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Can-Am Manuals
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commander 1000
Shop manual
Can-Am commander 1000 Shop Manual
2011 side-by-side vehicles
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Table Of Contents
424
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424
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424
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Safety Notice
Engine Identification Number (EIN)
Introduction
Vehicle Information
VIN Decal Description
Hoisting the Vehicle
Rear of Vehicle
Engine Emissions Information
Owner Responsibility
Transporting the Vehicle
Manual Information
Manual Layout
Manual Procedures
Fastener Grade/Torque
Tightening Torque
Application Procedure
Fastener Information
Self-Locking Fasteners Procedure
Threadlocker Application for Blind Holes
Threadlocker Application for an Adjustment Screw
Threadlocker Application for Pre-Assembled Parts
Threadlocker Application for Stud Installation in Blind Holes
Application for Stripped Thread Repair
Gasket Compound Application
Mounting with a Press
Standard Thread Repair
Threadlocker Application for Case-In Components
Service Tools Index
Fuse Box
Maintenance
Break-In Inspection
Periodic Maintenance Schedule
Periodic Maintenance Procedures
Air Filter Replacement
General
Air Filter Installation
Muffler Spark Arrester Cleaning and Inspection
Engine Oil Level Verification
Engine Oil and Filter
Engine Oil Change
Engine Oil Filter Replacement
Oil Filter Removal
Engine Coolant Level Verification
Oil Filter Installation
Recommended Engine Coolant
Cooling System Draining
Engine Coolant Replacement
Engine Coolant Specific Gravity Check
Cooling System Drain Plug Torque
Radiator Hose Clamp
Bleed Screw Installation
Cooling System Bleeding
Cooling System Inspection
Coolant Expansion Tank Vents
Cooling System Leak Test
Cvt Air Filter Cleaning
Engine Valve Clearance Adjustment
Pressure Cap Test
Valve Clearance
CVT Air Filter
Cvt Air Inlet/Outlet Cleaning
Drive Belt Inspection
Drive Pulley, Driven Pulley and One-Way Bearing Maintenance
Gearbox Oil Level Verification
Gearbox Oil Replacement
Battery Inspection
Fuel Pump Prefilter Cleaning
Fuel Pump Pressure Test
Fuel System Inspection
Fuel Tank Vent Breather Filter Replacement
Spark Plug Replacement
Throttle Body Inspection
Front Differential Oil Level Verification
Front Differential Oil Replacement
Vehicle Speed Sensor (Vss) Cleaning
Drive Shaft Boot and Protector (Visual Inspection)
Rear Final Drive Oil Level Verification
Rear Final Drive Oil Replacement
Drive Shaft Joint Inspection
Propeller Shaft U-Joint Condition
Propeller Shaft U-Joint Lubrication
Shock Absorber Inspection
Shock Absorber Spherical Bearing Lubrication
Steering System Inspection
Wheel Bearing Inspection
Wheel Lug Nut Torque Check
Front Suspension Arm Lubrication
Spherical Bearing Lubrication
Brake Disc
Brake Fluid Replacement
Brake Pads
Brake System Inspection and Cleaning
Bleeding Procedure Using a Vacuum Pump
Brake Fluid Bleeding
Brake Fluid Filling
Manual Bleeding Procedure
Bleeder Torque
Passenger Handhold Condition
Tow Hitch Inspection
Preseason Preparation
Engine Internal Lubrication
Fuel System Protection
Storage
Storage Oil
Battery Removal
Chassis Lubrication
Drive System
Vehicle Cleaning
Rolled over Vehicle
Special Procedures
Submerged Vehicle
Engine Removal and Installation
Engine Removal
ENGINE, CVT and GEARBOX (Cont'D)
Vehicle and Engine Preparation
Lifting Engine
Vehicle Speed Sensor
Engine Installation
Engine Mount Installation
Engine Mount Removal
Final Assembly
Air Intake System
Air Filter Housing
Air Filter Housing Removal
Exhaust System
Muffler
Muffler Inspection
Muffler Removal
Spark Arrester
Exhaust Pipe
Exhaust Pipe Inspection
Exhaust Pipe Removal
Head Pipe
Rear Cylinder
Rear Head Pipe Inspection
Rear Head Pipe Installation
Rear Head Pipe Removal
Lubrication System
Engine Lubrication Circuit
Engine Oil Pressure
Low or no Oil Pressure
High Oil Consumption
Oil Contamination
Oil Cooler Inspection
Oil Cooler Installation
Engine Oil Pressure Regulator
Oil Pressure Switch
Oil Pressure Switch Activation
Oil Pressure Switch Removal
Oil Pressure Regulator Inspection
Oil Pressure Regulator Installation
Oil Pump
Oil Pump Removal
Oil Pump Inspection
Engine Oil Strainer
Oil Pump Final Test
Oil Pump Installation
Oil Strainer Removal
Oil Strainer Cleaning and Inspection
Oil Strainer Installation
Reed Valve
Reed Valve Installation
Cooling System
Radiator
General
Procedures
Thermostat
Thermostat Removal
Radiator Inspection
Radiator Removal
Thermostat Installation
Thermostat Test
Coolant Temperature Sensor (Cts)
Radiator Cooling Fan Relay (R1)
Radiator Installation
Relay Installation
Radiator Cooling Fan
Radiator Cooling Fan Operation
Relay Continuity Test
Radiator Cooling Fan Fuse Location
Radiator Cooling Fan Test
Radiator Cooling Fan Removal
Water Pump Housing
Water Pump Housing Inspection
Water Pump Housing Removal
Water Pump Housing
Water Pump Impeller
Water Pump Impeller Installation
Water Pump Shaft and Seals
Oil Seal
Rotary Seal
Rotary Seal and Oil Seal Installation
Magneto System
General
Magneto Cover
Magneto Cover Access in Vehicle
Magneto Cover Inspection and Cleaning
Magneto Cover Removal
Procedures
Stator
Stator Connector Access
Stator Static Test
Rotor
Stator Inspection
Stator Installation
Stator Removal
Stator Static Test Insulation
Rotor Inspection
Rotor Installation
Sprag Clutch
Sprag Clutch Removal
Sprag Clutch Gear
Sprag Clutch Gear Removal
Sprag Clutch Inspection
Sprag Clutch Installation
Sprag Clutch Gear Installation
Starter Drive Gear Inspection
Starter Drive Gear Installation
Starter Drive Gears
Top End
Intake Manifold
Cylinder Head No. 1
Cylinder Head No. 2
Cylinders and Pistons
General
Inspection
Leak Test
Preparation
Diagnosis
Intake Manifold Removal
Procedures
Intake Manifold Installation
Valve Cover Inspection
Valve Cover Installation
Valve Cover Removal
Rocker Arm Removal
Rocker Arm Bore Diameter
Rocker Arm Inspection
Rocker Arm Installation
Rocker Arm Shaft
Cylinder Head
Cylinder Head Access
Cylinder Head Inspection
Cylinder Head Installation
Camshaft Removal
Camshaft Inspection
Camshaft Journal
Camshaft Lobe
Camshaft Installation
Valve Spring Removal
Valve Springs
Valve Spring Free Length
Valve Spring Inspection
Valve Spring Installation
Valve Inspection
Valve Removal
Valve Stem Seal
Valves
Intake Valve
Valve Installation
Valve Stem Diameter
Valve Guide Inspection
Valve Guide Installation
Valve Guide Removal
Cylinder
Cylinder Installation
Cylinder out of Round
Cylinder Taper in Diameter
Piston Installation
Piston Measurement
Piston Removal
Connecting Rod/Piston Pin Clearance
Piston Pin Diameter
Connecting Rod Small End Diameter
Engine Type
Lower Compression Ring
Piston Rings
Ring Inspection
Ring Removal
Oil Scraper Ring
Ring End Gap
Ring Installation
Timing Chain
Engine Lacks Acceleration or Power
General
Procedures
Timing Chain Tensioners
Troubleshooting
Unusual Engine Noise or Vibration
Timing Chain Tensioner Adjustment
Timing Chain Tensioner Inspection
Timing Chain Tensioner Installation
Camshaft Timing Gear Inspection
Camshaft Timing Gear Installation
Camshaft Timing Gear Removal
Camshaft Timing Gears
Camshaft Timing
Camshaft Timing Cylinder 2
Camshaft Timing Cylinder 1
Timing Chain Guide (Tensioner Side)
Timing Chain Removal
Timing Chain Removal PTO Side
Timing Chain Inspection
Timing Chain Installation
Timing Chain Guide
Timing Chain Guide Inspection
Timing Chain Guide Removal
Bottom End
Engine Drive Shaft
Crankcase and PTO Cover
Crankshaft
Engine Drive Shaft Removal
General
Oil Seal Replacement
Procedures
Engine Drive Shaft Inspection
Engine Drive Shaft Installation
PTO Cover Oil Seal
PTO Oil Seal Inspection
PTO Oil Seal Installation
PTO Oil Seal Removal
PTO Cover
PTO Cover Installation
PTO Cover Removal
Plain Bearing Installation
Plain Bearing Removal
Drive Gear Removal
Drive Gears
Breather Gear
Crankcase
Crankcase Disassembly
Drive Gears Inspection
Crankcase Cleaning
Crankcase Inspection
Oil Strainer
Plain Bearing Installation
Crankcase Assembly
Crankshaft Locking
Connecting Rod Big End Axial Play
Crankshaft Axial Play
Crankshaft Inspection
Connecting Rod Big End Radial Play
Crankshaft Radial Play MAG/PTO Side
Crankshaft Assembly
Crankshaft Journal Diameter
Crankshaft Radial Play
Crankshaft Installation
Continuously Variable Transmission
CVT Cover
CVT Cover Access
CVT Cover Draining
CVT Cover Removal
CVT Cover Installation
Drive Belt Installation
Drive Belt Removal
Drive Pulley Removal
First Locking Method
Second Locking Method
Drive Pulley Disassembly
Drive Pulley Removal Continuation
Governor Cup
Sliding Sheave
Drive Pulley Cleaning
Fixed Sheave
Bushings
Drive Pulley Inspection
Roller and Slider Shoe
Roller Outer Diameter
Centrifugal Lever Bore Diameter
Sliding Sheave Large Bushing
Clutch Spring Squareness
One-Way Clutch
Sliding Sheave Small Bushing
Spring
Drive Pulley Installation
Driven Pulley
Driven Pulley Removal
Driven Pulley Disassembly
Driven Pulley Cleaning
Driven Pulley Inspection
Bushing Bore Diameter
Bushings Bore Diameter
Wear on Teeth both Sides
Driven Pulley Assembly
Spring Free Length
Wear on Contact Surface
Width on Top Surface
Driven Pulley Installation
CVT Air Guide Inspection
CVT Air Guide Installation
CVT Air Guide Removal
Gearbox and 4X4 Coupling Unit
Gearbox Components and 4X4 Coupling Mechanism
Gear Indication Fails
Gear(S) Is (Are) Hard to Shift
Gearbox Overview
Unusual Gearbox Noise And/Or Vibrations
VSS Access
VSS Circuit Protection
VSS Input Voltage Test
VSS Location
GBPS Reset
VSS Installatoin
VSS Removal
GBPS Access
GBPS Communication Link Continuity Test
Multimeter Probe Positions
4WD Indicator Switch
4WD Indicator Switch Access
4WD Indicator Switch Test
GBPS Removal
Actuator
Actuator Access
Actuator Installation
Actuator Removal
Gearbox Oil Seal Replacement
Gearbox Oil Seals
Shift Drum Shaft Oil Seal
Shift Shaft Oil Seal
Gearbox Removal
Output Shaft Oil Seal
Gearbox Disassembly
Gearbox Left Cover
Position for Soft Hammer
Index Lever and Index Washer
Main Shaft and Shift Forks
Gearbox Right Cover
Shift Shaft and Shift Drum
Output Shaft and 4X4 Coupling Mechanism
Countershaft
Gearbox Bearings
Bearings
Diameter Free Pinion
Free Pinions
Gearbox Inspection
Bearing Pin Outer Diameter
Countershaft Bearing Journals
CVT Side
Width of Shift Fork Engagement
Bearing Journal CVT/MAG Side
Free Pinion Bearing
Main Shaft
Shift Fork Claw Thickness
Coupling Fork
Coupling Sleeve Groove Width
Gearbox Assembly
Sealing Compound Application
Shift Lever
Shifter Cable
Engine Management System
Diagnostic Mode
Fuel System
Limp Home Mode
Monitoring System
Communication Tools and B.U.D.S.
Diagnostic Tips
Status Lights
USB Light
Missing Module
Module List
No Vehicle Detected
Connecting the PC to the Vehicle
Diagnostic Connector Location
Mpi-2
MPI-2 Power
B.U.D.S. Software
How to Establish Communication Using B.U.D.S. Software
Electronic Modules Updates
Writing Changes
Diagnostic System and Fault Codes
Pilot Lamps
Active Fault Codes
Fault Codes
Inactive Fault Codes
Occurred Fault Codes
Analog/Digital Gauge
LCD Gauge
Park Brake
Specific Faults
TAS Fault
TPS Fault
Intelligent Throttle Control
Normal/Sport Modes
Performance Key
System Main Features
Override Switch
Seat Belt Switch
Sport/Normal Switch
Throttle Accelerator
TAS Failure
TAS Test with B.u.D.s
TAS Wire Information
Air Filter
EFI Sensors
Electronic Fuel Injection (Efi)
General
System Description
Adjustment
Fuel Injectors
Fuel Rail
Idle Speed
Diagnostic Tips
ECM First Initialization
Engine Control Module (Ecm)
Procedures
Quick Test to Validate ECM Operation
Troubleshooting
ECM Access
ECM Connector Identification
Continuity Test of ECM Ground Circuits
ECM Adapter Tool
ECM Power Supply Test
ECM Removal
ECM Automated Data Transfer
ECM Installation
ECM Replacement
ECM Manual Data Entry
Fuel Injector
Fuel Injector Leak Test
Fuel Injector Resistance Test
Fuel Injector Input Voltage Test
Fuel Injector Installation
Fuel Rail Removal
Fuel Rail Installation
Throttle Body
Throttle Body Description
Throttle Body Access
Throttle Body Cleaning
Throttle Body Installation
Throttle Position Sensor (Tps)
Throttle Position Sensor Initialization
TPS Resistance Test
TPS Wear Test
Crankshaft Position Sensor (Cps)
Manifold Air Pressure and Temperature Sensor (Mapts)
Cts (Coolant Temperature Sensor)
Fuel Tank and Fuel Pump
General
System Description
Fuel Pump Pressure Test
Fuel Tank Leak Test
Inspection
Fuel System Diagnostic Flow Chart
Troubleshooting
Fuel Hose and Oetiker Clamps
Fuel Tank
Procedures
Fuel Tank Inspection
Fuel Tank Installation
Fuel Pump Input Voltage Test
Fuel Pump Quick Test
Fuel Level Sender
Fuel Tank Vent Valve
Electrical System
Fuse Box 2
General
Power Distribution Diagram
Controller Area Network (Can)
General
System Description
Diagnostic Guidelines
General
Ignition System
System Description
Troubleshooting
Ignition Coil
Ignition Switch
Procedures
Spark Plug
Charging System Output
General
Inspection
System Description
PROCEDURES (Cont'D)
Console Switches
Lights, Gauge and Accessories
Switches Access
Switches Removal and Installation
Multifunction Gauge Circuit Protection
Multifunction Gauge Installation
Multifunction Gauge Removal
Multifunction Gauge Wire Identification
Front Drive
Rear Drive
Wheel Hub Inspection
Wheel Hub Installation
Wheel Hub Removal
Drive Shaft Boot
Drive Shaft Inspection
Drive Shaft Installation
Drive Shaft Removal
Propeller Shaft U-Joints
Rear Final Drive
Chassis
General
Procedures
Wheels and Tires
Wheels
Steering System
Adjustment
General
Steering Alignment
Diagnostic Tips
Procedures
Steering Column
Steering Wheel
Troubleshooting
Rack and Pinion
Tie-Rod Ends
Knuckles
Wheel Bearings
Front Suspension
General
Procedures
Shock Absorber
Springs
Shock Absorber Bushings
Upper Suspension Arm
Ball Joints
Lower Suspension Arm
Suspension Arm Bushings
Rear Suspension
General
Procedures
Rear Suspension
Shock Absorbers
Shock Absorber Bushings
Springs
Anti-Sway Bar
Trailing Arm
Brakes
Brake System Pressure Validation
General
Inspection
Brake Light Switch
Master Cylinder
Procedures
Brake Pads
Caliper
Brake Disc
Body
Upper Console
Lower Console
Lateral Console Panels
Glove Box Removal and Installation
Cargo Box
Cargo Box Tilt Release Mechanism
Cargo Box Support
Upper Tail Gate
Lower Tail Gate
Adjustment
Cargo Box Adjustments
General
Cargo Box
Cargo Box Gas Shock
Procedures
Frame
Cage
General
Procedures
Frame
Commander 800R and 1000
Technical Specifications
General
Wiring Diagram Codes
Wiring Diagram Information
Wiring Diagram Location
Connector Information
Deutsch Connectors
General
Connector Information
Deutsch Connectors
Packard Connectors
Packard Connector (Multifunction Gauge)
Molex Connector
Battery and Starter Cable Terminals
Furukawa Connector
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Table of Contents
Troubleshooting
Troubleshooting
144
Engine control module (ecm)
250
Fuel system diagnostic flow chart
278
Ignition system
292
TROUBLESHOOTING
346
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