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2008 DS 450 EFI X
Can-Am 2008 DS 450 EFI X Manuals
Manuals and User Guides for Can-Am 2008 DS 450 EFI X. We have
1
Can-Am 2008 DS 450 EFI X manual available for free PDF download: Shop Manual
Can-Am 2008 DS 450 EFI X Shop Manual (385 pages)
Brand:
Can-Am
| Category:
Offroad Vehicle
| Size: 58.78 MB
Table of Contents
Table of Contents
5
Preseason Preparation
13
Special Procedures
15
Turn over
15
ATV Immersion
15
ATV Submerged for a Short Time
15
Troubleshooting
17
Technical Guidelines (Engine)
17
High Engine Operating Temperature
17
Low or no Oil Pressure
17
Oil Contamination (White Appearance)
18
The Clutch "Slips"
18
Unusual Engine Noise And/Or Vibration at Idle Speed
19
Unusual Engine Noise And/Or Vibrations While Operating
19
Unusual Engine Noise And/Or Vibrations
19
Gear Is Hard to Shift
20
Diagnostic Flow Chart
21
Engine Removal and Installation
23
Engine Removal
24
Air Intake System
31
Air Filter Removal
32
Air Filter Cleaning
32
Air Filter Installation
32
Air Filter Housing Cleaning/Draining
32
Air Filter Housing Removal
33
Air Filter Housing Installation
34
Exhaust System
35
Muffler Removal
36
Muffler Inspection
36
Muffler Installation
36
Exhaust Pipe Removal
37
Exhaust Pipe Inspection
37
Spark Arrester Removal
38
Heat Shield Removal
38
Heat Shield Installation
38
Spark Arrester Cleaning
38
Lubrication System
39
Lubrication System Maintenance
42
Recommended Oil
42
Engine Oil Level Verification
42
Engine Oil Replacement
42
Oil Filter Removal
43
Oil Tank Strainer
44
Oil Filter Installation
44
Engine Oil Pressure
45
Oil Tank Strainer Cleaning
45
Oil Tank Strainer Installation
45
Oil Tank Removal
46
Oil Hose Connector
47
Oil Tank Installation
47
Oil Hose Connector Removal
47
Engine Oil Pressure Regulator
48
Oil Hose Connector Inspection
48
Oil Hose Connector Installation
48
Oil Pressure Regulator Removal
48
Oil Pressure Pump
49
Oil Pressure Regulator Inspection
49
Oil Pressure Regulator Installation
49
Oil Pressure Pump Removal
49
Oil Pressure Pump Inspection
50
Oil Pressure Pump Installation
51
Outer and Inner Rotor Clearance
51
Engine Oil Strainer
52
Engine Oil Strainer Removal
52
Engine Oil Strainer Cleaning and Inspection
52
Oil Suction Pump
53
Oil Suction Pump Removal
53
Oil Suction Pump Inspection
53
Oil Nozzle
54
Oil Tube
54
Cooling System
57
Cooling System Leak Test
60
Oetiker Clamp Replacement
60
Coolant Replacement
61
Recommended Coolant
61
Draining the System
61
Refilling the System
62
Coolant Tank Cap Test
63
Coolant Tank Removal
63
Coolant Tank Installation
64
Radiator Removal
64
Cooling Fan
65
Radiator Installation
65
Cooling Fan Relay Test
65
Cooling Fan Removal
65
Thermostat Removal
66
Thermostat Test
66
Thermostat Installation
66
Coolant Temperature Sensor (CTS)
66
Water Pump Housing Removal
67
Water Pump Housing Inspection
67
Water Pump Housing Installation
67
Water Pump Impeller Removal
68
Water Pump Impeller Inspection
68
Water Pump Impeller Installation
68
Water Pump Shaft Removal
68
Water Pump Shaft Inspection
69
Water Pump Bearing Inspection
69
Water Pump Bearing and Seals Removal
69
Water Pump Bearing Installation
69
Water Pump Inner Seal Installation
70
Water Pump Outer Seal Installation
70
Water Pump Shaft Installation
71
Magneto/Starter
73
Magneto Cover Removal
75
Magneto Cover Inspection
76
Magneto Cover Installation
76
Crankshaft Position Sensor (CPS)
77
Stator Continuity Test
77
Test at Stator Connector
78
Stator Insulation Test
79
Stator Output Voltage Test
80
Stator Removal
81
Stator Inspection
81
Stator Installation
81
Rotor Removal
82
Rotor Inspection
83
Rotor Installation
83
Sprag Clutch Removal
84
Sprag Clutch Inspection
84
Sprag Clutch Installation
84
Starter Drive Gears
85
Sprag Clutch Gear Removal
85
Sprag Clutch Gear Inspection
85
Sprag Clutch Gear Installation
85
Starter Drive Gears Removal
86
Starter Drive Gears Inspection
86
Starter Drive Gears Installation
86
Starter Voltage Test
86
Starter Cable Continuity Test
87
Starter Removal
87
Starter Installation
88
Cylinder Head/Cylinder
91
Cylinder Head/Cylinder Maintenance
95
Valve Clearance Inspection
95
Cylinder Leak Test
96
Valve Clearance Adjustment
96
Valve Cover Removal
97
Valve Cover Inspection
99
Valve Cover Installation
99
Camshaft Timing Gear
100
Timing Chain Tensioner Removal
100
Timing Chain Tensioner Inspection
100
Camshaft Timing Gear Inspection
101
Camshaft Timing Gear Installation
101
Camshaft Removal
103
Camshaft Inspection
103
Camshaft Radial Clearance
104
Decompressor Inspection
104
Camshaft Installation
105
Valve Lifter Bucket Removal
105
Valve Lifter Bucket Inspection
105
Valve Lifter Bucket Installation
106
Cylinder Head Removal
106
Cylinder Head Inspection
107
Cylinder Head Installation
107
Valve Springs Removal
108
Valve Spring Inspection
109
Valve Spring Installation
109
Valve Removal
109
Valve Stem Seal Removal
110
Valve Inspection
110
Valve Stem
110
Valve Face and Seat
110
Valve Installation
111
Valve Guide
112
Valve Guide Inspection
112
Valve Guide Removal
112
Valve Guide Installation
112
Cylinder Removal
113
Cylinder Inspection
113
Cylinder Taper
113
Cylinder out of Round
114
Chain Tensioner Hole
114
Cylinder Installation
114
Piston Removal
114
Piston Inspection
115
Piston/Cylinder Clearance
115
Piston Installation
116
Piston Rings Removal
117
Piston Rings Inspection
117
Piston Rings Installation
117
Piston Pin Removal
118
Piston Pin Inspection
118
Connecting Rod Small End Bushing
118
Piston Pin Installation
119
Crankcase/Crankshaft
121
Main Shaft Oil Seal Removal
123
Main Shaft and Bearing Inspection
123
Main Shaft Oil Seal Installation
123
Primary Drive Gear Removal
124
Primary Drive Gear Inspection
124
Primary Drive Gear Installation
124
Timing Chain and Chain Tensioner Guide Removal
124
Timing Chain Drive Gears
125
Timing Chain and Chain Tensioner Guide Inspection
125
Timing Chain and Chain Tensioner Guide Installation
125
Timing Chain Drive Gears Inspection
126
Bearing Pin
126
Intermediate Gear
126
Control Gear
127
Timing Chain Drive Gears Installation
127
Crankcase Disassembly
127
Crankcase Inspection
128
Ball Bearings
129
Crankshaft Main Bearings
129
Balancer Shaft Oil Seal
129
Ball Bearings Removal
129
Ball Bearings Installation
130
Balancer Shaft Oil Seal Removal
130
Balancer Shaft Oil Seal Installation
130
Crankshaft Main Bearings Removal
130
Crankshaft Main Bearings Installation
131
Crankcase Assembly
132
Balancer Shaft Inspection
132
Balancer Shaft Installation
132
Crankshaft Locking Procedure
133
Turning Crankshaft from Magneto Cover
133
Turning Crankshaft Using Rear Wheels
133
Locating the TDC of the Compression Stroke
133
Locking Crankshaft
134
Crankshaft Inspection
134
Crankshaft Gear
134
Connecting Rod Big End Axial Play
134
Crankshaft Gear Replacement Procedure
135
Crankshaft Gear Removal
135
Crankshaft Installation
135
Clutch
137
Clutch Adjustment
140
Adjustment at Clutch Lever
140
Adjustment at Clutch Cover
141
Clutch Release Cover Removal
142
Clutch Release Cover Disassembly
143
Clutch Release Cover Inspection
143
Clutch Release Cam
143
Clutch Release Cover Assembly
144
Clutch Release Cover Installation
144
Adjustment Screw
144
Clutch Cable Removal
145
Clutch Lever Removal
145
Clutch Cable Installation
145
Clutch Lever Installation
146
Retaining Plate and Clutch Spring Removal
146
Retaining Plate and Clutch Spring Inspection
146
Clutch Spring
147
Retaining Plate and Clutch Spring Installation
147
Clutch Removal
147
Clutch Disassembly
148
Clutch Inspection
148
Clutch Hub
148
Clutch Assembly
149
Clutch Installation
149
Inner Plate
149
Clutch Cover Removal
150
Clutch Cover Inspection
151
Clutch Cover Installation
151
Shift Shaft Oil Seal
151
Clutch Drum Removal
152
Clutch Drum Inspection
153
Clutch Drum Installation
154
Gearbox
155
Neutral Indicator Switch
158
Shifting Mechanism
158
Neutral Indicator Switch Test
158
Shifting Mechanism Removal
158
Shifting Mechanism Inspection
160
Shifting Mechanism Installation
160
Shift Shaft
160
Tooth Segment, Springs and Pawls
160
Gearbox Removal
161
Gearbox Disassembly
162
Gearbox Inspection
163
Clutch Shaft
163
Shift Drum
164
Shift Fork
164
Shift Fork Shaft
164
Gears
164
Gearbox Assembly
166
Engine Management System (EMS)
167
Power Distribution
168
ECM Interaction with the Electrical System
169
ECM Inputs/Outputs
169
Controller Area Network
170
Engine Control Module
170
Engine RPM Limiter
170
Drowned Mode
170
Diagnostic Mode
171
Communication Tools/B.u.D.s. Software
173
Multi-Purpose Interface-2 (MPI-2)
173
MPI-2 Power Supply
173
Monitoring System/Fault Codes
177
TPS "Adaptation Failure" Fault
178
Fault Code P1600
178
Fault Code P1601
178
Fault Code Table
179
Electronic Fuel Injection (EFI)
185
Air Induction
185
General Recommendations
186
Throttle Body
186
Intake Manifold
186
Fuel Rail
186
Electrical System
187
Electrical Connectors
187
Resistance Measurement
187
Basic Adjustments
188
Idle Speed
188
Closed Throttle and Idle Actuator Reset
188
Engine Control Module (ECM)
189
ECM Connector Removal
189
ECM Connector Installation
189
ECM Connector Probing
190
Power Supply to ECM
190
ECM Grounds Test
191
ECM Power Circuit Test
192
ECM Wake up Circuit Test
192
ECM Main Relay Circuit Test
193
ECM Removal
193
ECM Installation
193
ECM Replacement
194
ECM Automated Data Transfer
194
ECM Manual Data Entry
194
Fuel Injector
197
Injector Leakage Test
197
Injector Test with B.U.D.S.
197
Injector Input Voltage Test
197
Injector Control Circuit Test
198
Injector Resistance Test
198
Injector Removal
199
Injector Installation
199
Fuel Rail Removal
199
Fuel Rail Installation
201
Mechanical Inspection
201
Throttle Body Removal
201
Throttle Body Installation
203
Throttle Position Sensor (TPS)
204
TPS Wear Test
204
TPS Resistance Test
204
TPS Voltage Test
205
TPS Removal
205
Idle Air Control Valve
206
TPS Installation
206
IACV Resistance Test
206
IACV Visual Inspection
207
CPS Voltage Test
208
CPS Resistance Test
208
Manifold Absolute Pressure Sensor (MAPS)
209
MAPS Inspection
209
MAPS Test with B.U.D.S.
209
MAPS Input Voltage Test
209
MAPS Circuit Continuity Test
210
MAPS Removal
210
Ambient Air Pressure and Temperature Sensor (AAPTS)
211
AAPTS Resistance Test (Temperature Function)
211
MAPS Installation
211
AAPTS Circuit Continuity Test (Temperature Function)
212
AAPTS Input Voltage Test (Pressure Function)
213
AAPTS Circuit Continuity Test (Pressure Function)
213
AAPTS Removal
214
AAPTS Installation
214
CTS Resistance Test
215
CTS Removal
215
Fuel Tank/Fuel Pump
217
Fuel Tank Leak Test
219
Fuel Pump Pressure Test
220
Fuel Hose and Oetiker Clamps
222
Fuel Hose Replacement
222
Fuel Pump Quick Test
222
Fuel Pump Input Voltage Test
223
Fuel Pump Winding Continuity Test
224
Fuel Pump Relay Quick Test
224
Fuel Pump Relay Input Voltage Test
225
Fuel Pump Circuit Continuity Test
225
Fuel Pump Removal
226
Fuel Pump Installation
227
Fuel Tank Draining
228
Fuel Tank Removal
228
Fuel Tank Inspection
229
Fuel Tank Installation
229
Ignition System Description
231
Ignition System Operation
231
Ignition System Testing
231
Ignition Testing Sequence
231
Intermittent Ignition Problems
233
Multiple Problems
233
Ignition Switch Operation
233
Ignition Switch Input Voltage Test
233
Ignition Switch Continuity Test
234
Ignition Switch Removal
235
Ignition Switch Installation
235
Engine Stop Switch Operation
235
Engine Stop Switch Continuity Test
236
Engine Stop Switch Wiring Test
236
Ignition Coil Input Voltage Test
238
Ignition Coil Ground Circuit Continuity Test
239
Ignition Coil Resistance Tests
240
Primary Winding Resistance Test
240
Spark Plug Cap Resistance Test
240
Ignition Coil Removal (Front Coil)
241
Ignition Coil Removal (Rear Coil)
241
Ignition Coil Installation
241
Spark Plug
242
Testing for Spark Occurrence
242
Spark Plug Removal
242
Troubleshooting a Fouled Spark Plug
243
Spark Plug Analysis
243
Spark Plug Installation
243
Charging System
245
Voltage Regulator/Rectifier
246
Voltage Regulator/Rectifier General Information
246
Voltage Test Using B.U.D.S.
246
Voltage Test with a Multimeter
247
DC Current Test with an Inductive Ammeter
248
Battery Information
249
Weak or Discharged Battery
249
Battery Voltage Test
249
Battery Removal
250
Battery Cleaning
251
Battery Inspection
251
Battery Storage
251
New Battery Activation
251
Electrical System Main Grounds
252
Starting System
253
Starting System Operation
253
Engine Cranking Conditions
253
Starter will Not Crank Engine
253
Starter Solenoid Test
254
Solenoid Battery Cable Continuity Test
255
Solenoid Diode Test
255
Power Signal to Solenoid Coil
256
Solenoid Dynamic Test
257
Continuity Test of Solenoid Ground Control Circuit
258
Start Button Input Voltage Test
259
Start Button Continuity Test
260
Clutch Switch Function
261
Clutch Switch Continuity Test
261
Clutch Switch Replacement
261
Lights
263
Lights System Description
263
Lights System Operation
263
Lights System Testing
263
Headlight Input Voltage Test
265
Headlight Bulb Replacement
266
Headlight Switch
267
Headlight Beam Aiming Adjustment
267
Headlight Switch Continuity Test
267
Taillight/Brake Light Operation
268
Taillight/Brake Light Circuit Test
268
Taillight/Brake Light Bulb Replacement
269
Neutral Indicator Light (Green) Operation
269
Neutral Indicator Light Testing
269
Check Engine Indicator Light (Yellow)
271
Neutral Indicator Light Removal
271
Neutral Indicator Light Installation
271
Check Engine Indicator Light Operation
271
Low Fuel Level Indicator Light Operation
272
Low Fuel Level Indicator Light Dynamic Test
273
Low Fuel Level Indicator Light Testing
273
Input Voltage Test
275
Drive Chain/Rear Axle
277
Drive Chain Adjustment
279
Drive Chain Inspection
279
Drive Chain Cleaning
280
Drive Chain Lubrication
280
Drive Chain Removal
280
Drive Chain Installation
281
Front Sprocket Removal
282
Front Sprocket Inspection
282
Front Sprocket Installation
283
Rear Sprocket Removal
283
Rear Sprocket Inspection
284
Rear Sprocket Installation
284
Rear Axle Removal
284
Rear Axle Inspection
285
Rear Axle Installation
285
Rear Sprocket Hub Removal
286
Rear Sprocket Hub Installation
286
Chain Tensioner Inspection
287
Chain Tensioner Removal
287
Chain Tensioner Disassembly
287
Chain Tensioner Assembly
287
Chain Tensioner Installation
288
Wheels/Tires
289
Tire Pressure
290
Tire Inspection
290
Tire Replacement
290
Wheel Removal
291
Wheel Installation
291
Front Wheel Hub Removal
291
Front Wheel Hub Installation
293
Rear Wheel Hub Removal
293
Rear Wheel Hub Installation
294
Wheel Bearing Inspection
295
Wheel Bearing Removal
295
Wheel Bearing Installation
295
Steering
297
Steering Adjustment
299
Steering Alignment
299
Handlebar Grip Removal
300
Handlebar Grip Installation
300
Multifunction Switch Removal
300
Multifunction Switch Installation
300
Throttle Lever Removal
301
Throttle Lever Installation
301
Throttle Cable Removal
301
Throttle Cable Installation
303
Throttle Cable Adjustment
303
Handlebar Removal
304
Handlebar Installation
305
Steering Column Removal
305
Steering Column Inspection
306
Steering Column Bearing Replacement
306
Steering Column Installation
307
Tie-Rod Removal
307
Tie-Rod Inspection
308
Tie-Rod Installation
308
Knuckle Removal
308
Knuckle Installation
309
Front Suspension
311
Factory Settings
313
Spring Preload
313
Shock Absorber Compression
313
Shock Absorber Rebound
314
Spring Preload Adjustment
314
Shock Absorber Compression/Rebound Adjustment
314
Lubrication
315
Shock Absorber Removal
316
Shock Absorber Disassembly
316
Shock Absorber Inspection
316
Shock Absorber Assembly
317
Shock Absorber Installation
317
Upper Suspension Arm Inspection
317
Upper Suspension Arm Removal
317
Upper Suspension Arm Installation
318
Upper Ball Joint Inspection
318
Upper Ball Joint Removal
318
Upper Ball Joint Installation
318
Lower Suspension Arm Inspection
319
Lower Suspension Arm Removal
319
Lower Suspension Installation
320
Lower Ball Joint Inspection
320
Lower Ball Joint Removal
320
Lower Ball Joint Installation
321
Rear Suspension
323
Shock Absorber Rebound Damping
325
Shock Compression and Rebound Adjustment
326
Spring Removal
328
Spring Installation
328
Swing Arm Removal
329
Swing Arm Inspection
329
Swing Arm Disassembly
330
Swing Arm Assembly
330
Swing Arm Installation
331
Bell Crank Lever Removal
331
Bell Crank Lever Disassembly
331
Bell Crank Lever Assembly
332
Pivot Arm Removal
332
Pivot Arm Disassembly
333
Pivot Arm Assembly
333
Pivot Arm Installation
333
Brakes
335
Front Brakes
336
Rear Brake
337
Parking Brake
338
Brake Fluid
338
Recommended Brake Fluid
338
Brake Fluid Level Verification
338
Brake Fluid Replacement
339
Brake Fluid Draining
339
Brake Fluid Bleeding
339
Caliper Removal
340
Caliper Inspection
342
Caliper Installation
342
Brake Pads Inspection
342
Brake Pads Replacement
342
Brake Disc Inspection
344
Brake Disc Removal
344
Brake Disc Installation
344
Brake Lever Replacement
345
Front Master Cylinder Removal
346
Front Master Installation
346
Rear Master Cylinder Removal
346
Rear Master Cylinder Disassembly
347
Rear Master Cylinder Assembly
348
Rear Master Cylinder Installation
348
Brake Pedal Removal
348
Brake Pedal Bearing Replacement
349
Brake Disc Hub Removal
350
Brake Disc Hub Inspection
350
Brake Disc Hub Installation
350
Rear Caliper Bracket Removal
350
Front Brake Light Switch Test
351
Front Brake Light Switch Removal
351
Front Brake Light Switch Installation
352
Rear Brake Light Switch Test
352
Rear Brake Light Switch Removal
352
Rear Brake Light Switch Installation
353
Flexible Brake Hose Removal
353
Rear Flexible Brake Hose
354
Flexible Brake Hose Installation
354
Body Parts
357
Seat
359
Vehicle Care
360
Body Repair
360
Decal Removal
360
Decal Installation
360
Seat Installation
361
Seat Cover Replacement
361
Access Cover Removal
362
Console Removal
362
Console Installation
362
Front Bumper Removal
362
Front Fender Removal
364
Front Grille Removal
364
Front Grille Installation
364
Side Panel Removal
364
Front Fascia Removal
365
Footrest Removal
365
Footrest Installation
365
Footrest Support Removal
365
Rear Bumper Removal
366
Skid Plate Inspection
366
Skid Plate Removal
366
Skid Plate Installation
366
Nerf Bar Removal
367
Nerf Bar Inspection
367
Nerf Bar Installation
367
Frame
369
Frame Cleaning
370
Rear Frame Extension
370
Frame Welding
370
Rear Engine Supports
371
Rear Frame Extension Installation
371
Footpeg Removal
371
Footpeg Installation
372
Side Member Removal
372
Lower Suspension Arm Attachments
373
Side Member Installation
373
Lower Suspension and Arm Attachment Removal
373
Ds 450/Ds 450 X
375
Wire Colors
383
Connector Location Area
383
Connector Identification
383
Terminal Location in Connector
383
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