Can-Am 2010 DPS Technical Manual
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Can-Am 2010 DPS Technical Manual

Can-Am 2010 DPS Technical Manual

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Summary of Contents for Can-Am 2010 DPS

  • Page 1 2010 2 1 9 1 0 0 3 8 8...
  • Page 2 2010 DPS/ACS Technical Manual...
  • Page 3 Bombardier Recreational Products Inc. (BRP) Valcourt (Quebec) Canada ™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates. ® Renegade™ Can-Am™ ™ DPS™ Outlander™ This document contains the trademarks of the following companies: ®...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTICE ......................II INTRODUCTION ..

  • Page 5: Safety Notice

    Indicates an instruction which, if not rectly service and repair the DPS™ and ACS sys- followed, could severely damage vehicle com- tems on 2010 Can-Am™ ATVs. ponents or other property. This edition was primarily published to be used by NOTE: Indicates...

  • Page 6: Introduction

    INTRODUCTION INTRODUCTION This Technical Manual covers the following BRP made 2010 Can-Am ATVs with a DPS or ACS system. OUTLANDER™ ENGINE MODEL COLOR MODEL NUMBER Yellow, Red, Camo 2UAA, 2UAB, 2UAC, 2UAD, 2UAE XT-P Black 5JAB MAX XT Yellow, Red, Camo...
  • Page 7 vmr2010-002...
  • Page 8 SERVICE TOOLS INDEX FLUKE 115 MULTIMETER (P/N 529 035 868) Page: 9, 11, 32, 35, 37–38, 43–44 OETIKER PLIERS (P/N 295 000 070) Page: 44 SPRING REMOVER (P/N 529 036 007) Page: 46...

  • Page 10: Technical Manual

    Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) DYNAMIC POWER STEERING (DPS) SERVICE TOOLS Description Part Number Page 529 035 868 ........9, 11 FLUKE 115 MULTIMETER ............SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page LST 52616 ...........
  • Page 11 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-001_a vmr2010-003...

  • Page 12: General

    Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) GENERAL Steering torque may also come from the wheels due to rough terrain. Steering kickback is reduced During assembly/installation, use the torque val- while providing feedback to the driver. ues and service products as in the exploded view. The greater the power steering assist, the greater the load on the electrical system.

  • Page 13: System Description (Components)

    Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) The active DPS mode will be displayed in the lower portion of multifunction gauge. vmr2010-003-003 DPS UNIT The DPS module provides DC power to the mo- tor. The amount and duration of that DC power is determined by the inputs to the DPS module.

  • Page 14: Adjustment

    Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) Steering Torque Sensor PART ADJUSTED OR WHAT TO DO REPLACED – DPS unit – Steering column bearing – Tie rod – Tie rod end Reset Torque Offset – Knuckle in Setting, DPS –...

  • Page 15: Troubleshooting

    Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) TROUBLESHOOTING NO POWER STEERING ASSIST 1. DPS malfunction. - If the CHECK ENGINE light is on and a DPS FAULT message is visible in the gauge, check for fault codes using B.U.D.S. and carry out service action. 2.

  • Page 16: Procedures

    Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) 3. Faulty DPS ground circuit. - Carry out a DPS UNIT GROUND CIRCUIT TEST. Ensure DPS ground connector pins (DPS3-A and DPS3-B) and frame ground post are clean, corro- sion free, tight, and make good contact. Repair or replace wiring/connector as required.
  • Page 17 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) If NO voltage is measured, test the 40 A DPS fuse in the rear fuse box (PF2-F3). If good, check wires and connector pins. Replace or repair defective parts and reset fault codes. If battery voltage is measured, carry out the fol- DPS UNIT INPUT VOLTAGE TEST (CON- lowing...
  • Page 18 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) MULTIMETER PROBE RESISTANCE @ POSITIONS 20°C (68°F) DPS control connector (pin C) and diagnostic connector (pin 1) rmr2008-028-094_a Below 1 vmr2010-003-013_c DPS control connector (pin D) 1. DPS ground connector (GDN) and diagnostic connector (pin 2) 2.
  • Page 19 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-006_a 1. Negative (-) battery terminal 2. Rear fuse box battery terminal 3. Measure the battery voltage. NOTE: If battery voltage is low, recharge battery. mmr2009-023-027_e 4. Ensure the vehicle transmission is set to PARK. 1.
  • Page 20 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) 5. With the vehicle engine running in PARK, turn the handlebar side to side, momentarily against each stop and observe the indications on the B.U.D.S. DPS Monitoring page. The DPS Torque Sensor Nm increase with torque applied to handlebar.
  • Page 21 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) – Steering column shim adjustment at half bush- ings as described in the DPS UNIT INSTALLA- TION procedure detailed in this section. – TORQUE OFFSET RESET procedure detailed in this section. –...
  • Page 22 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) 14. Remove and discard the elastic nuts from the 2 hexagonal screws that secure steering column half bushings to the support on the frame. vmr2010-003-013_a 1. DPS connectors (3x) 12. Cut the locking tie securing the bellows at the bottom of steering column near the DPS unit, and pull the bellows upwards sufficiently to vmr2010-003-018_a...
  • Page 23 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-022_a vmr2010-003-019_a 1. Pitman arm 1. Shim 2. Tie rod ends 2. Steering column frame support 3. Half bushings NOTE: Leave the tie rod ends on the pitman arm at this time. They will come off easily when the 17.
  • Page 24 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-024_a vmr2010-003-026_a TYPICAL - LEFT SIDE ILLUSTRATED 1. Hexagonal forming screws Step 1: Remove DPS retaining screws (2 each side) Step 2: Discard conical washers under screw head 2. Position the DPS unit on the frame DPS mount- ing bracket by engaging the two hexagonal 20.
  • Page 25 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-029_a 1. O-ring seals on steering column vmr2010-003-023_a 1. Pitman arm 6. Index steering column splines with DPS unit 2. Tie rod ends inserted in pitman arm splines. 3. Hardened steel washer on tie rod end NOTE: The DPS shaft splines have a key which 4.
  • Page 26 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-032 vmr2010-003-033_a Pull bellows down over steering column bolt and 1. Drainage hole in DPS ring flange edge of DPS unit housing extension. Secure bel- 2. Steering column bellows lows using the appropriate locking tie. 9.
  • Page 27 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-036 vmr2010-003-035_a STEERING COLUMN SHIM MEASUREMENT 1. These nuts installed hand tight at this time NOTE: Ensure the forward end of the tool is in the 11. Torque unit mounting screws center of the steering column, and the rearward 24.5 N•m (18 lbf•ft).
  • Page 28 Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) If total shim thickness exceeds 4 mm (.157 in), NOTE: If torque is applied to elastic nuts in- carry out the following: stead of hexagonal screw head, use 24.5 N•m (18 lbf•ft).

  • Page 29: Pitman Arm

    Section 01 TECHNICAL MANUAL Subsection 01 (DYNAMIC POWER STEERING (DPS)) 20. Install and connect ECM. Torque ECM mount- 6. Test drive the ATV to ensure proper DPS oper- ing screws to 7 N•m (62 lbf•in). ation. 21. Install dash board and reconnect the following: PITMAN ARM –...

  • Page 30: Air Controlled Suspension (Acs)

    Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) AIR CONTROLLED SUSPENSION (ACS) SERVICE TOOLS Description Part Number Page 529 035 868 ..... 32, 35, 37–38, 43–44 FLUKE 115 MULTIMETER ............295 000 070 ........... 44 OETIKER PLIERS................529 036 007 ........... 46 SPRING REMOVER ...............
  • Page 31 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) vmr2010-004-033_a vmr2010-004...

  • Page 32: General

    Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) GENERAL ACS SUSPENSION SETTINGS During assembly/installation, use torque values RIDING RECOMMENDED SETTING PRESSURE COMFORT LOAD and service products as in the exploded views. ACS 1 0.5 bar (8 PSI) Softest WARNING Operator only ACS 2...
  • Page 33 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) The requested setting is controlled by the ACS electronic module. The module is equipped with a pressure transducer to keep air pressure con- stant in the system. Depending on the rider ad- justment, the module will increase pressure using the compressor or release pressure using the so- lenoid release valve.

  • Page 34: System Description (Components)

    Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) vmr2010-004-001_a vmo2007-003-017_b 1. Pneumatic valve cap TYPICAL - FRONT SERVICE COMPARTMENT 1. Front fuse box 4. Push and hold pneumatic valve pin using a small ACS Compressor Relay (R5) screwdriver. Compressor relay is located in the front fuse box, under front service compartment panel.
  • Page 35 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) Outlander 800R LTD vmr2010-004-105_a OUTLANDER 800R LTD MODEL 1. ACS compressor relay (R5) vmr2010-004...
  • Page 36 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) ACS Main Components ACS COMPONENTS MAIN FUNCTION Filter To filter air intake of the compressor To pressurize the system Compressor Solenoid release valve To release air in 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...

  • Page 37: Troubleshooting

    Section 01 TECHNICAL MANUAL Subsection 02 (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 ACS MODULE Refer to...

  • Page 38: Troubleshooting With B.u.d.s

    Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) TROUBLESHOOTING WITH B.U.D.S. ACS System Leak Test COMMU- 1. Connect vehicle to B.U.D.S. Refer to NICATION TOOLS AND B.U.D.S. SOFTWARE subsection of the appropriate Shop Manual. 2. Select Activation page. 3.
  • Page 39 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) 4. Set suspension mode to ACS 2 using the ACS button. 5. Wait until the actual setting shows 2 (LH dis- play). vmr2010-004-201_b Step 1: Activation page Step 2: ACS folder Step 3: Solenoid valve operation test button 5.

  • Page 40: Acs Manifold

    Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) 2. Disconnect solenoid valve connector. – Module hose – Shocks hose. vmr2010-004-003_a 1. Solenoid valve connector vmr2010-004-005_a 1. Manifold air inlet hose (from compressor) 3. Unscrew solenoid valve from manifold while 2.
  • Page 41 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) vmr2010-004-007_b Install air fittings, pneumatic valve and check valve as follows. vmr2010-004-006_a 1. Retaining screws 6. Unscrew air fittings, pneumatic valve and check valve. vmr2010-004-007_a RETAINING SCREWS ARE OFFSET TOWARD MODULE FITTING 1.

  • Page 42: Acs Module

    Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) ACS MODULE ACS Module Signal Circuit Continuity Test 1. Remove seats and RH side panel. 2. Disconnect multifunction gauge from vehicle. LIGHTS, GAUGE AND ACCESSORIES Refer to subsection of the appropriate Shop Manual. 3.
  • Page 43 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) ACS Module Removal RELEASING AIR 1. Release air pressure, refer to PRESSURE IN SYSTEM FOR SERVICING in this subsection. 2. Disconnect module hose from manifold air fit- ting as follows: 2.1 Push fitting ring toward manifold.

  • Page 44: Acs Compressor Relay (R5)

    Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) ACS COMPRESSOR RELAY (R5) Outlander 800R LTD TEST PROBES VOLTAGE ACS Relay Continuity Test FUSE AND RELAY Fuse box pin 12B (BE/PK) 1. Remove relay (R5), refer to Battery voltage at the beginning of this section.
  • Page 45 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) 2. Select Activation page. Outlander 800R LTD 3. Select ACS folder. TEST PROBES RESISTANCE 4. Press Compressor button to proceed. Compressor pin C (BE/VI) Close to 0 Fuse box pin 11A (BE/VI) ACS Compressor Input Voltage Test RELEASING AIR 1.
  • Page 46 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) vmr2010-004-101_a vmr2010-004-014_a 1. Actual setting (pressure transducer reading) 1. Connector of auxiliary line pressure transducer 8. Measure voltage between compressor connec- 8. Disconnect compressor connector. tor terminals as per the following table. TEST PROBES VOLTAGE Pin C (BE/VI)
  • Page 47 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) 10. To disconnect hoses, proceed as follows: 10.1 Push fitting ring toward manifold. 10.2 Hold ring in place. 10.3 Pull air hose. 11. Remove compressor side retaining bolts and nuts. vmr2010-004-019_a 1.
  • Page 48 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) vmr2010-004-025_a vmr2010-004-022_a A. 45° 1. Front support mounting nuts 2. Compressor connector Ensure that check valve is installed with arrows 3. Front support pointing toward T-fitting. NOTICE Do not remove rear support from compressor.

  • Page 49: Acs Air Filter

    Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) ACS AIR FILTER 5. Locate ACS compressor air filter. 6. Unscrew ACS compressor air filter from air box. ACS Air Filter Removal 1. Remove seat. 2. Remove central panel. vmo2010-004-009_a 1.

  • Page 50: Pressure Transducer (Acs Auxiliary Line)

    Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) 3. Rinse the prefilter with warm water until all 4. Set the FLUKE 115 MULTIMETER (P/N 529 035 cleaning solution disappears. 868) 4. Let the prefilter dry completely. 5. Measure resistance as per the following table. Filter (Disc) Cleaning TEST PROBES RESISTANCE...

  • Page 51: Acs Hoses

    Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) 4. Remove pressure transducer from hose. vmr2010-004-108 Pressure Transducer Ground Test 1. Remove seats and RH side panel. 2. Disconnect pressure transducer connector. vmr2010-004-030_a 1. Auxiliary line pressure transducer 2. Connector 3.

  • Page 52: Shock Absorbers

    Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) vmo2010-011-103 HOSE PROPERLY INSERTED INTO FITTING SHOCK ABSORBERS Shock Absorber Removal 1. Lift rear of vehicle until rear shock absorbers are vmr2010-004-031_a fully extended. 1. Auxiliary line adapter 2. Fitting ring 2.
  • Page 53 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) 5. Remove spring stopper and its cap then loosen the spring remover screw. 6. Remove spring from shock. Shock Absorber Inspection Inspect the spring for damage. Replace if neces- sary. Secure the end of shock body in a vise with its rod upward.
  • Page 54 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) vmr2010-004-701_a 1. Sleeve 2. O-ring vmr2010-004-703_a TYPICAL 1. Circlip 2. Small sleeve 3. Lower cap 4. Upper cap vmr2010-004-702_a 5. Large sleeve 1. Sleeve 2. O-ring Install shock absorber cap opening at 180° from spring stopper opening.
  • Page 55 Section 01 TECHNICAL MANUAL Subsection 02 (AIR CONTROLLED SUSPENSION (ACS)) vmr2010-004-027_a 1. Shock absorber fitting 2. Air hose fitting Ensure that there is no air leaks from shock ab- sorber fitting and air hose. Refer to ACS SYSTEM LEAK TEST (WITH B.U.D.S.) NOTICE Never screw shock absorber air hose by using the air hose fitting only.
  • Page 56 NOTES...
  • Page 57 NOTES...
  • Page 58 219 100 388 FAIT AU / MADE IN CANADA U/M:P.C. ®™ AND THE BRP LOGO ARE TRADEMARKS OF BOMBARDIER RECREATIONAL PRODUCTS INC. OR ITS AFFILIATES. ©2009 BOMBARDIER RECREATIONAL PRODUCTS INC. ALL RIGHTS RESERVED. PRINTED IN CANADA.

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