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Related Manuals for BOMBARDIER OUTLANDER 2004
Summary of Contents for BOMBARDIER OUTLANDER 2004
- Page 2 2004 Shop Manual Supplement OUTLANDER 400/400 XT MAX/MAX XT (Models dedicated to be used within the European community) This supplement must be used in conjunction with the 2004 Bombardier Outlander ATV Shop Manual (P/N 219 100 180).
- Page 3 National Library of Quebec trimester 2003 National Library of Canada 2003 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 2003 Technical Publications Bombardier Inc.
- Page 4 06 – Instruments and accessories ........05-06-1 ➁ DRIVE TRAIN 01 – Table of contents..............06-01-1 ➁ 02 – Front drive ................06-02-1 ➁ 03 – Rear drive ................06-03-1 *2004 Bombardier Outlander ATV Shop Manual (P/N 219 100 180). SHOP 219 100 180 VMR2004_113_00_02A.FM...
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Page 5: Table Of Contents
TECHNICAL DATA 01 – SI metric information guide..........11-01-1 ➀ ➁ 02 – Engine and vehicle ............11-02-1 ➀ WIRING DIAGRAM 01 – Wiring diagram..............12-01-1 *2004 Bombardier Outlander ATV Shop Manual (P/N 219 100 180). SHOP 219 100 180 VMR2004_113_00_02A.FM... -
Page 6: Safety Notice
Always use common shop safety practice. This information relates to the preparation and use of Bombardier ATV and has been utilized safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. - Page 7 INTRODUCTION INTRODUCTION This Shop Manual covers the following Bombardier made 2004 ATVs: Models Outlander 400 (viper red) ....8108 Outlander 400 (yellow) ....... 8110 Outlander 400 XT (yellow) ....8111 Outlander 400 MAX XT (yellow)..8112 Outlander 400 MAX (viper red)..8130 Outlander 400 XT (two tones)....
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Page 8: List Of Abbreviations Used In This Manual
INTRODUCTION LIST OF ABBREVIATIONS USED liter IN THIS MANUAL left hand ampere pound ampere pound (force) A•h ampere-hour meter alternate current magneto bottom dead center Max. maximum BTDC before top dead center Min. minimum °C degree Celsius milliliter Capacitor discharge ignition millimeter centimeter mile per hour... -
Page 9: General Information
Due to late changes, there may be some differences between the manufactured product and the descrip- tion and/or specifications in this document. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. - Page 10 INTRODUCTION CAUTION: Where possible, apply the torque on the nut. NOTE: Always torque screws, bolts and/or nuts in a criss-cross sequence. TIGHTEN- STRENGTH GRADE Grade 5.8 Grade 8.8 Grade 10.9 Grade 12.9 TORQUE 1.5 to 2 N•m 2.5 to 3 N•m 3.5 to 4 N•m 4 to 5 N•m (13 to 18 lbf•in)
- Page 11 Page______ ❏ ❏ Machine___________________ Report of error Suggestion ____________________________________________________________ We would be pleased if you could ____________________________________________________________ communicate to Bombardier any sug- gestions you may have concerning our publications. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ____________________________________________________ City and State/Prov. ________________________...
- Page 12 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0...
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Page 13: Drive Pulley
2. Drive pulley WARNING 3. Driven pulley Any drive pulley repairs must be performed by Refer to CVT section of 2004 Bombardier Outland- an authorized Bombardier ATV dealer. Sub- er ATV Shop Manual for drive pulley maintenance component installation and assembly toler- and repair. -
Page 14: Section 04 Fuel System
Carburetor Inspection Remove carburetor from vehicle (refer to CARBU- RETOR REMOVAL from 2004 Bombardier Out- lander ATV Shop Manual). Remove carburetor throttle shaft cover. Make sure that M4 Allen screw is still in place and tight. - Page 15 Bombardier Part Number 404 162 055 Mikuni Part Number 785-401003-O-0 Reinstall carburetor into vehicle (refer to CARBU- RETOR REMOVAL from 2004 Bombardier Out- lander ATV Shop Manual). Throttle Cable Verify also throttle cable adjustment. Refer to THROTTLE CABLE ADJUSTMENT from 2004 Bombardier Outlander ATV Shop Manual.
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Page 16: Section 05 Electrical
Section 05 ELECTRICAL Subsection 06 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES REMOVAL AND INSTALLATION NOTE: On the following illustrations, the head- lamp has been removed for a better comprehen- sion. WARNING Remove the protective rubber sleeve. It is recommended to always disconnect the battery when replacing any electric or elec- tronic parts. - Page 17 Section 05 ELECTRICAL Subsection 06 (INSTRUMENTS AND ACCESSORIES) TYPICAL TYPICAL Push bulb in and hold while turning counterclock- Install the protective rubber sleeve and connect wise to release. the headlamp connector. Install the new bulb by first pushing in while turn- NOTE: Take care do not pry the socket terminals.
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Page 18: Brake Lamp
Section 05 ELECTRICAL Subsection 06 (INSTRUMENTS AND ACCESSORIES) BRAKE LAMP Bulb Replacement Unscrew lens screws to expose bulb. 1. Lens 2. Screws Reinstall direction indicator lens. Push bulb in and hold while turning courterclock- wise to release. Removal Install the new bulb by first pushing in while turn- Unplug direction indicator wires from harness. -
Page 19: Direction Indicator Switch
Section 05 ELECTRICAL Subsection 06 (INSTRUMENTS AND ACCESSORIES) DIRECTION INDICATOR SWITCH Removal Unscrew and remove steering cover. Unscrew both sets of nut and screw retaining switch. Unscrew plastic button. 1. Switch 2. Screws 3. Connector Remove locking ties and unplug connector. Installation For installation, reverse the removal procedure. -
Page 20: Pin Number
1. Actuator 2. 2WD/4WD Connector (must be unplugged) Installation Remember that, when riding on public roads, For installation, reverse the removal procedure. Bombardier Outlander ATV must be set on 4WD mode. TESTS DIRECTION INDICATORS Note: Flashing rate: Approximately 72 cycles per minute. - Page 21 Section 05 ELECTRICAL Subsection 06 (INSTRUMENTS AND ACCESSORIES) Check: Check: in good condition Check: Check: in good condition 05-06-6 VMR2004_115_05_06A.FM...
- Page 22 Section 05 ELECTRICAL Subsection 06 (INSTRUMENTS AND ACCESSORIES) Direction indicator’s pilot lamp Unscrew console and check pilot lamp’s contacts for short circuit or broken wire. Interchange wires at pilot lamp’s contacts. If this doesn’t solve the problem, reinstall wires as they were first.
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Page 23: Steering System
For the installation, reverse the removal procedure. During assembly/installation, use torque values and service products from the exploded view in RIGHT AND LEFT REAR MIRRORS 2004 Bombardier Outlander ATV Shop Manual. Clean threads before applying a threadlocker. Re- Removal fer to SELF-LOCKING FASTENER and LOCTITE APPLICATION at the beginning of this manual for Unscrew mirror stem from mirror support. -
Page 24: Installation
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING SYSTEM) Installation Left side Make sure mirror support is tighten then screw mirror stem into mirror support. Right side Secure right side mirror using U-clamp, lock wash- er and nut. 07-02-2 VMR2004_116_07_02A.FM... -
Page 25: Suspension
VEHICLE MODEL OUTLANDER 400 / 400 XT / MAX / MAX XT ENGINE Refer to 2004 Bombardier Outlander ATV Shop Manual Refer to 2004 Bombardier Outlander ATV Shop Manual except for: Head lamp 35 W Brake lamp 10 W ELECTRICAL... -
Page 26: Wiring Diagram
Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) WIRING DIAGRAM WIRING CONNECTORS CODING WARNING Ensure all terminals are properly crimped on the wires and all connector housings are prop- erly fastened. AREA LOCATION Steering area 1. Wire colors 2. Connector housing area Service compartment 3. - Page 27 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) CONNECTOR LOCATION IN LEGEND HOUSING This is the wire position in the connector. The number or letter given refers to the physical identification stamped on the connector. NOTE: However, if no letters or numbers are indi- cated on the connectors, see the connector chart at the end of the OVERVIEW section for proper connector locations.
- Page 28 12-01-3 VMR2004_118_12_01A.FM...
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