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BOMBARDIER Oulander Max Series Operator's Manual

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  • Page 2 Outlander ™ Rotax ® Printed in Canada. (vmo2005-011 AP) ®™Trademarks of Bombardier Recreational Products Inc. or its affiliates. ©2004 Bombardier Recreational Products Inc. All rights reserved. * Bombardier and the sprocket design are trademarks of Bombardier Inc., used under license.
  • Page 3 SAE experience problems which cannot be U.S. equivalent in parenthesis. Where resolved by an authorized Bombardier precise accuracy is not required, some ATV dealer. conversions are rounded off for easier use.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. NOTICE................. 7 INTRODUCTION ..
  • Page 5 SECTION II – BOMBARDIER 2-UP VEHICLE SAFETY VIDEOCASSETTE . .. 69 Objective................69 Outline .
  • Page 6 24) Tool Box ..............101 25) Rewind Starter Handle .

  • Page 7: Notice

    SPECIFICATIONS ..............139 INTERNATIONAL METRIC INFORMATION GUIDE ......144 WARRANTY BRP LIMITED WARRANTY NORTH AMERICA: 2005 BOMBARDIER † ATV 146 BRP INTERNATIONAL LIMITED WARRANTY: 2005 BOMBARDIER †...

  • Page 8: Introduction

    NOTICE This Operator's Guide has been pre- pared to acquaint the owner/operator of a new vehicle with the various ve- hicle controls, maintenance and safe operating instructions. It is indispens- able for the proper use of the product. This Operator's Guide uses the follow- ing symbols.
  • Page 9 INTRODUCTION Your dealer should have provided you with some basic information on the partic- ular controls and features of your new vehicle. Please take the time to study this Operator's Guide and all on-product warning labels as well as the Safety Video- cassette that came with this vehicle.

  • Page 10: Safety Information

    SAFETY INFORMATION ____________ ____________ SAFETY INFORMATION...

  • Page 11: Special Safety Messages

    WARNING Operator: • A person under 16 years old should never operate this vehicle. • Never carry more than one (1) passenger on this vehicle. • Passenger must be seated on the designated passenger's seat and hold on to the grab handles at all times. •...
  • Page 12 Never operate this vehicle without proper instruction. Take a training course offered by BRP. All operator should receive training from a certified instructor. See your authorized Bombardier ATV dealer for more informations. Always follow this age recommendation: A person under 16 years old should never operate this vehicle.
  • Page 13 Always inspect your vehicle each time you use it to make sure it is in safe op- erating condition. Always follow the inspection and maintenance procedures and schedules described in this Operator's Guide. The operator and the passenger must always keep both hands on the han- dlebars or grab handles and both feet on the footrests of the vehicle during operation.

  • Page 14: Operation Warnings

    Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use proper gear and maintain a steady speed when climb- ing a hill. If you stall or roll backwards, follow the special procedure for braking described in this Operator's Guide.
  • Page 15 OPERATION WARNINGS While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. NOTE: The following illustrations are general representations only. Your model may differ. WARNING V00A0AQ POTENTIAL HAZARD Operating this vehicle without proper instruction.
  • Page 16 WARNING V00A1AQ POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle. WHAT CAN HAPPEN A lack of respect for this age recommendation can lead to severe injury or death of the child. Even though a child may be within the age group for which this vehicle is recommended, he may not have the skills, abilities, or judgment needed to operate this vehicle safely and may be involved in a serious accident.
  • Page 17 WARNING V00A1BQ POTENTIAL HAZARD Failure to follow the age recommendations for the passenger. WHAT CAN HAPPEN A child, under 12, may not have the ability needed to ride safely and may be involved in a serious accident. HOW TO AVOID THE HAZARD No one under 12 should be riding on this vehicle.
  • Page 18 WARNING V00A1CQ POTENTIAL HAZARD Carrying more than one (1) passenger on this vehicle. WHAT CAN HAPPEN Carrying more than one (1) passenger reduces your ability to balance and control this vehicle. Could cause an accident, resulting in harm to you and/or your passengers. HOW TO AVOID THE HAZARD Never carry more than one (1) passenger.
  • Page 19 WARNING V00A2DQ POTENTIAL HAZARD Allowing passenger to sit in a location other than the designated passenger seat. WHAT CAN HAPPEN Passenger seated in a location other than the designated passenger seat could : – impair vehicle stability which could lead to a loss of control –...
  • Page 20 WARNING V00A1DQ POTENTIAL HAZARD Operating this vehicle on paved surfaces. WHAT CAN HAPPEN The tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Never operate this vehicle on any paved surfaces, including sidewalks, driveways, parking lots and streets.
  • Page 21 WARNING V00A1EQ POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, even a dirt or gravel one.
  • Page 22 WARNING V00A1FQ POTENTIAL HAZARD Riding this vehicle without wearing an approved helmet, eye protection and protective clothing. Passenger should also have an approved helmet with a rigid chin guard. WHAT CAN HAPPEN The following items concern the operator and the passenger: –...
  • Page 23 WARNING V00A07Q POTENTIAL HAZARD Riding this vehicle after consuming alcohol or drugs. WHAT CAN HAPPEN Could cause the passenger to fall off. Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident or death of passenger and/or operator.
  • Page 24 WARNING V00A08Q POTENTIAL HAZARD Operating this vehicle at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the vehicle, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and op- erating conditions, and your experience.
  • Page 25 WARNING V00A1GQ POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, for the operator and the passenger, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Do not try to show off. ___________ ___________ SAFETY INFORMATION...
  • Page 26 WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition.
  • Page 27 WARNING V00A1HQ POTENTIAL HAZARD Removing hands from handlebars for the operator and from grab handles for the passenger, or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the vehicle or could cause you to lose your balance and fall off the vehicle.
  • Page 28 WARNING V00A1IQ POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the vehicle overturning, passenger ejection or loss of con- trol.
  • Page 29 WARNING V00A1JQ POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn or passenger ejection. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control this vehicle on...
  • Page 30 WARNING V00A1KQ POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Vehicle could go out of control, causing a collision, an overturn or a pas- senger ejection. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described further in this Operator's Guide.
  • Page 31 WARNING V00A1LQ POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate this vehicle on hills too steep for the vehicle or for your abil- ities.
  • Page 32 WARNING V00A1MQ POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or cause vehicle to over- turn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described further in this Operator's Guide. Always check the terrain carefully before you start up any hill.
  • Page 33 WARNING V00A1NQ POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or cause vehicle to over- turn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described further in this Operator's Guide.
  • Page 34 WARNING V00A1OQ POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or cause vehicle to over- turn. HOW TO AVOID THE HAZARD Never attempt this maneuver when the passenger is on board. Always disembark him before executing.
  • Page 35 WARNING V00A1PQ POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in vehicle overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Operator and passenger must keep their weight uphill.
  • Page 36 WARNING V00A1QQ POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or a collision. Could cause the vehicle to overturn. HOW TO AVOID THE HAZARD The operator is responsible for the safety of his passenger. In doubt, disem- bark him before riding over obstacles.
  • Page 37 WARNING V00A1RQ POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this vehicle. You may also regain traction unexpectedly, which may cause the vehicle to overturn or passenger ejection. HOW TO AVOID THE HAZARD Never slide or skid with passenger. Always remember that the vehicle han- dling and stability may be affected when riding with a passenger.
  • Page 38 WARNING V00A1SQ POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this vehicle in fast flowing water or in water deeper than that specified further in this Operator's Guide.
  • Page 39 WARNING V00A1TQ POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind the vehicle, resulting in serious injury. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no obstacles or people behind the vehicle.
  • Page 40 WARNING V00A0OQ POTENTIAL HAZARD Operating this vehicle with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this vehicle, or operation of this vehicle with im- proper or uneven tire pressure, may cause loss of control, and increases the risk of an accident.
  • Page 41 All parts and accessories added to this vehicle should be approved by BRP and should be installed and used according to instructions. If you have questions, consult an authorized Bombardier ATV dealer. Do not install passenger seat or use the racks to carry more than one (1) passenger.
  • Page 42 WARNING V00A1UQ POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle including operator and passenger, as well as other loads and added accessories.

  • Page 43: Safety Warning

    WARNING V03M01Q POTENTIAL HAZARD Transporting inflammable or dangerous material can lead to explosions. WHAT CAN HAPPEN This can cause serious injury or death. HOW TO AVOID THE HAZARD Never transport inflammable or dangerous material. While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death.

  • Page 44: Pre-Operation Check

    SAFETY WARNING To fully appreciate the pleasures and excitement of riding this vehicle, there are some basic rules and tips that you should follow. Some may be new to you while others may be common sense or obvious. Irrespective, we ask that you take a few minutes to read this Operator's Guide completely before you operate this vehicle.

  • Page 45: Clothing

    • Check for oil leaks on the en- Correct any problem you may have gine/transmission and drive train found before riding. See an autho- components. rized Bombardier ATV dealer as nec- • Ensure fuel valve is in fully open essary. position (ON). • Clean headlamps and taillight.

  • Page 46: Carrying Loads/Passenger

    Clothing Actual weather conditions should help you decide how to dress. However, it is important that the operator and the passenger always wear the appropriate protective clothing and apparel, including an approved helmet, eye protection, boots, gloves, long sleeved shirt and pants. The passenger should have an ap- proved helmet including a rigid chin guard.

  • Page 47: Recreational Riding

    Your vehicle can help you perform a number of different LIGHT tasks ranging from snow removal to pulling wood or carrying cargo. A variety of accessories are available from your authorized Bombardier ATV dealer. However, always re- spect the load and capacities of the vehicle. Overloading of the vehicle can over- stress the components and cause failure.

  • Page 48: Design Limitation

    Recreational Riding Respect the rights and limitations of others. Stay away from areas designated for other types of off road use. This includes snowmobile trails, equestrian trails, cross country ski trails, mountain bike trails, etc. Never assume there are no other users on the trail.

  • Page 49: Uphill Driving

    Design Limitation Although the vehicle is exceptionally rugged for its class, it is still a light vehicle by definition and its operation must be restricted to its proper purpose. The addition of weight to any part of the vehicle changes its gravitational stability and modifies its performance.

  • Page 50: Riding Techniques

    Uphill Driving Due to configuration, this vehicle has excellent climbing ability, so much so that tipover is possible before traction is lost. For example, its common to encounter terrain situations where the top of the hill has eroded to a point that the hill peak rises very sharply.
  • Page 51 Riding Techniques Riding your vehicle too fast for the conditions may result in injury. Apply only enough throttle to proceed safely. Statistics show that high speed turns usually result in mishaps and injury. Always remember that this vehicle is heavy! Its pure weight alone may entrap you should it fall and pin you down.
  • Page 52 This vehicle is not designed for riding on roads or highways. (In most places it is an illegal practice). Riding your vehicle on roads or highways could cause a collision to occur with another vehicle. The tires of this vehicle are not suited for paved road use.
  • Page 53 Mud or marsh lands may be encountered near water. Be prepared for sudden “holes” or changes in depth. Similarly so, be watchful of hazards such as rocks, logs, etc., partially covered by vegetation. If your trip crosses frozen waterways, make sure that the ice is thick enough and sound enough to support the total weight of yourself, your passenger, the vehicle and its load.
  • Page 54 V00A1WL If you do get into a slide or skid, it may help to turn the handlebar into the direction of the skid until you regain control. Never jam the brakes and lock the wheels. Respect and follow all posted trail signs. They are there to help you and others. Obstacles in the “trail”...
  • Page 55 Uphill Do not forget, the operator is responsible for the safety of the passenger. In doubt, disembark him before climbing hill. Always remember that the vehicle handling, stability and braking distance may be affected when riding with a pas- senger. If you decide to keep your passenger, he must synchronize his movements with yours.
  • Page 56 Downhill Do not forget, the operator is responsible for the safety of the passenger. In doubt, disembark him before going down the hill. Always remember that the vehicle handling, stability and braking distance may be affected when riding with a passenger. If you decide to keep your passenger, he must synchronize his movements with yours.

  • Page 57: Routine Maintenance

    Side Hilling Do not forget, the operator is responsible for the safety of the passenger. In doubt, disembark him before proceeding. Always remember that the vehicle handling, stability and braking distance may be affected when riding with a pas- senger. If you decide to keep your passenger, he must synchronize his movements with yours.

  • Page 58: Hang Tag

    Part of your responsibility towards safety is to respect the contents of this Op- erator's Guide. It provides valuable advice on how to properly take care of your vehicle. If further assistance is required your authorized Bombardier ATV dealer is always willing to help.

  • Page 59: Location Of The Important Labels

    HANG TAG This vehicle comes with a hang tag and labels containing important safety infor- mation. Any person who rides this vehicle should read and understand this information before riding. V00M0BL ___________ ___________ SAFETY INFORMATION...
  • Page 60 The following labels are on your vehicle and they should be considered perma- nent parts of the vehicle. If missing or damaged, they can be replaced free of charge. See an authorized Bombardier ATV dealer. NOTE: The following illustrations used in this Operator's Guide are a general representation only.
  • Page 61 V07M0UL ___________ ___________ SAFETY INFORMATION...
  • Page 62 LABEL 1 LABEL 3 V07M06Y LABEL 4 V00M0CY LABEL 2 V07M07Y LABEL 5 V00M05Y V01M0RY ____________ ___________ SAFETY INFORMATION...
  • Page 63 LABEL 6 LABEL 8 V07M0YY LABEL 9 V00M0DY LABEL 7 V00M0AY V07M21Y ___________ ___________ SAFETY INFORMATION...
  • Page 64 LABEL 10 V01M0SL LABEL 11 V01M0TL LABEL 12 V07M17Y While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. ____________ ___________ SAFETY INFORMATION...

  • Page 65: Safety Training

    SAFETY TRAINING _____________ ____________ SAFETY TRAINING...

  • Page 66: Introduction

    INTRODUCTION Objective The objective of this course is to give the Bombardier 2-UP vehicle owner the information required to operate a 2-UP vehicle safely. The course will be offered to all 2-UP vehicle buyers, and members of their immediate fam- ilies.

  • Page 67: Section I - General Safety Information

    Discuss CPSC (Consumer Prod- 1. 417,200 ATV-related injuries uct Safety Commission) Injury and 2. 1,463 ATV-related deaths. Death Statistics. c) Discuss Bombardier's age and size C) Age and Size Requirements recommendation. for the 2-UP Vehicle d) Discuss what protective clothing –...

  • Page 68: Expected Results

    E) Riding with a Passenger – Before riding with a passenger, the operator should first become highly familiar with the operation of the 2-UP vehicle. – Once ready, the operator should be- gin riding with a passenger at very low speed and on familiar terrain. F) ATV-Related Local, State and Federal Laws –...

  • Page 69: Section Ii - Bombardier 2-Up Vehicle Safety Videocassette

    SECTION II – BOMBARDIER 2-UP VEHICLE SAFETY VIDEOCASSETTE Objective Body Posture The purpose of this section is to: You and your passenger must position your body weight to lessen the hazard a) Indicate guidelines prior to viewing of tipping over. You and your pas-...

  • Page 70: Expected Results

    4. Make sure fuel and oil caps are tight. 5. Secure front and rear of vehicle. Law Observance Refer to section I. C) Recap – Questions and answers. – Review of the CPSC injury and death data. – Review of safety messages, such as wearing protective head gear and clothing.

  • Page 71: Section Iii - Operator's Guide Review

    SECTION III – OPERATOR'S GUIDE REVIEW Objective – Know the meaning of the warning and caution symbols in the Opera- The purpose of this section is to: tor's Guide and what they refer to. a) Emphasize the importance of ob- –...

  • Page 72: Section Iv - Hands-On Riding

    SECTION IV – HANDS-ON RIDING Objective 3. Dealer representative checks off the scoring chart when you The purpose of this section is to: have completed the maneuvers a) Familiarize you with the pre-opera- satisfactorily. tion check. 4. Dealer representative and you b) Remind you about the protective continue with the maneuvers clothing that should be worn by...

  • Page 73: Driving Maneuver List

    DRIVING MANEUVER LIST Hands-on riding practice should incorporate the maneuvers described below. Trainees are required to perform a minimum number of repetitions of each of the eight driving maneuvers. The person giving the training must demonstrate each maneuver and then have the trainee repeat the following minimum number of repetitions.
  • Page 74 Maneuver #3 Maneuver #4 Sharp turns less than 90 - left and Slalom (minimum repetition: three right. Corners 90 degrees and less times). than 90 degrees (minimum repetition: two clockwise and two counterclock- FINISH wise). START START FINISH V01A4IY TYPICAL 1.
  • Page 75 Maneuver #5 Maneuver #6 Quick stop: large oval with panic Riding over obstacle (minimum rep- maneuver (minimum repetition: two etition: once with left wheels, once times). with right wheels, and once with both wheels). FINISH START START 1.5 m (5’) 1.2 m (4’) 1.8 m (6’) FINISH...
  • Page 76 Maneuver #7 Maneuver #8 Traversing hills (minimum repetition: U-turn and K-turn (minimum repeti- once each direction). tion: one time). 9 m (30’) 2.4 m Uphill (8’) START FINISH V01A5SY TYPICAL — U-TURN Uphill START FINISH V01A4LY 2.4 m TYPICAL (8’) 1.

  • Page 77: Instructor's Check List

    • Failure to perform the required training may constitute a violation of the Bombardier ATV dealer agreement. • If you would like further information on the 2–UP vehicle safety training course, please contact BRP at 1–800–366–6992 in the US or at 1–800–361–9980 in Canada.
  • Page 78 Section II: Bombardier 2-Up Vehicle Safety Videocassette Review the Bombardier 2-UP vehicle Safety Videocassette with your trainee. Make sure to answer any questions your trainee may have. Section III: Operator's Guide Review Review the Operator's Guide with your trainee. Emphasize the need for periodic and frequent reviews of the guide.
  • Page 79 5) Quick Stop Quick stop as used in article I above. Large oval with panic maneuver (minimum repetition: two times). 6) Riding Over Obstacles Riding over obstacles – 4 x 4 pieces of wood should be placed in vehicle's path so rider can drive over them (minimum repetition: once with left wheels, once with right wheels, and once with both wheels).
  • Page 80 Trainee's Scoring Chart Exercise Pass Fail 1. Starting and stopping 2. Turning 3. Sharp turns 4. Slalom 5. Quick stops 6. Riding over obstacles 7. Traversing hills (if there is no hill available, make sure to review the description of the maneuver in the Operator's Guide with the trainee) 8.

  • Page 81: Vehicle Information

    VEHICLE INFORMATION _____________________...

  • Page 82: How To Identify Your Atv

    These numbers are required by the authorized Bombardier ATV dealer to complete war- ranty claims properly. No warranty will be allowed by BRP if the engine identifica- tion number (EIN) or vehicle identification number (VIN) is removed or mutilated in any way.

  • Page 83: Compliance Label

    Compliance Label This label indicates vehicle's compliance in many countries. Label Location Under seat, on the upper bar of frame. Outlander MAX V00M02Y U.S.A. AND CANADA V00M03Y OTHER COUNTRIES IN THE WORLD _____________________...

  • Page 84: Emission Requirements

    EMISSION REQUIREMENTS The California Air Resources Board (CARB) requires that your ATV comply with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions supplied. A noncompliance Red Label (as well as a Green Label) is obtained annually during California Vehicle registration.

  • Page 85: Controls/Instruments/Equipment

    CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment are optional. V07A1OM _____________________...
  • Page 86 27-29 V07A1RM While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. ______________________...

  • Page 87: Throttle Lever

    NOTE: This section gives basic func- tions of the various controls of your ATV. For more details of how to op- erate one control in conjunction with some others, refer to OPERATING IN- STRUCTIONS further in this section. 1) Throttle Lever Located on the right side of handlebar.

  • Page 88: Brake Lever Lock

    4) Brake Lever Lock To release mechanism: Squeeze brake lever. Lever lock should auto- Located on left side of handlebar on matically return to its original position. the brake lever. When applied, it pre- Brake lever should return to rest posi- vents the vehicle from moving.

  • Page 89: Multi-Function Switch

    Headlamp Switch WARNING Located on the top of multi-function Before moving vehicle in reverse, switch. Place headlamp switch to LO ensure the path behind is clear of for the low beam and taillight. Place obstacles or bystanders. Remain headlamp switch to HI for the high seated.
  • Page 90 Engine Stop Switch Located at the middle of multi-function switch. The engine will turn over but will not start if the engine stop switch is turned to OFF position. V07I06Y TYPICAL 1. Start button 2. Engine stop switch To start engine, place the engine stop switch to RUN.

  • Page 91: Speedometer

    This button is used to override the re- verse speed limiter system and while power backing up. To do this, press the override button. WARNING Never activate the override button while throttle is open as loss of control may result, causing severe personal injury or death.
  • Page 92 V07G01Y TYPICAL 1. Rectifier harness 2. Change wire connectors V07I0AY 3. Fuse holders TYPICAL Plug connectors to change units from 1. Display selector button 2. Display miles to kilometers. Unplug to return 3. 4WD indicator lamp to miles reading. 4. Oil pressure indicator lamp 5.
  • Page 93 Indicator Lamps 4-Wheel Drive (AMBER) When this indicator light is ON, it indicates the 4WD system is activated. Oil Pressure (RED) When this indicator light is ON, it indicates a low oil pressure condition of the engine. V07I0BY CAUTION: If the light does not TYPICAL turn off right after engine starting, stop engine.

  • Page 94: 12-Volt Power Outlet

    See an autho- be blocked and the engine could rized Bombardier ATV dealer for more misfire. details. Unscrew counterclockwise and re-...

  • Page 95: Fuel Gauge

    WARNING Always stop engine before re- fueling. Open cap slowly. If a differential pressure condition is noticed (whistling sound heard when loosening fuel tank cap) have vehicle inspected and/or re- paired before further operation. Fuel is flammable and explosive under certain conditions. Never use an open flame to check fuel level.

  • Page 96: Brake Pedal

    RES (reserve) When fuel is exhausted in the fuel tank when in the ON position, an emergen- cy supply of fuel is available by turn- ing the knob to RES. The reserve con- tains approximately 12% of the fuel tank capacity. Use this position only when the ON supply is empty.

  • Page 97: Grab Handles

    15) Grab Handles The conversion of the vehicle is easy, remove the passenger's seat then in- The grab handles are located on each stall the convertible rack or vise ver- side of passenger's seat. sa. Use the procedure describes be- low to remove and install the features correctly.

  • Page 98: Operator's Seat

    Passenger's Seat Installation – Continue lifting movement until you can release the front retaining de- – Insert front tabs of seat under vice then completely remove con- frame rod. vertible rack. Convertible Rack Installation – Insert front tabs of rack into frame hook.

  • Page 99: Access Panel

    Seat Installation Insert front tabs of seat into frame hooks. When seat rests in its position, firmly push seat down to latch. NOTE: A distinctive snap will be felt. Double check that the seat is secure by giving it a tug to confirm proper latching.

  • Page 100: Cargo Racks

    The compartment is equipped with Refer to SPECIFICATIONS for carry- a drain plug. Remove plug to allow ing loads and cargo weight distribution draining when necessary. Reinstall recommendations. plug when finished. 21) Trailer Hitch Located near rear axle. Convenient hitch to install a ball to tow a trailer or other equipment.

  • Page 101: Fuses

    24) Tool Box To remove the radiator cap, press and turn it counterclockwise. Reverse the The tool box is located in the service removal procedure to install. compartment. It contains tools for basic maintenance, this Operator's Guide and the ATV Winch Operator's Manual with the XT models .

  • Page 102: Dipstick

    V07A0PY V07C21Y 1. Winch 1. Rewind starter handle 2. Front skid plate 26) Dipstick 28) Winch Control Switch Located on the right side of engine. XT Models Allow to check the oil level in the en- gine. Located on the left side of the handle- bar.

  • Page 103: Fairlead

    29) Fairlead XT Models Located on the front of skid plate. The fairlead is used to prevent the damages to the vehicle and guide the wire rope into the winch. V07A0PZ 1. Front skid plate 2. Fairlead 3. Winch hook _____________________...

  • Page 104: Liquids

    SG, SH or SJ. Only use high-quality high-detergent oil. NOTE: The same oil lubricates both engine and transmission. For im- proved overall performance and wear protection use Bombardier synthetic oil 5W40 (P/N 293 600 039). _____________________...
  • Page 105 Oil Viscosity SAE 5W30 is recommended for all seasons. However, during the hottest days of the summer and bitter cold days of the winter, refer to the following chart to select the proper viscosity. °C °F V07C24Y RH SIDE OF ENGINE 1.

  • Page 106: Engine Coolant

    NOTE: A cooling system that fre- quently requires coolant is the indica- tion of leaks or engine problems. See an authorized Bombardier ATV dealer. Coolant Replacement Refer to MAINTENANCE section. _____________________...

  • Page 107: Brake Fluid

    NOTE: A low level may indicate leaks or worn brake pads. See an autho- rized Bombardier ATV dealer. Brake Lever Fluid Reservoir Turn steering in the straight-ahead position to ensure reservoir is level. Check the brake fluid level, the reser-...

  • Page 108: Break-In Period

    Contin- vehicle be inspected by an authorized ued wide open throttle accelerations, Bombardier ATV dealer. This inspec- prolonged cruising speeds and engine tion will give you the opportunity to overheating are detrimental during the discuss the unanswered questions break-in period.

  • Page 109: Pre-Operation Check

    • Check for oil leaks on the en- Correct any problem you may have gine/transmission and drive train found before riding. See an autho- components. rized Bombardier ATV dealer as nec- • Ensure fuel valve is in fully open essary. position (ON). • Clean headlamps and taillight.

  • Page 110: Operating Instructions

    OPERATING INSTRUCTIONS General Press the start button and hold until the engine starts. The transmission lever must be on PARK or NEUTRAL to allow engine to CAUTION: Do not hold the start start. button more than 30 seconds. A rest period should be observed be- NOTE: For your convenience, an tween the cranking cycles to let the...

  • Page 111: Warm Engine Starting

    Warm Engine Starting Set transmission lever in PARK posi- tion. Start the engine as explained above but without the choke. If the engine Push the engine stop switch in OFF does not start after two 5-second at- position. tempts with the electric starter, pull Turn key in ignition switch to OFF.

  • Page 112: 2Wd/4Wd Selector

    2WD/4WD Selector The 4WD mode may be selected or deselected when the vehicle is stopped. CAUTION: The vehicle must be stopped to engage or disengage 2WD/4WD selector. Mechanical damage may occur if selector is en- gaged or disengaged while driving. CAUTION: If the rear wheels are spinning, release the throttle and...

  • Page 113: Special Procedures

    Clean the spark plug cap area then re- engine is hot. move it. Remove the spark plug (tools are supplied in tool box). See an authorized Bombardier ATV WARNING dealer as soon as possible. Always wear eye protector and Post-Operation Care gloves when cleaning the spark plug hole.

  • Page 114: Turn Over

    Before starting engine, check engine oil level and refill if necessary. If the oil pressure light stays ON after starting engine, stop engine and see an autho- rized Bombardier ATV dealer as soon as possible. ATV Immersion Should the ATV become immersed, it...

  • Page 115: Cargo And Transportation

    CARGO AND TRANSPORTATION While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. Cargo When cargoing vehicle, respect these maximum loads. WARNING TOTAL LOAD ALLOWED: 235 kg (517 lb) The vehicle handling, stability (includes weight of operator,...

  • Page 116: Transportation

    Transportation Front Location When transporting a vehicle, secure vehicle to trailer or in pickup box with suitable tie-downs. Using ordinary ropes is not recommended. WARNING V07A0EY Rear Location V00A174 Never tip this vehicle on end for transporting. We recommend that you carry the vehicle in its nor- mal operating position (on all four wheels).

  • Page 117: Maintenance Information

    MAINTENANCE INFORMATION _____________________...

  • Page 118: Maintenance Chart

    MAINTENANCE CHART The maintenance is very important, if you are not familiar with safe service prac- tices and adjustment procedures, see your authorized Bombardier ATV dealer. I: Inspect, verify, clean, adjust, lubricate or replace if EVERY Initial in- necessary spection...
  • Page 119 I: Inspect, verify, clean, adjust, lubricate or replace if EVERY Initial in- necessary spection To be C: Clean 10 h or performed 100 h or 200 h or 30 days L: Lubricate 25 h or 50 h or 1 year or 2 years or or 300 km 750 km...
  • Page 120 EVERY RIDE Customer Vehicle cleaning and protection Customer To be performed by an authorized Bombardier ATV dealer. The initial main- tenance is very important and must not be neglected. Pre-ride inspection item. Every 100 hours, check coolant strength. More often under severe use such dusty area, sand, snow, wet or muddy conditions Make sure the spark plug is correctly gapped.

  • Page 121: Maintenance

    MAINTENANCE While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. WARNING WARNING Unless otherwise specified, engine The engine oil can be very hot. In should not be running for all main- order to avoid potential burns, do tenance procedures.
  • Page 122 Contact an authorized Bombardier ATV dealer. Coolant Replacement WARNING In order to avoid potential burns, do not remove the radiator cap or loosen the coolant drain plug if the engine is hot. Open the access panel and remove the radiator cap.
  • Page 123 Install radiator cap. Inspect all connec- tions for leaks and check coolant level in the reservoir. Drive Belt See an authorized Bombardier ATV dealer to check the width and the con- dition of drive belt. V07C09Y Valve Adjustment 1.
  • Page 124 LOW PRESSURE ONLY, NEVER USE Stop engine and allow muffler to cool. A HIGH PRESSURE WASHER. Reinstall the clean-out plug. See an authorized Bombardier ATV dealer to check the performance of Radiator the cooling system. Periodically check the radiator area for cleanliness.

  • Page 125: Carburetor

    Carburetor When liquids/deposits are found, the air filter must be inspected/dried/re- See an authorized Bombardier ATV placed depending on its condition. dealer each year to verify and clean the fuel system. Remove air filter as explained below. Air Filter Removal...

  • Page 126: Electrical

    Unscrew the spark plug one turn. Clean the spark plug and cylinder head with pressurized air if possible. WARNING Always wear safety goggles when using pressurized air. Unscrew spark plug completely then remove it. Installation V07C0HY Prior to installation make sure that 1.
  • Page 127 V07G0HY Fuses V07G0OY 1. Battery If a fuse is damaged, replace it by one 2. Holding strap of the same rating. Cleaning CAUTION: Do not use a higher rat- ed fuse as this can cause severe Clean battery, battery casing and bat- damage.
  • Page 128 Headlamps CAUTION: Never touch glass por- tion of an halogen bulb with bare fingers, it shortens its operating life. If glass is touched, clean it with iso- propyl alcohol which will not leave a film on the bulb. Unplug connector from headlamp. V07G02Y 1.

  • Page 129: Drive Train

    Drive Train Drive Shaft Boot/Protector Inspection Visually inspect drive shaft protectors and boots conditions. Check protec- tors for damage or rubbing against shafts. Check boots for cracks, tears, leaking grease etc. Repair or replace damaged parts as necessary. V04G02Z 1. Headlamp cover 2.
  • Page 130 Push and pull the wheels from the the identical model and manufac- upper edge to feel the play. See an turer. authorized Bombardier ATV dealer if For unidirectional tread pattern, there is any play. ensure that the tires are installed in the correct direction of rotation.

  • Page 131: Steering System

    CAUTION: Always use the recom- TIRE PRESSURE mended wheel nuts (P/N 250 100 FRONT REAR 039). Using a different nut could cause damages to the rim. MAX. UP to 34 kPa 34 kPa 235 kg (5 PSI) (5 PSI) Steering System (517 lb) 31 kPa 31 kPa...
  • Page 132 V07I0GY 1. Cable protector 2. Throttle cable adjuster V07I0IY 3. Lock nut 4. Throttle lever housing Remove the carburetor side cover. Screw in the throttle cable adjuster. Remove: – inner housing protector V07F04Y Insert the needle of lubricant can in the end of throttle cable adjuster.

  • Page 133: Suspension

    Check trailing arms for distortion, Tighten lock nut and reinstall protector. cracks or bending. See an authorized Bombardier ATV dealer if any problem is detected. A-Arms Check A-arms for cracks, bending or other damages. See an authorized Bombardier ATV dealer as necessary.

  • Page 134: Brake

    0.2 mm (.010 in) warpage Turn the adjusting cams counterclock- wise for a light load and a smooth road condition. See your authorized Bombardier ATV dealer if a problem is detected con- cerning the brake system. Brake Fluid Replacement WARNING...
  • Page 135 Seat Fasteners Remove seat(s) and/or convertible rack and check latch mechanisms and pins for wear. See an authorized Bombardier ATV dealer for parts re- placement if damaged. Vehicle Cleaning and Protection Never use a high pressure washer to clean the vehicle. USE LOW PRES- SURE ONLY (like a garden hose) .

  • Page 136: Troubleshooting

    Start engine with spark plug grounded to the engine away from spark plug hole. If no spark appears, replace spark plug. – If trouble persists, contact an authorized Bombardier ATV dealer. 6. Engine compression. – As the engine is pulled over with the rewind starter, “cycles” of resistance should be felt as piston goes past top dead center.
  • Page 137 Contact an authorized Bombardier ATV dealer. 4. Engine is overheating. – Check ENGINE OVERHEATING in SPECIAL PROCEDURES. – If overheating persists, contact an authorized Bombardier ATV dealer. 5. Air filter/box plugged or dirty. – Check air filter and clean if necessary. –...
  • Page 138 Check the position of the air intake tube. 4. CVT dirty or wear. – Contact an authorized Bombardier ATV dealer. Transmission lever is hard to move 1. Transmission gears are in a position that prevents the transmission lever to work.

  • Page 139: Specifications

    SPECIFICATIONS OUTLANDER™ VEHICLE MODEL MAX XT ENGINE Bombardier-Rotax 4-TEC, 4-stroke. Over Type Head Camshaft (OHC) Number of cylinder Single cylinder Number of valves 4 valves with mechanical lifters (adjustable) Displacement 400 cc (24.4 cu. in) Bore Standard 91 mm (3.58 in) 62 mm (2.42 in)
  • Page 140 OUTLANDER™ VEHICLE MODEL MAX XT ELECTRICAL Make Denso Magneto generator Type 400 W @ 6000 RPM Ignition type CDI (Capacitor Discharge Ignition) Ignition timing Not adjustable Engine RPM limiter 8000 RPM (any gear in forward) Vehicle speed limiter 15 km/h (9 MPH) in reverse Make Spark plug Type...
  • Page 141 OUTLANDER™ VEHICLE MODEL MAX XT DRIVE TRAIN Shaft driven/single auto-lock differential Front differential (shear pump) Rear axle Shaft driven Turning radius 2 m (79 in) SUSPENSION Independent suspension Type MacPherson type Front Travel 178 mm (7 in) Independent suspension Type Trailing arms Rear Travel...
  • Page 142 OUTLANDER™ VEHICLE MODEL MAX XT LOADING CAPACITY Front racks 40 kg (90 lb) 80 kg (175 lb) Rear racks includes tongue load Rear storage box 10 kg (22 lb) 235 kg (517 lb) includes operator Total vehicle load allowed and passenger, all other loads and added accessories.
  • Page 143 VEHICLE MODEL MAX XT LIQUIDS and GREASES SAE 5W30, 4–stroke mineral-based. API Engine oil type classification SG, SH or SJ or Bombardier (engine and transmission) synthetic oil 5W40. Refer to OIL VISCOSITY CHART for other grade Ethylene-glycol/water mix (50% coolant, 50% distilled water).

  • Page 144: International Metric Information Guide

    INTERNATIONAL METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length ..........meter ........ mass ..........kilogram ......force........... newton......liquid ..........liter ........temperature ........Celsius ......°C pressure ..........kilo pascal......torque ..........newton-meter ....land velocity ........kilometer per hour..... km/h navigation velocity ......

  • Page 145: Warranty

    WARRANTY _____________________...

  • Page 146: Brp Limited Warranty North America: 2005 Bombardier Atv

    ††† warranted separately by the tire and winch manufacturer. If such tire or winch are installed on your Bombardier ATV, please contact the manufacturer or ask your authorized Bombardier ATV dealer for warranty coverage and assistance. Warn Industries inc. (for the winches), Carlisle Tire &...
  • Page 147 3) CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on 2005 Bombardier ATVs purchased as new and unused by its first owner from a Bombardier dealer authorized to distrib- ute Bombardier ATV products in the country in which the sale occurred (“Bom- bardier ATV dealer”), and then only after the BRP specified pre-delivery inspection...
  • Page 148 Bombardier ATV dealer and gives the coordinates of the new owner; or b) BRP or an authorized Bombardier ATV dealer receives a proof that the former owner agreed to the transfer of ownership, in addition to the coordinates of the new owner.
  • Page 149 VALCOURT, QC, J0E 2L0 WAUSAU WI 54401 Tel : (819) 566-3366 Tel : (715) 848-4957 * In the USA, products are distributed and serviced by Bombardier Motor Corpo- ration of America. © 2004 Bombardier Recreational Products Inc. All rights reserved.

  • Page 150: Brp International Limited Warranty: 2005 Bombardier Atv

    3) CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on 2005 Bombardier ATVs purchased as new and unused by its first owner from a Bombardier dealer authorized to distrib- ute Bombardier ATV products in the country in which the sale occurred (“Bom- bardier ATV distributor/dealer”...
  • Page 151 BRP’s obligations under this warranty are limited to, at its sole discretion, repair- ing parts found defective under normal use, maintenance and service, or replac- ing such parts with new genuine Bombardier parts without charge for parts and labor, at any authorized Bombardier ATV distributor/dealer.
  • Page 152 AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE, OR PROVINCE TO PROVINCE. Neither the distributor, any Bombardier ATV dealer nor any other person has been authorized to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against BRP.
  • Page 153 BOMBARDIER RECREATIONAL PRODUCTS INC. BOMBARDIER ATV CUSTOMER ASSISTANCE CENTER VALCOURT, QC, J0E 2L0 Tel : (819) 566-3366 * In the USA, products are distributed and serviced by Bombardier Motor Corpo- ration of America. © 2004 Bombardier Recreational Products Inc. All rights reserved. †...

  • Page 154: Privacy Obligation/Disclaimer

    If you prefer not to have your name and address released, please let us know by writing to the address below. Bombardier Recreational Products Inc. Warranty Department 75 J.A. Bombardier Street...

  • Page 155: Change Of Address/Ownership

    STOLEN UNITS: If your personal vehicle is stolen, you should notify BRP or an au- thorized Bombardier ATV dealer. We will ask you to provide your name, address, phone number, the vehicle identification number and the date it was stolen.
  • Page 156 AFFIX PROPER POSTAGE Bombardier Recreational Products Inc. WARRANTY DEPARTMENT 75, J.A. Bombardier Sherbrooke, QC Canada J1L 1W3 V00A2G _____________________...
  • Page 157 STOLEN UNITS: If your personal vehicle is stolen, you should notify BRP or an au- thorized Bombardier ATV dealer. We will ask you to provide your name, address, phone number, the vehicle identification number and the date it was stolen.
  • Page 158 AFFIX PROPER POSTAGE Bombardier Recreational Products Inc. WARRANTY DEPARTMENT 75, J.A. Bombardier Sherbrooke, QC Canada J1L 1W3 V00A2G _____________________...
  • Page 159 STOLEN UNITS: If your personal vehicle is stolen, you should notify BRP or an au- thorized Bombardier ATV dealer. We will ask you to provide your name, address, phone number, the vehicle identification number and the date it was stolen.
  • Page 160 AFFIX PROPER POSTAGE Bombardier Recreational Products Inc. WARRANTY DEPARTMENT 75, J.A. Bombardier Sherbrooke, QC Canada J1L 1W3 V00A2G _____________________...
  • Page 161 ATV MODEL No. VEHICLE IDENTIFICATION NUMBER (V.I.N.) ENGINE IDENTIFICATION NUMBER (E.I.N.) Owner: NAME STREET CITY STATE/PROVINCE ZIP/POSTAL CODE Purchase Date YEAR MONTH Warranty Expiry Date YEAR MONTH To be completed by the dealer at the time of the sale. DEALER IMPRINT AREA Please verify with your dealer to ensure your vehicle has been registered with BRP.

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