lbf•in) 2.5 ± 0.5 N•m (22 ± 4 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) LH SIDE SHOWN, RH SIDE IDENTICAL vmr2012-047-101_a vmr2013-046...
Page 767 Subsection XX (BODY (RENEGADE)) BODY PARTS See FRAME 4.5 ± 0.5 N•m On applicable models (40 ± 4 lbf•in) 2.5 ± 0.5 N•m (22 ± 4 lbf•in) vmr2012-047-102_a vmr2013-046...
Page 768 Subsection XX (BODY (RENEGADE)) BODY PARTS 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 4.5 ± 0.5 N•m (40 ±...
Page 769 Subsection XX (BODY (RENEGADE)) REAR BUMPER 23 ± 2 N•m (17 ± 1 lbf•ft) 2.5 ± 0.5 N•m (22 ± 4 lbf•in) 2.5 ± 0.5 N•m (22 ± 4 lbf•in) 10 ± 2 N•m (89 ± 18 lbf•in) 10 ± 2 N•m (89 ±...
Page 770 Subsection XX (BODY (RENEGADE)) PROCEDURES FRONT BODY MODULE Front Body Module Removal PLASTIC RIVET CONSOLE 1. Remove . See procedure in this sub- Plastic rivets are used in the riveting of the vari- section. ous body parts. Plastic rivets can be reused many GAUGE SUPPORT LIGHTS, 2.
Page 771 Subsection XX (BODY (RENEGADE)) vmr2012-047-005_a SOME PARTS REMOVED FOR CLARITY vmr2012-047-003_a 1. Bolt securing front body module to bumper FROM UNDERNEATH LH FRONT FENDER 1. Ignition switch connector 10. Remove front fuse box from its support. 8. Remove screws securing front fender to footrest panel (on both sides).
Page 772 Subsection XX (BODY (RENEGADE)) 12. Remove front body module by pulling it for- wards. 13. Install front body module on an appropriate support. Front Body Module Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Tighten front body module fasteners to specifica- tion.
Page 773 Subsection XX (BODY (RENEGADE)) 8. Place a clean rag into fuel tank filler tube. 5. Remove console by pulling it rearwards. 9. Remove rear body module by pulling it rear- wards. 10. Install rear body module on an appropriate support. 11.
Page 774 Subsection XX (BODY (RENEGADE)) vmr2012-047-015_a RH SIDE PANEL SHOWN vmr2012-047-013_a 1. Lower tab SOME PARTS REMOVED FOR CLARITY 1. Plastic rivets (3 on LH side) 4. Remove side panel by pulling it outwards. Inner Fender Panel Installation Side Panel Installation The installation is the reverse of the removal pro- The installation is the reverse of the removal pro- cedure.
Page 775 Subsection XX (BODY (RENEGADE)) vmr2012-047-004_a TYPICAL 1. Screw securing front fender 4. Remove screw securing rear fender to footrest panel. vmr2012-047-009_a TYPICAL 1. Screw securing rear fender 5. Remove footrest panel from vehicle. Footrest Panel Installation The installation is the reverse of the removal pro- cedure.
Page 776 Subsection XX (FRAME) FRAME SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page model 9600 ........... 3 BLIND THREADED INSERT INSTALLER........vmr2013-047...
Page 777 Subsection XX (FRAME) 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) Models Rear frame 24.5 ± 3.5 N•m extension (18 ± 3 lbf•ft) 24.5 ± 3.5 N•m 61 ± 9 N•m (18 ± 3 lbf•ft) (45 ± 7 lbf•ft) 61 ± 9 N•m (45 ±...
Page 778 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. Frame Insert Replacement To install a new blind threaded insert, use the fol-...
Page 779: Technical Specifications
Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) OUTLANDER SERIES (500/650/800R/1000) SERVICE PRODUCTS Description Part Number Page 293 550 019 ........... 11 CV GREASE................... 293 600 121 ..........5 XPS 4-STROKE SYNTH. BLEND OIL (SUMMER) ......293 600 112 ..........5 XPS 4-STROKE SYNTHETIC OIL (ALL CLIMATE) ......
Page 780 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) ENGINE (CONT'D) 34° ABDC Intake valve closing 45° ABDC 800R 1000 60° ABDC 39° BBDC 50° BBDC Exhaust valve opening 800R 55° BBDC 1000 2° ATDC 0° ATDC Exhaust valve closing 800R 5°...
Page 781 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) ENGINE (CONT'D) 0.20 mm to 0.40 mm (.008 in to .016 in) Rectangular Service limit 0.60 mm (.024 in) 0.20 mm to 0.40 mm (.008 in to .016 in) Ring end gap Tapered face Service limit 0.70 mm (.028 in)
Page 782 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) ENGINE (CONT'D) 42.016 mm to 42.040 mm (1.6542 in to 1.6551 in) Crankshaft main bearing journal diameter (MAG/PTO side) 42.000 mm (1.6535 in) Service limit Crankshaft radial play (MAG/PTO side) Service limit 0.07 mm (.0028 in) 34.004 mm to 34.020 mm (1.3387 in to 1.3394 in) Crankshaft bearing journal diameter (in PTO cover)
Page 783 API service classification SG, SH or SJ COOLING SYSTEM Ethyl glycol/water mix (50% coolant, 50% water). Type Use premixed coolant sold by BRP (P/N 219 700 362) or coolant specifically designed for aluminum engines Coolant 500/650/800R 3.4 L (.9 U.S. gal.)
Page 784 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) TRANSMISSION (CONT’D) 55.000 mm to 55.040 mm (2.165 in to 2.167 in) Drive pulley sliding half large bushing 55.200 mm (2.173 in) Service limit 32.000 mm to 32.040 mm (1.26 in to 1.261 in) Drive pulley sliding half small bushing Service limit 32.200 mm (1.268 in)
Page 785 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) GEARBOX (CONT’D) 400 ml (13.5 U.S. oz) Capacity 800R 1000 450 ml (15.22 U.S. oz) Gearbox oil XPS SYNTHETIC GEAR OIL (75W 140) (P/N 293 600 140) Recommended 800R or a 75W140 API GL-5 synthetic gear oil 1000 0.10 mm to 0.20 mm (.004 in to .008 in) Service limit...
Page 786 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) GEARBOX (CONT'D) N.A. Service limit 17.990 mm (.7083 in) 800R MAG side 19.977 mm to 19.990 mm (.7865 in to .787 in) 1000 Service limit 19.973 mm (.7863 in) N.A. Service limit 24.970 mm (.9831 in) 800R Countershaft...
Page 787 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) ELECTRICAL SYSTEM (CONT'D) Type Maintenance free Voltage 12 volts Battery Nominal rating 18 A•h Power starter 0.7 KW output High 2 x 60 W Headlights 2 x 55 W Taillights 2 x 8/27 W Turn signal lights (CE models only) 4 x 10 W Position lights (CE models only)
Page 788 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) ELECTRICAL SYSTEM (CONT’D) 30 A – Main – Fan – Main 40 A accessories power – DPS motor 40 A – ACS (if equipped) – Brake lights relay control – Gauge 10 A –...
Page 789 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) FUEL SYSTEM (CONT'D) Type Regular unleaded gasoline Inside North 87 (R+M)/2 or higher Fuel America Minimum octane rating Outside North 92 RON or higher America 20.5 L (5.4 U.S. gal.) Fuel tank capacity Fuel remaining when low fuel light turns ON ±...
Page 790 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) FRONT SUSPENSION (CONT’D) 340 mm (13.39 in) 1-UP 350 mm (13.78 in) XT-P 387 mm (15.24 in) Spring free length 354 mm (13.94 in) 2-UP XT-P 362 mm (14.25 in) 1000 LTD Standard models Models with DPS 5 positions cam...
Page 791 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) BRAKES Front brake 214 mm cross drilled disc brakes with hydraulic Type twin-piston calipers Rear brake 214 mm cross drilled disc brake with hydraulic Type twin-piston caliper Capacity 260 ml (8.8 U.S. oz) Brake fluid Type DOT 4...
Page 792 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) CHASSIS SST G2 Steel DIMENSIONS Standard Models 218.4 cm (86 in) Models with DPS 1-UP XT Models 226.3 cm (89.1 in) XT-P Models Overall length Standard Models 238.8 cm (94 in) Models with DPS 2-UP XT Models...
Page 793 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) WEIGHT AND LOADING CAPACITY 331 kg (729 lb) 500 with DPS 338 kg (743 lb) 500 XT 365 kg (802 lb) 337 kg (740 lb) 800R 650 with DPS 344 kg (756 lb) 1-UP 800R with DPS 650 XT...
Page 794 Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) WEIGHT AND LOADING CAPACITY (CONT’D) 581 kg (1,277 lb) 500 with DPS 588 kg (1,293 lb) 500 XT 615 kg (1,352 lb) 587 kg (1,290 lb) 650 with DPS 594 kg (1,306 lb) 800R with DPS 1-UP 650 XT...
Page 795: Outlander Series X Mr (650/1000)
Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES X mr (650/1000)) OUTLANDER SERIES X mr (650/1000) ENGINE ROTAX 660, 4-stroke, 2 cylinders (V-twin), liquid cooled Engine type ROTAX 1010, 4-stroke, 2 cylinders (V-twin), 1000 liquid cooled 4 valves/cylinder (mechanical adjustment), single Valve train over head camshaft (SOHC) with timing chain 82 mm (3.23 in)
Page 796 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES X mr (650/1000)) ENGINE (CONT'D) 0.005 mm (.0002 in) Intake and Valve out of round exhaust 0.06 mm (.0024 in) Service limit 4.998 mm to 5.018 mm (.1968 in to .1976 in) Valve guide diameter Service limit 5.050 mm (.1988 in)
Page 797 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES X mr (650/1000)) ENGINE (CONT'D) 34.959 mm to 34.975 mm (1.3763 in to 1.377 in) Timing chain side 34.950 mm (1.376 in) Service limit Camshaft main bearing journal 21.959 mm to 21.980 mm (.8645 in to .8654 in) Spark plug side Service limit 21.950 mm (.8642 in)
Page 798 If not available, use a 5W30 motor oil that meets the requirements for API service classification SG, SH or SJ COOLING SYSTEM Ethyl glycol/water mix (50% coolant, 50% water). Use premixed coolant sold by BRP Type (P/N 219 700 362) or coolant specifically Coolant designed for aluminum engines 3.5 L (.9 U.S.
Page 799 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES X mr (650/1000)) TRANSMISSION (CONT'D) 6.113 mm to 6.171 mm (.241 in to .243 in) Drive pulley sliding half centrifugal lever pivot bolt bore diameter 6.300 mm (.248 in) Service limit 55.000 mm to 55.040 mm (2.165 in to 2.167 in) Drive pulley sliding half large bushing Service limit 55.200 mm (2.173 in)
Page 800 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES X mr (650/1000)) GEARBOX (CONT'D) 0.10 mm to 0.20 mm (.004 in to .008 in) Service limit 0.25 mm (.01 in) Output shaft backlash N.A. 1000 Service limit N.A. 5.25 mm to 5.35 mm (.207 in to .211 in) Coupling sleeve groove width Service limit 5.50 mm (.217 in)
Page 801 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES X mr (650/1000)) GEARBOX (CONT'D) 24.984 mm (.9836 in) Free pinion Bevel gear shaft Service limit bearing 1000 N.A. N.A. Service limit N.A. Free pinion bearing 24.987 mm to 25.000 mm (.9837 in to .9843 in) 1000 Service limit 24.984 mm (.9836 in)
Page 802 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES X mr (650/1000)) ELECTRICAL SYSTEM (CONT'D) -Main 30 A -Fan 40 A -Main accessories power -DPS motor 40 A -ACS (if equipped) -Brake lights relay control -Gauge -Taillights 10 A -Brake relay -DPS control -Ignition coils -Fuel injectors...
Page 803 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES X mr (650/1000)) DRIVE SYSTEM Drive system type Selectable 2WD/4WD Open differential with Visco-lok, straight Front drive bevel gears Front drive ratio 3.6:1 Angle drive with straight bevel gears Rear drive 1000 Angle drive with spiral bevel gears Rear drive ratio 3.6:1...
Page 804 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES X mr (650/1000)) REAR SUSPENSION (CONT'D) Type Shock absorber 1000 Type 0.35 bar to 6.90 bar 1000 ACS pneumatic pressure range (5 PSI to 100 PSI) 5 position cam Preload adjustment type 1000 BRAKES Front brake...
Page 805 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES X mr (650/1000)) DIMENSIONS 2 250 mm (88.58 in) Overall length 1000 2 460 mm (97 in) 1 180 mm (46.5 in) Overall width 1000 1 270 mm (50 in) 800 mm (31.5 in) Handlebar overall width 1000 780 mm (30.7 in)
Page 806 Section 01 TECHNICAL SPECIFICATIONS Subsection 02 (RENEGADE SERIES(500/800R/1000)) RENEGADE SERIES(500/800R/1000) SERVICE PRODUCTS Description Part Number Page 293 550 019 ........... 26 CV GREASE................... 293 600 121 ........... 21 XPS 4-STROKE SYNTH. BLEND OIL (SUMMER) ......293 600 112 ........... 21 XPS 4-STROKE SYNTHETIC OIL (ALL CLIMATE) ......
Page 807 Section 01 TECHNICAL SPECIFICATIONS Subsection 02 (RENEGADE SERIES(500/800R/1000)) ENGINE (CONT'D) Intake 0.06 mm to 0.14 mm (.0024 in to .0055 in) Valve clearance 0.11 mm to 0.19 mm (.0043 in to .0075 in) Exhaust 4.966 mm to 4.980 mm (.1955 in to .1961 in) Intake Service limit 4.930 mm (.1941 in)
Page 808 Section 01 TECHNICAL SPECIFICATIONS Subsection 02 (RENEGADE SERIES(500/800R/1000)) ENGINE (CONT'D) 82.023 mm to 82.037 mm (3.2293 in to 3.2298 in) Cylinder bore 800R 90.993 mm to 91.007 mm (3.5824 in to 3.583 in) 1000 Maximum 0.038 mm (.0015 in) Cylinder taper 0.090 mm (.0035 in) Service limit Maximum...
Page 809 Connecting rod/piston pin clearance (radial play) Service limit 0.080 mm (.0031 in) LUBRICATION SYSTEM Type Wet sump. Replaceable cartridge oil filter Oil filter BRP Rotax paper type, replaceable Engine oil pressure Minimum 300 kPa (44 PSI) at 6000 RPM vmr2012-045...
Page 810 API service classification SG, SH or SJ COOLING SYSTEM Ethyl glycol/water mix (50% coolant, 50% water). Type Use premixed coolant sold by BRP (P/N 219 700 362) or coolant specifically designed for aluminum engines Coolant 3.4 L (.9 U.S. gal.)
Page 811 Section 01 TECHNICAL SPECIFICATIONS Subsection 02 (RENEGADE SERIES(500/800R/1000)) TRANSMISSION (CONT’D) 30.060 mm to 30.100 mm (1.183 in to 1.185 in) Driven pulley sliding fixed bushing 30.200 mm (1.189 in) Service limit Torque gear on driven pulley Service limit 7.500 mm (.295 in) 190 mm (7.48 in) Driven pulley spring free length Service limit...
Page 812 Section 01 TECHNICAL SPECIFICATIONS Subsection 02 (RENEGADE SERIES(500/800R/1000)) GEARBOX (CONT’D) 0.10 mm to 0.20 mm (.004 in to .008 in) 800R Service limit 0.25 mm (.01 in) Output shaft backlash N.A. 1000 Service limit N.A. 5.25 mm to 5.35 mm (.207 in to .211 in) Coupling sleeve groove width Service limit 5.50 mm (.217 in)
Page 813 Section 01 TECHNICAL SPECIFICATIONS Subsection 02 (RENEGADE SERIES(500/800R/1000)) GEARBOX (CONT’D) N.A. 800R Service limit Free pinion bearing 24.987 mm to 25.000 mm (.9837 in to .9843 in) 1000 Service limit 24.984 mm (.9836 in) Main shaft N.A. 800R Service limit N.A.
Page 814 Section 01 TECHNICAL SPECIFICATIONS Subsection 02 (RENEGADE SERIES(500/800R/1000)) ELECTRICAL SYSTEM (CONT'D) 30 A – Main – Fan – Main 40 A accessories power 40 A – DPS motor – Brake lights relay control – Gauge 10 A – Taillights – Brake relay –...
Page 815 Section 01 TECHNICAL SPECIFICATIONS Subsection 02 (RENEGADE SERIES(500/800R/1000)) FUEL SYSTEM (CONT'D) Type Regular unleaded gasoline Inside North 87 (R+M)/2 or higher Fuel America Minimum octane rating Outside North 92 RON or higher America 20.5 L (5.4 U.S. gal.) Fuel tank capacity Fuel remaining when low fuel light turns ON ±...
Page 816 Section 01 TECHNICAL SPECIFICATIONS Subsection 02 (RENEGADE SERIES(500/800R/1000)) REAR SUSPENSION Torsional Trailing arm Independant (TTI) with Suspension type external sway bar Suspension travel 236 mm (9.3 in) Renegade Renegade X Shock absorber Renegade FOX Racing Shox HPG shocks (gas) Type FOX Racing Shox HPG piggyback shocks (gas) with Renegade X xc dual-speed compression, rebound...
Page 817 Section 01 TECHNICAL SPECIFICATIONS Subsection 02 (RENEGADE SERIES(500/800R/1000)) WHEELS (CONT’D) Renegade Front Renegade X 305 x 152 mm (12 x 6 in) Rim size Renegade Rear Renegade X 305 x 191 (12 x 7.5 in) Wheel nut torque 100 N•m ± 10 N•m (74 lbf•ft ± 7 lbf•ft) CHASSIS SST G2 Steel...
Page 818 Subsection XX (WIRING DIAGRAM INFORMATION) WIRING DIAGRAM INFORMATION GENERAL WIRING DIAGRAM LOCATION The wiring diagram are located in the back cover pocket. WIRING DIAGRAM CODES Fuse Identification Front Fuse Box WIRING DIAGRAM The fuses are identified on the as per the following example: vmr2012-046-002_a FUSE IDENTIFICATION 1.
Page 819 Subsection XX (WIRING DIAGRAM INFORMATION) Multifunction Switch Identification XX/XX- 18 2-BF-A V06G1GA THE SHADED PART INDICATES THE WIRE GAUGE Example: The number that follows the wire color indicates the wire size used, in this case 18 gauge wire. Connector Housing Location Area XX/XX-18 -BF-A vmr2012-046-004_a...
Page 820 Subsection XX (WIRING DIAGRAM INFORMATION) TROUBLESHOOTING XX/XX-18 2- BF -A DIAGNOSTIC TIPS IMPORTANT: When trying to solve an electrical V06G1JA problem, check the following: THE SHADED PART INDICATES A CONNECTOR – The ignition switch is turned ON. NOTE: For a complete list of the connector iden- –...
Page 821 Subsection XX (WIRING DIAGRAM INFORMATION) Simplifying Electrical System Tests IMPORTANT: In an electrical circuit, the battery usually provides power to a switch, which then For complex systems where there are electronic supplies the electric component when the switch modules, sensors, actuators, relays etc., it is of- contacts are closed (low power circuits).
Page 822 2013-2015 (G2)
Page 823 2013-2015 (G2)
Page 824 2013-2015...
Page 825 2013-2015...
Page 826 TERMINAL IDENTIFICATION MAX. CURRENT MAX. FUSE CURRENT MAX. WATT ZONE # ZONE DESCRIPTION WELDED JOINT FRAME GROUND COLOR CODE OUTLANDER 2013 BEIGE 100 amps 125 amps 1450 watts SHRINKED JOINT EGINE GROUND STEERING AREA BLACK NAME ZONE-CONNECTOR NAME-TERMINAL #/A 65 amps 80 amps 930 watts MAIN...

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