TABLE OF CONTENTS

SAFETY NOTiCE..................... . ............................................................ VIII

INTRODUCTION ................................................................................... IX
GENERAL INFORMATION. .. . .. ... .. . . ..... . .. ...... . ..... .... ....... ......... ... .... .... ........ ................. IX
VEHICLE INFORMATION.. .. ... . . . ...... . ................................................................ . ..... . . .. X
ENGINE EMISSIONS INFORMATION ..... . . ................................................................. . .. . X
SELF-LOCKING FASTENERS PROCEDURE ... .... ......... ....... ................ .... ......................... XI
LOCTITE® APPLICATION PROCEDURE.. . ...................................... ................................ XI
TIGHTENING TORQUES . . .. . . . . . . .... ........................... . ... .................... . ....................... XIV
MANUAL INFORMATION .. . . . .... . .. .. . ... . .. .. ................. . ... . ............ ....... .................... . ... XVI

01 MAINTENANCE
01 - MAINTENANCE CHART . .......................... . ....... .. . , . .. . ..... .. .. ... . ... . . .. . . .. . . .. . . . . . . . . . . .. . . .. 1
MAINTENANCE CHART .. . . ............ . .... . . . .. .. . .. ........ .. . . ... .. ... .. . .... . ... .... . . .. . .. .. . .. .. . ..... .. .. . ... 1
02 - PRESEASON PREPARATION...................................................... . ........ ..... .. .. . .... .. . . 5
03 - STORAGE PROCEDURES ............................................ ............................ ... ... . .. ... . 7
FUEL STABILIZER ... . . . . . . .. . .. .. .... . .. . .. . . . .... . . . ... .. ... . .......... .. . . .. ... .. ... . .. . .. . . .. . .. ... .. .. .. 7
ENGINE LUBR iCATION ...... .. .. . . ... . .. .... .. . .... ... .... . ...... .. .. .. ........... ..... .. .. ... . . .. ... .. . .. . . . .. . ... 7
RAG S INSTALLATION. ....... .. .. . .... .. .. ... . .... . .. .. ... .. ...... .. ......... . .. .. . .. . .. ... .... .. .. . .. . . . .... . . 7
COO LA NT DENS iTY. . . . ... . . . ... .......... . ...... ... .. ..... . .. .. .. .. . ... .... .. .... .... . . . . . . .... .. . .. .. . .. . . . . . .. ... . 8
DR IVE AND DRI VEN PU LLEYS PROTECTION ... ....... ... .. ..... .. ....... ... .. . .. .. . .. . ..... . .. ... ... .... . . ... .... 8
VEHICLE CLEAN ING ... . ... . .......... .... .......... . .. . .. .. ... .. ... .. .. . .. ..... .. . .. .. .. . . ... ... .. . .. ..... . . ... . . ... . 8
VEHICLE PROTECTION ............ .. ... .. ... .. .. .. ... .... .... .. . ............ .. ... . .... ... . . .. ... .. . .. .. . .... . .. .. .... 8
04 - SPECIAL PROCEDURES ............................................ ...................... ... .................. 9
TURN OVER . .... . .. .... . ....... .. .... .. .. .. ........... .. .. .. ..... . .... .................... . . .. ... .. . ...... . ... .. .... .. 9
ATV IMMER SiON. . .. . . . .... . .. .. ... ...... . .......... ......... . ...... . .... . ... . . . .. .. . ... . .. . .. .. .. . .. .. ... .. ..... . . .. 9

02 TROUBLESHOOTING
01 - TROUBLESHOOTING CHART...................................................... ... ..................... 11
ELE CTRI CAL Sy STEM ....... ... ... ........................... .. .. .. .............. . .... . .... .. . ... .. . .. . ... . ..... . ... 11
COOLIN G Sy STEM ... .. .. .. . .. .. .. . .. .. . .. ....................... . ... .. .. . . ..... . ... . . .. . . .. .. ... . . .. .. . .. .. . .. .... . 12
MAGNETO SySTEM .... . ....... .. .. ........ .. .. .... ... .. ..... ... .. . .. .. .. . ..... .. .. .. .. .. .. .. .... ... . .. . .... .. . ..... 13
LUBR iCATION .................... . .. .. ........................... . .. .. .. ... ..... ... ..... .. .. . .. .. .. . .. .. . .... .. . . . .. . 14
CY LINDER AND HEAD ... .. ... . .. . .... . .... . ... . ......... . ..... .. ................ .. .. .. .. ... .. . .... . .... .. . . ..... . 15
CRANKS HAFT . .. .......... . . . .. .. .. .. . . ... . ... ... . . .. .. . .......... . . . .... . . . .. . . . . . .... . .. . .... .. . . .. .. . ... . . .. .. . . . 15
GEAR BOX .... . ....... . . . .. . ..... . .. . ..... ... ... . .. ................ . ... .... . . . . . . . . .. .. . . .. .. . .. .. .. .. . .. .. . .. .... . .. . 15
CO UPLI NG UN IT ..... . .... . . . .. .. . . .. . ... .. . . .. . .. . .......... . . . .. . . . .... . . . .... . . . .... ... .... . .. .. .... . .... . . . .. .. 17
CVT .. . .. . ....... . . .. ... .. . .. ... . .... . . ... .... ........ . .. . . . . .. . . . .. . . . . . .. . . .. ..... .... . .... .. .. . .. .... . ....... . 17
ENGINE GENERAL .. . .. . .... . .. .. . .... . .. .. . ..................... .. . .. ... . .... .. . .. .. .... . .... . .... .. .. . .... . .. . 20

03 ENGINE AND GEARBOX (V490N660N81 0)

01 - ENGINE REMOVAL AND INSTALLATION............................. .... ............................... 25
GENERAL . ... . .. . . . . . ... .... . .. .. . . . ........... . ............... ....... . ..... . . .. .. . ... . .. . .. . .................. 26
PROCEDURES... . ....... . ...... .. ........ . .. . .. . .. .. ..... . . ......... . . . .... . .... ... . ... .. ....... . ...... . ..... 26
ENGI NE REMOVAL ...... . ... .. .. . .. . . .... .. ......... ... .. ..... .. . .. ............ .......... . ... .. ... .. .. .. . .. . .... . . . 26
ENGINE INSTALLATION .... . . ... . .. .. ... .. ..... .. . . .. . .. .... .... . .. .. ... .. .. . .. ... .. .. . ...... ... ..... .. . . . .. ... .. . .. 32
ENGINE MOUNT REPLACEMENT .... .. .. . .. .............. . ..... .. . ...... .. ... ..... ... .. .. ..... ... .... . .. ... ....... 33
02 - AIR INTAKE SySTEM.............................................. ... .. .. . . ... . ... . ..... ....... . ....... .. ... 35
GENERAL ...................................................... ..... . . .... ......... ... . . . . . ... . .. ..... .. . . .. . . . 37
PROCEDURES ....................................................... . ............... . .... .... ....... . ... . .... 37
AIR FI LTER ..... .. ... ......... .... .. .... .. .. .. .... .. ..... .. .......... ... .. . .. . ... .. . .... . .... .. .... . .... ... . . 37
AIR FI LTER HOUS iNG .. .. .. ... ...... . ... .. .. .. .... . .. . ..... .... .... . .. .... .. . .. ... ... .. .... ..... ... . .. . ... .. ..... .. 37
RE STRICTOR . . .... . ..... .... .... .. .. .. .. ... . .. .. .. .. ...... .. .... .. .. .. ... .. ...... ....... . . .. . .. ...... . .. .... . .. . . 39
03 - EXHAUST SYSTEM. . . . . . . . . . .. . . .. . . . . . . . . .. .. . . .. . . .. . . . . . . .. . . .. . . . . . . .. . . .. . . .. . . .. . . .. . . . . . . . . . . . . . . . . .. 41
GENERAL ................................................................. . .................................... 42
PROCEDURES ................................................ ...... ........... . .............................. 42
TABLE OF CONTENTS

FRONT EXHAUST PiPE . ... . .. .. . .... .. ... .. . ........ . ... .. . .. ... .. .... . .. .. ..... . ... . . .. ... .. .... . .. .. . . ... ..... . 42
MUFFLER . . .... . ... .. . ... . . . . . ... . . . . . . . .... . . . .... . . . . . . . . . .. .. . . . . . . ... . .. . ... . .. . ... .. . . . . . . . . . . .. . . . .... . . . . .. . .. 43
"Y " EXHAUST PIPE . ...... .. . .. .. . .... ........... .. . ... .. ... .... . .. . ... . .. .. . . . .. . .... ... . . . .... .. ... .. ... .. . . 43
FUEL TANK PROTECTOR ................ ... .... ..... . .. ... .. .. .. . .. ..... .. ........ ... .. ...... ... . ......... . ...... 44
04 - LUBRICATION SySTEM..................................................................................... 45
COMPONENTS ............................... ... ............................................................. 46
ENGINE LUBRICATION ...................................................................................... 47
GENERAL ........................................ . ............................................................. 48
MAINTENANCE ................................. .. ................................................... .. . . .... 48
ENG IN E 0 IL ........................... . .. .. . . .... . .. ..... .."". "" " . " " ... "."".""" ... " " ." ." "" . " ." 48
INSPECTION .................................................................................................. 49
ENGINE OIL PRESSURE...... .. ..... ... .. .. . . .. . ....... .. .. ... .. .............. .. . .. .. . .. .. ... .... . . 49
PROCEDURES ................................................................................................ 49
OIL FILTER........................ ... . ... .. ..... ... . . .... ... . . . . ..... . ................. ...... . .... . .. . . .... . . . . . .. .. 49
OIL PRESSURE SWITCH (OPS) ........ .. .. . .... ............. . . . . . .... . . . . . .. . .. . . ... . .. .. . . . . .. . . ..... . . ... . . . . . .. 50
ENGINE OIL PRESSURE REGULATOR . .. ... .... .. .. ...... .. . ... .. .. ..... .. . .. .. ... .. ......... .... . .. ..... 51
OIL PUMP ... . 52
ENGINE OIL STRAINER . . . . . .. . . . .. . . .. . .. .. . .. .. . .. .. . . . .. .. . .. .. . . . .. .. . .. . .. .. . .. .... .. ............... 54
REED VALVE . .. . . .. .. . ... .. .. . . . . ... ... . .. . ..... . .. . .... .... . ... . .. ...... . ............. . . . . . ... . .. . . ... . . . .. . . . . .. 54
05 - COOLING SySTEM............................ . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . .. . . .. . . .. . . .. . . . . . . .. . . . . . . . . . . 55
GENERAL .................................................. ... ................................................. 58
INSPECTION.................................................................................................. 58
COOLING SYSTEM LEAK TEST........ . .. . ..... ... . . .. . ..... . .. . ... .... ... . ............. . .... . ....... .. . ... 58
MAINTENANCE .............................................................................................. 59
COOLANT REPLACEMENT... ... .. .. . .. .. . . . . ... .. . ... .. .......... .. .. ... ... ..... .. .. . . .................. . ....... . . 59
PROCEDURES................................................................................................ 60
THERMOSTAT..... .. .. .................... .. ...... .... . . . .. .... ... .. .. . .. .. . ..... .. .. . .. . .. .......... .. ............ 60
RADIATOR CAP .... . . ... . ........................ . . . . .... . ... .......... . .. . ... . .. . . .. . . . . . ... . ...... . ...... . . . . . . . .. . 61
RADIATOR..... ..... . . . .. . . . ................ . ...... . ... . . . . .. .. . . .. . .. . . . .. . . . . . . ..... . .. . . . .... . ................... . 61
COOLANT TANK................................... . . . .. . . . . . .. . . . ... .. . . . .. . . . . ... . ........... . ........... . . . . .. . . . 61
COOLANT TEMPERATURE SENSOR (CTS) ... .. .. . .. .. . .......... .. .. . .. . . . . . . . . . .. . . .. ..... .. ........ . ... .. ... . . . 62
RADIATOR FAN RELAY (Rl) .................... .. .... ............. .. . .. .. ..... ..... .. ....... .... ...... .. .. .... .. 62
RADIATOR FAN .. . . . . ... . ..... . . . . . . . . . . .. .. .. . . . . . .. .. . . . . . . . . . . . . . . .. .. . . .... . ... . .. . . . .. .... . ... . . .. . .. . .. . .. .. . . . 63
WATER PUMP HOUSiNG .. .. .. .. . .... . . . .. . ........... . .. . . . ...... .. . ... .... . " . .. . . . . .. . .... . 65
WATER PUMP IMPELLER . .. .. . .. ...... .. . .. .... . " . . . .. . . . ... .. . .... ... .. . .. .. ... .. . .. .. ... ....... ..... .. ... ... .. 66
WATER PUMP SHAFT AND SEALS ..... .. .. . .. . .. . . . .. ... ............. . ... .... ..... ..... .. ...... .. ..... . ... . . . . 66
06 - MAGNETO SySTEM .. ... ... ... .............................................................................. 71
GENERAL .... ...... ............................................................................................ 73
PROCEDURES.. . ............................................................. .. . ... ..... . .................... 73
MAGNETO COVER .. . ......... . . ................. . .. .. ...... ........ .. ........ . . .. .. . .. ... . .. ... . . . .. . . . .... 73
STATOR . .. ....... . .... .... ... 74
ROTOR . .. . . . . .. . . . .. ... . .. .... . .... . . . .. .. . . . . .... . .... . .. .... . .. ... . . .... . ... .. . .. .. . . ... ... . ........ . . . .. 75
SPRAG CLUTCH ... .. ..... .. . .... .. ... .. .... .... ............ . .... . .. .. .. ..... . .. ... .. .... .. ............. .. ...... .. .. . 76
SPRAG CLUTCH GEAR ............ ... .. 77
STARTER DRIVE GEARS .......................................... .. .. ...... , .. .. .. . .. ... .... " ... . ...... . .. . ... . .. 77
07 - INTAKE MANIFOLD, CYLINDER HEAD AND CyLINDER ............................................... 79
GEI\JERAL...................................................................................................... 84
MAINTENANCE .. .... .. . ............................................................. .... .................... 84
VALVE ADJUSTMENT.. .. . ... . . . .... ... ...... . .. . .... . .... .. ... ... .... . . .. .. ... . ........ .. . .. ... 84
INSPECTION.... . ... .... ... .. . . ......................................................... .. .................... 85
LEA K TEST.... ... .. .. .. . .. .. ... .. . .. ... .. . .... .. .. . .. .. . ... .. .. .. .. .. ... .. .. ... ............. .. ............ . . .. . 85
PROCEDURES ............................................................... .... .. .. .... .. .. .. .. ...... . . ..... 87
INTAKE MANIFOLD ... ...... .. . .... . .... ... .. ... ..... ...... .... ..... .. . .... . .. .. .. . ....... . .. .... . .. ..... ... . . 87
VALVE COVER . .. . . .......... . . .. . . . . . .. . . . . . . .... . . . . .. . .... . . . . .. . . . . ... . .. . . . . . .. . . . . ... . . . .. . . . . . . . . . . . .. . . . . . . . 88
TIMING CHAIN TENSIONER ...... . .. . .... . .. .. .. ... .. . .... . .. " .. . .. " .. . .. ..... .. . ... ...... . .. .. ... .. . .... ... .. .. . 89
CAMSHAFT TIMING GEAR . .. .. . . .... . . .. . . .... .... . . . ... . . ... . .. ... . . . . . . .. . . .. . . . . . . ..... . .. . . . . . . . ... . . ........ . 90
II
 TABLE OF CONTENTS

ROCKER ARM ... ...... .. . . . . .. .. ... .. . .. .. ..... .......... . ...................... .... ... . .. ...... . ... .. ... . .... 92
TIMING CHAIN . . . . . .. . . .. .. .. . .. .... . .. . .. . . .... . . . .. .. ..... .. . .. .... . ... 93
CYLINDER HEAD .. ... . .. . .. .... . ............ . . . .. . .... . .. .. ... .. . . . . . . .. ........ .. .. .. . .... . . . .. .. ........ . .... .... 94
CAMSHAFT .... .. . .... . .. . . ..... . .. .... . .... . ... ... . ... .. .. .. .. .. .................. . .. .. .. . . .... . .. . . . . . .. .. . . . ..... 95
VALVE SPRIN G. ... .. .. .. .. . ..... . ....... . .... . ... . .. . .. . . . . . . .. ... .. . . . .. . ............ ... ... . . . .... .. . .. . .... . ..... 100
VALVE .......... ... . . . . . . .. . . .. .. . .. .. . .. .. .. . ..... . .. . .. . .... .. .. . ..... . ... .. . . ... .. .. . . . .... .. . . . . . .. . . . .... . .. .. . 102
VALVE GUIDE .. . .. .... . . . . . . . . ... . . . . . . . ... . .. ... .. ... .. .. ......... .. .. . . .. . . . . .. .. .. . . . . .... . .. .. .. . .. .. . .. .. . .. ... 104
Cy LINDE R ....... . .. . . .. .. .. ......... .. .. ... .... ..... .. 105
Pi STON ................... ... .. ......... . .... .. ............ .. . .. ... . 106
PI STON RINGS ..... . ...... . . .. . .......... ... . . . ......... . .... . . . .... . .............. . 111
08 - BOTTOM END .. . ................................. .. .............................. ........ .. .. .............. . 113
GENERAL . ........ .............................. . . .... ............................... ........ .............. .. . 117
PROCEDURES ... ........................... ........ . . ............................... .... . . ................. . 117
ENGINE DRIVE SHAFT.. .. ...... .. . ..... .. . .. .. . ..... .. .. .. .. . ... .. . . .. . .. .. .. . ......... ... .. .. . .... .. .. . 117
PTO COVER OIL SEAL ...... . .. .. ...... .. . . ... . . . ... .. . .. ........ . ....... . .. .. .. . . .. ... . ...... .. .......... .. .. . 119
PTO COVER .... . ... ....... . . ........ .. .... .. . . .. .. . . .. . . .. .. . ..... . ..... . .. . . . . . . .. ... . . ... . . .... .. . .. .... . .. . . . . .. 119
DRIVE GEAR S ..... .. . . .. ... . .. ... .. .. .... . . ...... . . . .. . . .. . . . .... . ..... .. . . . . . .. .. . . . .. . . . . . . . .. .. . ...... . .. . .. .. . 122
TIM ING CHAI N .......... ..... .... . .. ... ...... . ......... . .. .. . ....... .... ... . .... ... .... .... .. . ... . . ......... . .. . . 123
TIMIN G CH A IN GUiDE ... .. .. ... .. .. .. . .... .. . .. .. ... . . . ... . ... ... . ..... . ... . . . .... . ...... . .. .. . . . ...... . .. .. . .. . 124
CRANKCASE .... . ......... ... .... . .. .... . .. .... . .. .... . ...... .. . .. . . . ........ . ...... . .. .. . . . ..... . . .... . .. .. . ... . 124
CRANKSHAFT . ........................ .............. ............ . ..... .. .... ... ................ . ... .. . .. . . 128
09 - GEARBOX AND 4X4 COUPLING UNIT .. ............ .. .. ... .............. .... ......................... .. 135
GENERAL ... ............................... .... ......... . ..................... ..... ... . .. .. ...... .... .... ... . . 138
MAINTENANCE ............. . ......... . .. . ..... . ........................ . . . .. .... ...... . ................... . 138
GEA RBO X OIL CHANGE...... ........ ..... ... .. . ...... ........ .. . ........ .. . ...... .... ... ....... . .. 138
PROCEDURES ...................... . ... . . ... ... . ................ .. ........ . .. .. . . ........................... 139
GEARBOX POSITION INDICATOR SWiTCHE S.. ....... .. ...... .... . . . . .... ... .... . . ...... ...... . .... . .. . . . . . ... 139
4WD INDICATOR SWiTCH .... ... .. .. .. ... . .... ........ ........ .. ..... . 140
OIL SEALS ...... . ... . . ..... .... ..... . .. ........... . .... . ... . .. . ... .. . .. . .. . ... . . .. ... .. ...... . ..... . .. . ....... .... .. 140
ACTU ATOR ..................... .................... .. . .... . ... ... .......... . . .. .... .. .... .... . ... .. . .. .. ... 142
OUTPUT SHAFT AND COUPLING MECHANi SM...... . . . .. .. .... . .. ... ..... ...... .. . ..... 144
GEARBOX. ....... ............... ... . ...... . ......... . . .. . .. .. .... ...... ... .. ... .... . 149
10 - SHIFTER ...... ............. ............ .... ... . ..... . . .. ... ... .. ........... .. ....... ......................... . 167
GENERAL ...... . . . ............................ . .. .. .. ..... ............. .. .. ..... . ...... .. .... ................ . 168
PROCEDURES ................. . . .... ............................. .. . . .. . ........... . ............. .......... . 168
TRA NS M ISSION LEVER ...... . .. .. . ... . ... .. .. .. . .... ..... . . ..... . . . ........ . . . . . .... .. ... ... ... . . .. .. .. ... . . 168
LINK ROD . ................ .. .. .... . . ... . .. .. . ........ . ... ..... .. . . ........... .. .. ... ... .. .. ... .... . . . 169
SHIFTING PLATE..... .. . ... . . ... ... . .. ... .. . . . ........... .... . .. .. ... . . . . ... . . .. .. ... . . . .... . .. ... .... .. . . . .. . .. . .. 170

04 ENGINE MANAGEMENT (V490N660N810)

01 - OVERViEW...................... ................................. .. .. . ........................... . ........... 173
OPERATING PRINCiPLE .................................................................................... 174
AIR INDUCTION .. ........ . . . .... .. .. .. ... .... .. . .. .. .......... .. 174
FUEL SySTEM ...... .. ....... ... ... .... . .... .... .. ........... . 174
ELE CTRI CAL SYSTEM . .. ... .... . .. ........ .. ....... .. ..... ....... ... .. . .. .... . ... .. .... . . 176
ENGINE MANAGEMENT SySTEM ........................ ... ............... . ............... ... . . . .... ... 178
ELE CTRO NI C FUEL INJ ECTIO N ........ .. .. .. . .. .. .. .. ......... . 178
IGNITION........... ...... . ............ .. .. .. ..... .. .. .. . .. . . . .. ... .. .. ..... .. .. . .. .... .. .. .. ..... 178
ENGINE MODES OF OPERATION ... ... .. ...... . .. ... . .. .. .. ... . . .. . ...... .... ... .. .. . .... . . . .. .. . .. .. ... .... .. 179
MONITORING SYSTEM .... ... .. .. . . . ... ..... ............ .. . ... . . ..... . .. ... . ... ... .. . . . .. .. . .. .. .. . ... . . . . ..... . 180
DIAGNOSTIC MODE ... . . . .. .. ............ .. . . .. . ..... .. . ... . . . . ... .. . ... . . . .... . . . .. .. . . . .. . . . . . . . .... 180
ENGINE MANAGEME NT SYSTEM FLOW CHART ............ . . . .... ......... .. .... .. .. . . . .. .... ..... . ........ 181
02 - EMS DIAGNOSTiC......... ................................. ................................ . ............... 183
GENERAL .......... .. .... .... ................................ .. .. .... .......................... .. .... . ........ 183
FAULT CODES 184
FAULT CO DE TABLE ..... ... . . . .. .. . . . 185
III
TABLE OF CONTENTS

03 - ADJUSTMENT AND REPAIR PROCEDURES........................................................... 193

GENERAL .................. ..... ... ........................................................................... 193
FUEL Sy STEM ............................. . .. . .. ... .. . . . ................................... .. ........ ... ... ..... ... 193
ELECTRICAL SySTEM ........ . ....... . .. .. . . . ... . .. . .................... ...... ...... ........ . ...... ..... . . .... . .. . 194
BASIC ADJUSTMENTS. .... .. .. ..... . .......................... ... ....................................... . 197
IDLE SPEED . ....... ...... . .. ... . . . . . ..... .. . ..... . .... .... ... . . ..... . ... . . . . . . . . .. ... . . ...... . ... .. ..... .. . .... . ... 197
THROTILE CABLE ........ ....... ... ....... . ... . .. ... . . . . . ..... .. ... ... . ........ .... .. .... . . . .... ... .. . ... . . . . ... .. 197
CLOSED THROTILE AND IDLE ACTUATOR RESET ............... . .. ........... ... .. .. ... .. ... . .. . .. .... . ..... 198
IGNITION TIMING.. .. .. ............. .. ......................... ....... .. .. .............................. ... .. ...... 199
REPAIR PROCEDURES ............................................. . ....................................... 199
MAIN RELAY (R2).. ........ . . .. .. ..... ... .. .. . .. .. ... .. .... .. ..... .... .. . .... ... ..... ... .. .. .. . ......... .. ... ... .. . 199
D1 DIODE (ECM)..... ........ ..... .. .................. .. .. .. .. ...... .. ... . ... ... ..... .. . .. .. ..... .. . ........... .... 199
ENGINE CONTROL MODULE (ECM) ... .. ........ ... .... ....... ............. .. ....... .. ... . .. .... ...... .... .. . ... 200
FUEL INJECTOR. .. ............... . ... . .. . . . . .. . ......... .... . ...... . ..... .. .. .. ... . . ... .... .. ...... ... ... .. . .. . ... 203
FUEL RAIL. ... . ....... .. . . .... .... ... . . .. . . .. . . . . . . . . ... . . .. ... .. . . ... . .. . . ...... . . . . . .. . .. .. . .... . . . . . .. . .. . . .... .. 206
THROTILE BODy. ... . . . .. . . .......... ..... ... ... . ... ....... ...... . ... ........ ..... ................ .. .. . .. . . . ...... 207
THROTILE POSITION SENSOR (TPS) ...... ..................... .. ................... . .. . ... . .... . ............... 210
IDLE BYPASS VALVE (lBV) .......................... . . . . . .... . ... .. ...... . ...... . .. ....... . ... . ... . . .. .. . ... . ...... 212
CRANKSHAFT POSITION SENSOR (CPS) ..... .. .......... . .. . .. . ..... .. ..... .. ..... .. .... .. . .. ... ..... .. ... .. . . . 214
CAMSHAFT POSITION SENSOR (CAPS) .. . .. ... . . . ........ .. .......... ........... .. .. .. . . . .... ......... . .... . ... 215
MANIFOLD AIR PRESSURE AND TEMPERATURE SENSOR (MAPTS) .... ... .. . ......... .. ... .. ..... .... . . . . 216
COOLANT TEMPERATURE SENSOR (CTS) ..... .................... . . . . . ... ......... . .... ... .... .. . .. . .... ...... 218

05 FUEL SYSTEM
01 - FUEL TANK AND FUEL PUMP. .. ......................................... .. .............................. 219
GENERAL ...................... .......................................... . .. .. ................................ 221
INSPECTION........................ . ...................................................................... . . 221
FUEL TANK LEAK TEST.. ... .. . . ...................... . . . ... . . . .. . .. .. . .... .. . .. .. . . . .... . .... . ... . .... . .... . ...... 221
FUEL PRESSURE TEST ... .......... ...... . . . ... .. ........ .. . .. . .. . . ......... ..... .. . .......... ....... . . . . ...... . .. 224
PROCEDURES.. .. .. . .............. . . ... ........... .. ......................... ... ............................ 225
FUEL HOSE AND OETIKER CLAMPS ........... .. .... ..... ........... . ...................... .... ... .. .......... 225
IN-LINE FUEL FILTER .......... ....................... ... . ....... ...... . . .. . . ................. .. ... ............ . 225
FUEL TANK .. . .. ........... .......... .. ............ . .. .. .. ........... ..... .. ..... . .... ... .. ... .. ..... .. .. ........... 226
FUEL PUMP . ............ ................... . .. .. .. .................... ... ...... . ....... .......................... 228
FUEL SYSTEM DIAGNOSTIC FLOW CHART........................................................... 230

06 ELECTRICAL SYSTEM
01 - COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE ............................................... 231
COMMUNICATION TOOLS ............... . . ........................................... ... ................. 231
MULTI-PURPOSE INTERFACE (MPI) ........ .. .. ........ .. ... ...... .. .... .... .. .. .............. .. . .. .. . ... ....... 231
MULTI-PURPOSE INTERFACE-2 (MPI-2) . .. . ..... .. . .. . . . . . .. .. ... . ... . .... . ...... . .. . . .. .. . ....... ... . ...... . ... 232
B.U.D.S. SOFTWARE .. . .. . . . ................. .... ....................... .. ........................ ... ....... . ..... 233
02 - IGNITION SySTEM. . ... .. ..... . ................ . ........................................................... 235
GENERAL ..................................... .... ........................................... .. ............... 235
PROCEDURES.................................. .. .......................................... .. ............... 235
IGNITION SWiTCH .. . ... ...... .. . . . . . .. .................. .. . . . . .. . .. .... . .. ..... . ... . . ... . .......... . ..... . .... .. . . 235
ENGINE RUN/STOP SWiTCH . ...... .. . .... . ... .. . .... . .... .. .. ..... . .......... .. .. .... . ... . . .. .... .. . .... . .... . .. 237
IGNITION COIL... ...... . ....... ... .. ... .. . . . . . .. .......... . .... .. ... ..... ....... ....... . .. .... ...... .. .. ..... .. . .. . 238
SPARK PLUG. . ... . .. .. ................. . .. . .... . ... . ... . ...... .. . .......................... . .. . . . ... . . .. . .... . ... .. 240
03 - CHARGING SySTEM............................ .................................................... .. . . ... 243
GENERAL .. ............................................ ......................................... .... ....... ... 243
PROCEDURES ... . .................................. . ........................................ . ... ... . ........ 244
VOLTAGE REGULATOR/RECTIFIER ........... .... ....................... .. ............... ..... ............ . .. ... 244
STATOR ................ . .... .. . ..... .... ... . . . . .. .. . .... . .... . . . .......... . . . . . .. . . .. ......... .......... . ... . ....... 246
BATIERY ... ............ . ... .. .. .. . .. . . . .. ........ ....... . ..... ......... . . .. . . . . .......... . .... . ...... . .............. 248
MAIN GROUND ... . .. .. ...... . ..... . ... ......... .. . ... . ...... .. ...... . ......... ......... . . . .. . ...... . . . ... .. . . ..... 251
IV
 TABLE OF CONTENTS

04 - STARTING SySTEM........................................................................................ 253

GENERAL ..................................................................................................... 253
PROCEDURES ................ .. ................... .. ........................................................ 254
FUSES . . . ... .. . ............ ... . ... . . .. ... ... .. . .... ... .... ... . .. . ...... . .... ...... ......... .. ...... . .. . .. . .. . .. . . . 254
D2 DIODE (STARTER SOLENOID) ..... . ...... .. ............ . .. .. .... . . . .......... . ..... .. ... . .... . ...... . 254
START BUTTON . . . . . ... ............... .. ..... . .. .. . ... .. . ... ............. ...... . ... .... .... . . .. ..... .. . ... .. ...... . 255
STARTING SOLENOID ............ .. ....... . . .. ........ .. ..... . .. . ..... . ... .... .............. . ................. . 256
ELECTRIC STARTER .. ........... ............. .. ..... ................ .. ............... .. ........ .. 258
05 - DIGITALLY ENCODED SECURITY SYSTEM IDESS) ................................................... 261
GENERAL .... ................. ....... .. . ............. .... ....... .. ........... .. .. ...... . .... . . . .. ... .. .. . . . . ..... 261
DESS KEY PROGRAMMING .. . .... ..... . ....... . . . .. . . . .................. . . . . . ......... . ........ .. ............. 261
TROUBLESHOOTING....... . . ........ . ........... ................. . . ...... ..... .. .... .. ... ....... .. ... . .. 262
06 - LIGHTS, GAUGE AND ACCESSORIES ..................... . ............................................. 263
GENERAL............................................................................ ......................... 263
PROCEDURES ........................................................ .. ................... .. ................ 264
FUSES ..... ... ............... ... . .. ... . .. ....... . .. ... ... . .. ....... .... . . . .. ... . ... .. .. .. ..... . ..... . . .. .. . ..... .. . . 264
ACCESSORY RELAY (R3) ..... .... ..... .. . ... .. .. .. . ..... .... .. ..... .. ... ...... ....... . .......... ... .. . 265
MULTIFUNCTION GAUGE .. ....... .... .. . ..... ... .... . .. . .................. .. ............... .. 266
VEHICLE SPEED SENSOR (VSS).... . .... . ...... . ... ... . . . ...... ...... . ........ .. .... .. .. . ....... ..... . ..... ... . 276
FUEL LEVEL SENDER. . .. ............ .. .... .. . ... ............ . ...... ... .. .. .............. .. .. .. .......... . .. .. 277
MULTIFUNCTION SWiTCH ............. .. .. ... . .. . ... .. ............. ... ..... . ...... ... .. . .. .. ......... . 277
12-VOLT AUXILIARY POWER OUTLET. . . . .. ..... . .. . . . . . . .. ... . . . .. . .. . .... . .. . . . . .. . . . . .. ..... .. . ... . . . . .. . .. .. 279
12-VOLT POWER OUTLET ........ .. ......... . ........... .. ..... .. ........ . . . .. .. .... . ... . ... . . . . 279
HEADLAMP .. .. . .............. . . ... ..... . . . ........ . . . 280
TAILLIGHT ... .. ........... .. .......... . .. ... ............ . .. . ... . .. .. 283
WINCH ., ................................. .. ............ ... .... . .. . 283
WINCH CONTROL SWiTCH............ .. . . . . .. . . . .. . .. ...... .. .. .. ...... .. . . . .... . .... .. . . . . . . . . . . ........ . .... . . 285
D5 AND D6 DIODES (WINCH RELAY) ..... . .......... ... ....... . ............ . ...................... ... .... 286

07 TRANSMISSION
01 - CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ................................................. 289
GENERAL ..................................................................................................... 291
PROCEDURES........................... . ................................................................... 291
DRIVE BELT ....... . ..... ... . .. ... .. .. . ... .. .... .... ..... . ........... ..... . . ............ .. .. ..... .... .. ........ .. .. . 291
DRIVE PULLEY .... . .. . . ... . . . . ...... . .. .... .. . .... ...... . ... . ... . . . .... . . . .... . . . ... . .. .. ............. . .... . .. . 292
DRIVEN PULLEy.................. .. ..... . . .. ....... . . ... .... .. ............. . . .. .... ... .............. . ... .... ... 300
CVT AIR GUIDE ..... ...... . . . . . .... .... . . . . ........ . ...... .. ..... . ..... . . .. .. ... ... . . ..... . ..... .. ...... ...... . . .. . 305

08 DRIVETRAIN
01 - FRONT DRiVE ......... ....................................................................................... 307
GEI\JERAL ................ ... ................... ...................... ..................... .. .................. 309
PROCEDURES ........... . ................................................................................... 309
TIRES AND WHEELS ....... . ..... . . .. .. . . . ........ . . . .... . ........................ . ........... . ..... .. .. . ... ... . 309
WHEEL HUB.... . ............ . . . .. . .... . ....... . ...... . .. .... . .. ...... . .. ..... . ... .. . . ..... . ... . ... .. ... .. . . . . . .. . .. 309
FRONT DRIVE SHAFT............ ... ..................... . ........ .. ......... . ... . .. . .... .. ....................... 310
DRIVE SHAFT BOOT....... . ..... . .. . . ... . . ... . ... . .. . . .. .. ... . ..... . .. . .. .. . . . . . . ... .. ... ........ . .. . . . . . . ... . .. .. 312
FRONT DIFFERENTIAL. .. . ... .. . .... . ........ . .... .. ....... .. ........ ....... ............ .. .. .. .. . ... .. ... .. ...... 312
FRONT PROPELLER SHAFT . ......... ... ...... ..... ......... . ........ . . ... . .............. .... . . . . ...... . . . .... ... 316
PROPELLER SHAFT U-JOINT. ... . .. ....... . ... .. . .. . ............. . ... . . . ...... . .. ....... . ....... . .. . . .. ....... . 317
02 - REAR DRiVE ...... ........................................................................................... 319
GENERAL ............................................................................................... ...... 321
PROCEDURES ............................................................................................... 321
TIRES AND WHEELS..... .... .. . . ......... .. ....... . .. ............ . ... . ... . .. .... .. ......... .. ..... . ... .. . .. .... 321
WHEEL HUB.............. ..... ........... . ....... . .............. .. .... ..... .... .. .......... ....... . ............ 321
DIFFERENTIAL PROTECTOR . . ..... . ...... . .. .... ... . ............... .... .... . ... . ........... . .. . ........... . .. . 322
DRIVE SHAFT ............ . ... . ...................... . .......... . 322
V
TABLE OF CONTENTS

DRIVE SHAFT BOOT... ........ . . . . . ... . ..... . .... . .. . . .. . .. .. . . . ... ... . . . .... . . .. . .. .. . .... .... . .. .. . . . . . . .. ...... 323
REAR PROPELLER SHAFT .... .. ....... . ..... .... . ..... .. ... .... ... .. . . .... . .. .. .... .. .......... ... .. .. . .... .. .. .. 323
REAR PROPELLER SHAFT U-JOINT ... .. . .. .. ... .. ..... .. .... ... ............. .. . .... . ....... .... . .. . .. ......... 325
REAR DIFFERENTIAL ...... . ..... ............ ... . . ..... .... . .. .. ........ ....... ....... ... .... ........ .. . .... .. ... . 326

09 STEERING SYSTEM
01 - STEERING SySTEM........ .. .. .................. . .. .................. .. ................... .. .............. 331
GENERAL .. .. .. .. . ............. .. .. ............... ... . ... .. . .............. . .. .. . ............... .... .. ......... 333
PROCEDURES .. .................... .. .......... . .................... . ...... . ............ .. ......... . ........ 333
HANDLEBAR GRiP .......... ...... .. . . . . . . .... .. . .. .. .. ... .. . . . ... . . . .... .. ... . . . .. . . . . .. . .. ..... .. . . .. . . .. . .. . ... .
333
HANDLEBAR COVER .. . .. .. .......... . ..... .... .. . .. ....... . . .......... ... .. ..... . .. ......... .. . .. ....... .... . ....
333
HANDLEBAR ... .. . ........... . .... . .. .. . . . ....... . . . . .. .. . ... .. ...... . . .. . . .. . .. . . . . . .. . .. .. ... . .. . . . . . .. .. . . ... . .
333
STEERING COLUMN .... . . .......... . .... .. . ....... ....... ..... .. . ............ .. . .... . .... ... .... . ........ .. .. . .. 334
STEERING COLUMN BEARING ... . .. ... .. ..... ... .. .. ............... ... .... . .... . . .. . .. . .... . .. ... .. .. ........... 335
TIE-ROD ........... ....... .............. .... .. .... .... .. ........ ... .. .. . .... .. .. ....... . .. . . ... . .. .. ........ ... .. .. .
335
KNUCKLE . . .. .. ....... . .. .... . ..... . .. . . ... ...... .. . . .. .. . . . .. . . ... . . ... .. . . . .. . .. .. .. .. . .. ... . .. . ... . . .. . . . . .. . . . ..
336
338
WHEEL BEARING ....... .. . ...... . .. . .. .... . .... .. . .. ... ................ .. . .... ... .. .. . .... .. .. . .. . .. .. ... ..... .. .
MULTIFUNCTION SWiTCH . ........... .. ... ...... ........ .. . .. .. .... . .. ..... .. .. . .. ... .... . ... . ......... .. .. .. .. .339
THROTILE HANDLE ... . .......... . . . . . . .. ... ... ...... . .. . . . . 339
HANDLE BRAKE . ...... . . .... .. . . . . . .. .. . .... . .. .. .. . .. .. . .. . .. ..... . .. .. . . . . ... . .... ......... . ... . . . .. . ..... .. ....
340
ADJUSTMENT ............... . .................... ...................... . .................... ... ............. 340
STEERING ALIGNMENT......... ....... . ... ..... . . .. ........ .... ... .. ... .. ... ...... . .. . .. ... .. .... ... .. . ..... ..... 340

10 SUSPENSION
01 - FRONT SUSPENSiON............... ....................................................................... 343
GENERAL . . .... .. ........... . ..... . .. . .......... ......... . ..................... ... . ........................... 347
PROCEDURES .................. .. .................. .. .................. .... ................... . ........ . .... 347
TIRES AND WHEELS.. . .. ..... . . ..... .... .. ..... .. .... ..... ...... . . .. . .. . ... ... . .. ...... . ... .. . . .. . . ..... . . ....... 347
SHOCK ABSORBER AND SPR ING .... . ...... . ....... ... ........... . .... ... .... . .......... ... .. .... . .. ..... ...... 347
LOWER SUSPENSION ARM PROTECTOR ... .. . ..... .... .. . .... .. .. ... . ... .. .. . ........... . .. . ... .. .. .. ..... .. . 349
LOWER SUSPENSION ARM......... . .. ......... .. .. ...... .. . .. ..... .. . .. ....... . ... ........... .. ...... .. . . . ..... 349
LOWER BALL JOINT ..... .. .. ........ ........... .. ..... .... . .. ....... .. ... .. ..... . .. .. ........... .... . .. . . ...... 351
UPPER SUSPENSION ARM ... . .... ...... . .. . ..... . .. . .. . ... ... ... .. . . ... . . . .. .. . .... . .. .... ... . ...... . . .. . . .. .. 352
UPPER SUSPENSION ARM BRACKET.... ..... .... .. ..... . .. .. .. .... ... . .... .. .. . .. . .. .... ... ... .. ... .. .. . ... .. 353
UPPER BALLJOINT .. .. ... .. ...... ............. .. ............ ....... ...... ................ .. . ... ... .. .. .. ... 354
02 - REAR SUSPENSiON..... .. . . .. . . . . .... . . . . . . .. . . .. . . . . . . ... . .. . . .. . . .. . . . . . . ... . .. . . . . . . . . . . .. . . .. .. . . . . . .. 357
GENERAL .. .......... .. ................... . .. . ................. . ... . ................ . . . .. . .............. . ..... 359
PROCEDURES . ........ .. ............. .. . .. . . ................. ........................ .. .................... , 359
TIRES AND WHEELS ... .. .. .. .... .. ... .. .. . ....... ....... .. . ... . ........ ......... . .. ... .. ...... . .. . . ........ . . . . 359
REAR SHOCK .... ....... ...... .. . .... . . .. . . . . .. .. .. .......... . .. .. . .. .. .... . . . .. ... . .... . . . .... .... . ...... . .. . . . . 359
TORSION BAR .. ...... .. . .... .. ........ .... . ................... .. . ........... . ...... .. . ........ ..... .. ... ......... . 360
TRAILING ARM ... ....... .. . ...... . . . .. . . . .. . . ... .. . . .. .. .. .. . .. .. . ... . .. . .. .. . .. . . . ... . .. ...... . . . .. ... . .... . . ..... 361
TRAILING ARM BEARINGS ...... .. .... .... . .. .. ..... ...... ......... .. ..... . .. .. . .. .. .. . ... ... . ... .... ..... . ..... 362

11 BRAKES
01 - FRONT AND REAR BRAKES............................................................. ........... ....... 365
GENERAL . .. .................... .. .................. . . .. .................. . .. . .................. . . ... ......... 369
MAINTENANCE .................. . ................ . ... . .................... . .................... .. . . ........ 369
BRAKE FLUiD .. . ... .... .. .. ... .. ... .... .. .. .. .. ... .. .. ... ... .... ... .... ... ... ...... . ... .... . .. .. .. .. . .. ... ...... . 369
PROCEDURES ..... . .. .. ................ . ... .. .......................................................... . .... 371
REAR BRAKE LIGHT SWiTCH..... .. ... .. . . . ............... . .. .. . .. .. . . ......... . . . ... ... . .. . ... ....... ... . . .. ... 371
FRONT BRAKE LIGHT SWiTCH ...... . .. .. ... .... . .. ... ..... .. . ........ ..... ... .. . . ............... ......... ... . .. 372
PAR KING BRAKE MECHANiSM .... . . . . .. . . .. . . . . .. . .. .... . .. . . ... .. . . ... ... .. .. .. .... .. . . . . . . . ... . . .. . .. .. . . . ... 372
BRAKE LEVER .... ....... .. ........... .. . .. .... ...... . . . .... . .. .... . . . ....... . . ....... ...... . .. ..... . . . .... . .. .. . 373
FRONT MASTER CyLINDER .... . ...... . ... .. ... . . ....... .. .. .... ...... .. .. . . 373
REAR MASTER Cy LINDER.. .. .... . ...... . .... . .... .... .... ... ...... ... . .. . . . ... ... ... ....... .. .. .. .. .... . .... .. .. 374
VI
 TABLE OF CONTENTS

CALIPER ... ............. ... ..... ........ ..... ........ . . ...... . ...... . .. ..... ....... . .. ... .. .. ....................... 376
BRAKE PADS....... . . . ...... .. . . . ..... ... .... .... .. .... .. . . ... . ... .. .. ... .. ...... . . . ... . . ........ .. . . . ..... .. . .. .. . 377
BRAKE DiSC..... ... . . .. . ....... ... .. . .. .. ..... . . ..... . .. .. . .... .. ..... ... .... ... . . .... . . .. . . . . .... . . .. ... . . ... ... . . 379
BRAKE PEDAL. ... .. ..... . . . ....... .. .. ............. . .... .. .. ......... . .. . ....... .. ....... . ........... .. ... ....... . 380
BRA KE H0 SES ....... .. . .. ..... ....... .. ....... . ... .. .. . .... . .. .. .. .. ... ... ....... ... .. . .. .... ... ..... ... ....... . . . 380

12 BODY/FRAME
01 - BODy....................................................................................................... ... 383
GENERAL ........................ .. ................... . .......................................... . ............ 393
PROCEDURES ................... .. .......................................................................... 393
DECALS ...... . .. . .... .. . ... ... ... . .... ....... . ......... . . ... .. . ....... .. .............. ...... ... ..... . . . . .. ....... . 393
SEAT. . ............ . ......... . ...... .... . ....... . . . ... .. ..... .. .. . ....... . .. .... . . ... . .. . . ..... . . . ... ... . ...... . ...... 393
CENTRAL PANEL ....... .. .... . . . .... . .. ...... ......... . .... ... . . ... . .. ..... . ..... ... . ...... ....... . .. .. .......... . 395
DASH BOARD ....................... . . ...... . . ............... . . .......... . .. . . . . . . ................ ... . ... .. ....... 396
SIDE PANEL. .. ... .. .. . ....... .. . .... ... .... .......... ........ .. ... .... ..... .. ..... . .... . ... ......... . .... ... . ... ... 396
FOOTREST ..... . .... .... . ... .. ..... . .. .... . .. . .... . .. .. ... .... .. ... .. . .... .. . . . . .... .... . .... . ... .... . ..... 397
INNER FENDER .. ....... . ... . .... ....... ......... .. .. ... ... .. ... .... ... ........ ... ....... ... ...... ... .. ........... 397
HEAVY DU1Y BUMPER.. ............. ...... .......... ............ .. ..... .. . .. .. . . . ..... .. ....................... 397
FRONT BUMPER/FRONT SKID PLATE/FRONT FASCIA. ...... ..... ... ............ . ................. .. ........ 398
LUGGAGE RACK . ... ................. .... ............ . ....... ... .................... . ..... . .......... . .. ... . . .. ... 399
FENDER .. .. ........... .. .... . .. . ... . . .. ... .. ..... . .. .. . . .. .. .. . . . . .. . ..... . . .. . . ... .. . ... . .. .. . .. .. .. .. . ... ...... . . 399
FENDER SUPPORT .............. ........ . .. .. ....... ................... .. .. ... . ........ . ............. .. 402
02 - FRAME.................. . ............................... . ..................................................... 403
GENERAL ...... ................................ ........... . .................... ..................... .. ........ 405
PROCEDURES ............................................................................................... 405
FOOTREST SUPPORT...... . ....... . ......................... . . . . ... .. ..... . . . ....... . . . ........ ... ..... ..... . .. .. 405
BATIERY SUPPORT.... .. .. . ................. .... . .. . ... . ... .. . . ......................... .. .. . .. ... ........ 405
HITCH .... . . ................ .... . .. ...... . ...... ... .. ... . ...... . ........ .... . .. . ... . ... . ........ . . . . . . .. ...... . ...... 406
RECOVERY HOOK.. ... .... . .... . .. .. .. ..... .. .. .. . .. .. . ........... ...... ... .... .. . .. . . . .... .. . ... . .. . ........ . .. .. 406
FRAME ..... .......... .. . . .. ........ ........ ........ . . . .... ..... ............................... . .. .. . .. ......... .. . 407

13 TECHNICAL SPECIFICATIONS
01 - OUTLANDER SERIES ....................................................................................... 409
02 - RENEGADE MODELS .... ................................................................................... 419

14 ELEC"rRICAL CONNECTORS AND WIRING DIAGRAMS

01 - ELECTRICAL CONNECTORS. . . .. . ... . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . . . . . .. . .. . . .. . . . . . . .. . . .. . ... . . ... 429
DEUTSCH CONNECTORS . .......... . ... . .... .. . . .. . . .. . . .. . ... . ... . .. . .. . . . . . . . . . .. . . . .... .. .. .. . .. .. ..... .. . . . .. 429
ECM CONNECTORS.... ......... ...... ................ ..... . .. ... .... .. ... ... .... . .. . ....... .. . .......... 430
MULTIFUNCTION SPEEDOMETER CONNECTOR..... .. ...................... . . .. . .............. . .. . .... .. . ... 433
BATIERY AND STARTER CABLE TERMINALS.. .. . ...... ...... . . .. ....... .. ... .......... .. .. .... . .. .......... 434
02 - WIRING DIAGRAMS ..... ............................ ................................ ..... . ............... " 437
WIRING CONNECTORS CODING.... ............. . ... ......... . ..................... . .... . ... .. ........... . .... . 437

VII
SAFETY NOTICE

SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair 2008 Can-Am ATVs as describe
in the model list in the INTRODUCTION.
This edition was primarily published to be used by mechanica l techn icians who are already familiar with
all service procedures relating to BRP products . Mechan ical technicians should attend training courses
given by B.R.P.T.I .
Please note that the instructions will app ly only if proper hand tools and special service tools are used .
It is understood that this manual may be trans lated into another language . In the event of any discrepan-
cy, the English version shall prevai l.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-
vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read
and understand these . It does not include dealer modifications, whether authorized or not by BRP, after
manufacturing the product.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts . They are not to be interpreted as technical drawings or exact replicas
of the parts .
The use of BRP parts is most strongly recommended when considering replacement of any component.
Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those for which it was designed .

&. WARNING
Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair
procedures.

This manual emphasizes particular information denoted by the wording and symbols :

&. WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including pos-
sibility of death.

CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-
nents.
NOTE: Indicates supplementary information needed to fully complete an instruction .
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents.
We strongly recommend that any services be carried out and/or verified by a highly skilled professional
mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing
federal, provincial and state regulations .

VIII vmr2008-040
 INTRODUCTION

INTRODUCTION
GENERAL INFORMATION
This shop manual covers the following BRP made 2008 Can-Am ATVs .

MODEL COLOR ENGINE MODEL NUMBER

Outlander 500 Green, Red, Yellow V490 2TSA, 2TSC. 2TSD, 2TSE. 2T8F
Camo, Green,
Outlander 500 XT V490 2USA, 2U8B. 2USC, 2USD
Red, Yellow
Outlander MAX 500 Red V490 2WSC
Outlander MAX 500 XT Green, Red, Yellow V490 2XSA, 2XSB. 2XSC, 2XSD
Outlander 650 Green, Red, Yellow V660 2NSA. 2NSC, 2NSE. 2NSF, 2NSH. 2N8J
Camo, Green,
Outlander 650 XT V660 2PSA.2PSB,2PSC.2PSD,2P8E.2PSF
Red, Yellow
2R8A. 2RSC, 2RSD, 2RSE,
Outlander MAX 650 Green, Red, Yellow V660
2RSF, 2R8G. 2RSH
Camo, Green,
Outlander MAX 650 XT V660 2SSA.2SSB,2SSC.2SSD,2SSE.2SSF
Red, Yellow
Outlander SOO Green. Red, Yellow VS10 2HSA, 2HSC, 2HSE, 2HSF, 2HSH, 2HSJ
Camo, Green,
Outlander SOO XT VS10 2JSA, 2JSB. 2J8C,2JSD. 2JSE, 2JSF
Red, Yellow
Green, Red, Yellow 2KSA. 2KSC, 2KSD, 2KSE,
Outlander Max SOO VS10
Steel Gray Metallic 2KSF, 2KSG, 2KSH
Camo, Green, 2LSA. 2L8B. 2LSC, 2LSD,
Outlander MAX SOO XT VS10
Red, Yellow 2L7E, 2LSF, 2LSG
Outlander MAX SOO Ltd Steel Gray Metallic V8l0 2MSA. 2MSB. 2M8C
Renegade 500 Yellow V490 4ESA. 4E8B, 4ESC
Renegade SOO Yellow VS10 4B8A. 4B8B, 4B8C

vmr2008{)40 IX
INTRODUCTION

The information and component/system descrip- Engine Identification Number (E.I.N.)

tions contained in this manual are correct at time
of writing. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
Due to late changes, there may be some differ-
ences between the manufactured product and the
description and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.

VEHICLE INFORMATION
Model Number

I4--=-1

vmr2006-03 B-001_a
vmr2007-01 1-00l_a
1. Engine Identification Number IE. I. N.)
TYPICAL - VEHICLE IDENTIFICATION NUMBER LABEL
1. Model number

ENGINE EMISSIONS
Vehicle Identification Number (V.I.N.) INFORMATION
Manufacturer's Responsibility
Manufacturers of ATVs engines must determine
the exhaust emission levels for each engine horse-
power family and certify these engines with the
United States of America Environmental Protec-
tion Agency (EPA). An emissions control informa-
tion label, showing emission levels and engine
specifications, must be placed on each vehicle at
the time of manufacture.

Dealer Responsibility
When performing service on ATVs that carry an
emissions control information label, adjustments
must be kept within published factory specifica-
tions .
vmo2006-007-042_b Replacement or repair of any emission related
TYPICAL component must be executed in a manner that
1. VI.N. (Vehicle Identification Number) maintains emission levels within the prescribed
certification standards .
Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sion levels to exceed their predetermined factory
specifications.

x vmr2008·040
 INTRODUCTION

Exceptions include manufacturer's prescribed LOCTITE® APPLICATION

changes, such as altitude adjustments for exam- PROCEDURE
ple.
The following describes the most common ap-
Owner Responsibility plication procedures when working with Loctite
The owner/operator is required to have engine products .
maintenance performed to maintain emission NOTE: Always use proper strength Loctite prod-
levels within prescribed certification standards. uct as recommended in this manual.
The owner/operator is not to, and should not al-
low anyone to modify the engine in any manner Threadlocker
that would alter the horsepower or allow emis- Uncovered Holes (bolts and nuts)
sions levels to exceed their predetermined factory
specifications .

EPA Emission Regulations

Some ATVs manufactured by BRP are certified
to the EPA as conforming to the requirements
of the regulations for the control of air pollution
from new ATV engines. This certification is con-
tingent on certain adjustments being set to factory
standards. For this reason, the factory procedure
for servicing the product must be strictly followed
and, whenever practicable, returned to the origi-
nal intent of the design.
The responsibilities listed above are general and 1. ApplV here
in no way a complete listing of the rules and regu- 2. Do not applv
lations pertaining to the EPA requirements on ex-
haust emissions for ATVs products . For more de- Clean threads (bolt and nut) with solvent.
tailed information on this subject, you may contact Apply Loctite Primer N (P/N 293 800 041) on
the following locations: threads and allow to dry.
FOR ALL COURIER SERVICES: Choose proper strength Loctite thread locker.
U.S. Environmental Protection Agency Fit bolt in the hole.
Office of Transportation and Air Quality
1310 L Street NW Apply a few drops of thread locker at proposed
Washington D.C. 20005 tightened nut engagement area.

REGULAR US POSTAL MAIL: Position nut and tighten as required.

1200 Pennsylvania Ave. NW Blind Holes
Mail Code 6403J
Washington D.C. 20460
INTERNET: http://www.epa.gov/otaq/
E-MAIL: otaqpublicweb@epa.gov

SELF-LOCKING FASTENERS
PROCEDURE
The following describes the most common appli-
cation procedures when working with self-locking
fasteners .
Use a metal brush or a screw tap to clean the
hole properly then use a solvent, let act during 30
minutes and wipe off. The solvent utilization is to 1. On screw threads
ensure the adhesive works properly. 2. On hole threads

vmr200S'()40 XI
INTRODUCTION

Clean threads (screw and hole) with solvent. Preassembled Parts

Apply Loctite Primer N (P/I\J 293 800 041) on
threads (screw and nut) and allow to dry for 30
seconds .
Choose proper strength Loctite threadlocker.
Apply 2 or 3 drops along the threaded hole.
NOTE: To avoid a hydro lock situation, do not apply
too much Loctite.
Apply several drops on screw threads.
Tighten as required.
Stud in Blind Holes
2
AOOA30A

1 3 1. Apply here

2 I 2. Do not apply

Clean bolts and nuts with solvent.

U
1. On stud threads
2. On hole threads
Assemble components.
Tighten nuts .
Apply drops of proper strength Loctite on bolt/nut
contact surfaces.
Avoid touching metal with tip of flask.
3. Onto nut threads NOTE: For preventive maintenance on exist-
ing equipment, retighten nuts and apply proper
Clean threads (stud and hole) with solvent. strength Loctite on bolt/nut contact surfaces.
Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry. Adjusting Screw
Put 2 or 3 drops of proper strength Loctite thread-
locker along the threaded hole.
NOTE: To avoid a hydro lock situation, do not apply
too much Loctite .
Apply several drops of proper strength Loctite on
stud threads .
Install stud.
Install cover, etc.
Apply drops of proper strength Loctite on uncov-
ered threads.
Tighten nuts as required.
1. Apply here
2. Plunger

Adjust screw to proper setting.

Apply drops of proper strength Loctite threadlock-
er on screw/body contact surfaces.
Avoid touching metal with tip of flask.
NOTE: if it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)).

XII vmr2008·040
 INTRODUCTION

Stripped Thread Repair Gasket Compound

---72

7
1, Release agent
2, Stripped threads
3, Form-A-Thread
4, Tape
5, Cleaned bolt
6, Plate
7, New threads 1 3
8, Threadlocker
1, Proper strength Loctite
Standard Thread Repair 2, Loctite Primer N !PIN 293 800041) and Loctite 518
(PIN 293 800 038) on both sides of gasket
Follow instructions on Loctite FORM-A-THREAD 3. Loctite Primer N only
81668 package.
Remove old gasket and other contaminants with
If a plate is used to align bolt:
Loctite Chisel remover (PIN 413 708 500). Use a
- Apply release agent on mating surfaces. mechanical mean if necessary.
- Put waxed paper or similar film on the surfaces.
!'JOTE: Avoid grinding.
Twist bolt when inserting it to improve thread con-
Clean both mating surfaces with solvent.
formation.
Spray Loctite Primer N on both mating surfaces
NOTE: NOT intended for engine stud repairs .
and on both sides of gasket. Allow to dry 1 or 2
Repair of Small Holes/Fine Threads minutes.
Option 1: Enlarge damaged hole, then follow Apply Loctite 518 (PIN 293800038) on both sides
STANDARD THREAD REPAIR procedure. of gasket, using a clean applicator.
Option 2: Apply FORM-A-THREAD on the screw Place gasket on mating surfaces and assemble im-
and insert in damaged hole. mediately.
Permanent Stud Installation (light duty) NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite on the threads of
Use a stud or thread on desired length. hole. Tighten.
DO NOT apply release agent on stud. If holes are sunken, apply proper strength Loctite
Do a STANDARD THREAD REPAIR. on bolt threads.
Allow to cure for 30 minutes. Tighten as usual.
Assemble.

vmr2008-<l40 XIII
INTRODUCTION

Mounting on Shaft NOTE: Any Loctite product can be used here. A

low strength liquid is recommended as normal
Mounting with a Press strength and gap are required.
Install according to standard procedure .
Wipe off surplus .
Allow it to cure for 30 minutes.
NOTE: Norma lly used on worn-out housings to
prevent leaking or sliding.
It is generally not necessary to remove gasket
compound applied on outer gasket diameter.

AOOA3UA TIGHTENING TORQUES

1. Bearing Tighten fasteners to torque mentioned in explod-
2. Proper strength Loctite
3. Shaft ed views and/or text. When they are not speci-
fied, refer to following table .
Clean shaft external part and element internal part.
Apply a strip of proper strength Loctite on shaft & WARNING
circumference at insert or engagement point. Torque wrench tightening specifications
NOTE: Retaining compound is always forced out must strictly be adhered to.
when applied on shaft. Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must
DO NOT use antiseize Loctite or any similar prod- be installed or replaced with new ones, where
uct. specified. If the efficiency of a locking device
No curing period is required. is impaired, it must be renewed.
Mounting in Tandem
In order to avoid a poor assembling, tighten
Apply retaining compound on internal element screws , bolts or nuts in accordance with the
bore. following procedure:
Continue to assemble as shown above. Manually screw all screws, bolts and/or nuts.
Case-In Components Apply the half of the recommended torque value.
CAUTION: Be sure to use the proper tightening
Metallic Gaskets torque for the proper strength grade.
NOTE: When possible, always apply torque on the
nut.
Torque to the recommended torque value .
NOTE: Always torque screws, bolts and/or nuts in
a criss-cross sequence .

~ t
AOOA3VA 1
1. Proper strength Loc tite

Clean inner housing diameter and outer gasket di-

ameter.
Spray housing and gasket with Loctite Primer N
(P/N 293 800 041 ).
Apply a strip of proper strength Loctite on leading
edge of outer metallic gasket diameter.
XIV vm r200S.<J40
 INTRODUCTION

4.8 8.8 9.8 10.9 12.9

Property
class
and
head
@ 0 0 0 0 Q©
markings
EgJ ~~ Cf3J ~~
Property 5 8 10 12

@~@ @~@ @~@ @~@

class
and
nut
markings
AOOA88S

FASTENER GRADEfTORQUE
FASTENER SIZE ",

5.8 Grade 8.8 Grade , 10.9 Grade 12.9 Grade

1.5 - 2 N-m 2.5 - 3 N-m N-m 3.5 - 4 N-m 4 - 5 N-m
M4
(13 - 18 Ibf-in) (22 - 27 Ibf-in) (31 - 35 Ibf-in) (35 - 44 Ibf-in)
3 - 3.5 N-m 4.5 - 5.5 N-m 7 - 8.5 N-m 8 - 10 N-m
M5
(27 - 31 Ibf-in) (40 - 47 Ibf-in) (62 - 75 Ibf-in) (71 - 89 Ibf-in)
6.5 - 8.5 N-m 8 - 12 N-m 10.5 - 15 N-m
M6 16 N·m (142 Ibf·in)
(58 - 75 Ibf-in) (71 - 106 Ibf.in) (93 - 133 Ibf·in)
M8 15 N.m (133 Ibf.in) 25 N.m (18Ibf·ft) 32 N·m (23 Ibf-ft) 40 N-m (30 Ibf.ft)
M10 29 N-m (21 Ibf·ft) 48 N-m (35 Ibf·ft) 61 N-m (45 Ibf·ft) 73 N-m (53 Ibf-ft)
M12 52 N·m (38 Ibf.ft) 85 N·m (63 Ibf·ft) 105 N·m (77 Ibf.ft) 128 N-m (94 Ibf-ft)
M14 85 N-m (63 Ibf·ft) 135 N.m (100 Ibf-ft) 170 N.m (125 Ibf.ft) 200 N-m (148 Ibf.ft)

vm r200B'()4 0 xv
INTRODUCTION

MANUAL INFORMATION This manual uses technical terms which may be

different from the ones of the PARTS CATALOGS.
The manual is divided into many major sections as
you can see in the main table of contents at the When ordering parts always refer to the specific
beginning of the manual. model PARTS CATALOGS.
Each section is divided in various subsections, and
again, each subsection has one or more division.
The Illustrations show the typical construction of
the different assemblies and, in all cases, may not
reproduce the full detail or exact shape of the parts
shown, however, they represent parts which have
the same or a similar function.
CAUTION: Most components in the vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners
could cause damage to the vehicle or possible
personal injury.
As many of the procedures in this manual are inter-
related, we suggest that before undertaking any
task, you read and thoroughly understand the en-
tire section or subsection in which the procedure
is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before starting any
procedure, be sure that you have on hand all re-
quired tools, or approved equivalents.
The use of RIGHT and LEFT indications in the text,
always refers to the driving position (sitting on the
vehicle).

V07AOGA

TYPICAL
1. Left
2. Right

XVI vmr2008-040
 INTRODUCTION

TYPICAL PAGE

~
Page heading
indicates section
, - - - - - - - - - - - - - - - - - - - -- -- - - - - - and subsection
_ _ _ _ _ _ _ _ _ _ _ _ _......._ _ _ _ _ _ _ detailed.
Section 03 ENGINE
. Subsection 04 . (REMOVAl AND INSTALLATION)

REMOVAL ANDINST~LLATI().N . . . :------7--

. Subsection title
indicates
beginning of the
~
26
subsection.

j4..!...---Exploded view
assists you in
identifying parts and
related positions.

Tightening torque - - - ; - - - - - 7 : J .'

nearby fastener. In this
case, nut must be
torqued to
10 Nem or 89 Ibfein.
'.....:------7-;--- Drop represents a
CAUTION: Pay attention '4 liquid product to
to torque specifications. be appl ied to
Some of these are in a surface.
Ibf·in instead of Ibfoft.

L
Use appropriate torque
wrench .

Illustration -----+----}•..:-:.-..-=-:~~_ _'___ _'____=_ ,"'-....,;_-------_==_~

number for
publishing

p'OC"'. 1-'"--/--r~
Document Bold face number Page number
number for indicates special
publishing procedure
process . con cerning this
part.

vmI20OB ..Q40-00' _aen

vmr200S'()40 XVII
INTRODUCTION

TYPICAL PAGE

Section 03 ENGINE
Subsection 06 (MAGNETO SYSTEM)

Title indicates ~· BEARING STATOR AND TRIGGER COIL

main procedure
to be carried-out . Inspection Removal
Ball bearing no. 10 must rotate free ly. Othewise. Remove.
r.place it. - magn.tohousingcover,no. 7."...
..------------;-- Bold face number
Removal - screw no. 11 and 12 following part
- sta[Qrwithtrigge r coil no. 13. name refers to
exploded view
at beginning of
subsection.

Call-outs for --~.~~J.~"';;;

' _~
.~-----------'
1. S~dfOl
above illustration. Installation 2. SralofScroVo'S
3. Tr,gge( coil
For instaHationalso heat the magneto housing 4. rr'.q{JfJr coil SCI6WS
up to about 1oO"e (2 12°F) to put ball bearing !n
place. Inspection
Place new ball be aring in f reeze r for 1 0 minutes Checkstatorand triggereoil condition. II damaged
approximately. replace the faultypart.
Reins tall other (emoved parts in the reverse order. For electrical inspection, relerto CHARGING SYS-
TEM for the stator andIGt'lITION S'r'SrEM'for the

trigger coil . tL_________--'___

- Reference to look
up a certain section
and subsection.
In this case it
concerns
IGNITION SYSTEM.

13. vmr1OOB-046

V01A71S

XVIII vmr200S-D40
 Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)

MAINTENANCE CHART
MAINTENANCE CHART
The schedule should be adjusted according to operating conditions and use.
NOTE: The chart gives an equivalence between number of hours and months/year. Perform the mainte-
nance operation to whatever time comes first.
IMPORTANT: ATV rental operations or intensive use of ATV, will require greater frequency of inspection
and maintenance.

10 HOURS OR 300 KM (185 mil

(The initial maintenance is very important and must not
be negle«;:ted.)
A : ADJUST
C: CLEAN EVERY 25 HOURS OR 750 KM (470 mi
I: INSPECT I EVERY 50 HOURS OR 1500 KM (930 mil
L: LUBRICATE
R: REPLACE EVERY 100 HOURS OR 3000 KM (1865 mil
OR 1 YEAR
EVERY 200 HOURS OR 6000 KM
(3730 mil OR 2 YEAR
PART;TASK REFER TO
ENGINE . .

Engine oil and filter R ' R LUBRICATION SYSTEM

INTAKE MANIFOLD, CYLINDER
Valve adjustment I,A I,A
... HEAD AND CYLINDER
Condition of engine seals I I ENGINE
ENGINE REMOVAL AND
Engine mounting fasteners I I
INSTALLATION
Air filter (1) C R AIR INTAKE SYSTEM
...
Exhaust system I I I
EXHAUST SYSTEM
Spark arrester C I
Coolant I I I (2) R
Radiator cap/cooling system pressure test I I COOLING SYSTEM
Radiator condition/cleanliness (radiator fins) I I
ENGINEMANAGEMENT SYSTEM
Sensors (4) I I . I
ENGINE MANAGEMENT
Fault code reading (4) I I
' ... ...
FUEL SYSTEM
Throttle body I I I,L
I~A ENGINE MANAGEMENT
Throttle cable I,A
L
Fuel lines, fuel rail, connections, check valves
I I
and fuel tank pressure test (4)
FUEL TANK AND FUEL PUMP
In-line fuel filter R
Fuel pump pressure test .. I

vmr2008-041
Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)

10 MOURS OR 300 KM (186 mit

tnt- lailial ..a.......ce it nry 1..,.l1Int .nd mult not
III HfiHtM., .
A: ADJUST
-'w __.

C: CLEAN EVERY 25 HOURS OR 750 KM (470 mi

I: INSPECT EVERY 60 HOURS OR .15~ KM (9~O,~,!)
L: LUBRICATE
R: REPLACE EVERY 100 HOURS OR 3000 KM (1865 mil
OR 1 YEAR
EVERY 200 HOORS OR 600CfKM
(3730 ml) OR 2 YEAR
I
PART CfASI< REFER TO
ELECTRICAL SYSTEM
Spark plug (3) (4) I R IGNITION SYSTEM
Battery connections I I CHARGING SYSTEM
ECM connectors (visual inspection without ;
I ,
disconnecting)
:
Electrical connections and fastening ELECTRICAL CONNECTORS
(ignition system, starting system, fuel I I
injectors etc.)
DIGITALLY ENCODED SECURITY
Digitally Encoded Security System 1 I I
SYSTEM
Condition of ignition switch, start button and
I I
engine run/stop switch ,
LIGHTS, GAUGE AND ACCESSORIES
Condition of lighting system (HI/LO intensity,
I I
brake light, beam aiming, etc.)
Refer to BASIC GUIDE TO WINCHING
Winch connections
TECHNIOUES
--. ..
CONTINUOUSLY VARiABLE TRANSMISSION (CVT) ~, . ,,,--,"-. ~

Drive belt I
Drive and driven pulleys I, C
CVT
One-way bearing inside CVT I. L
CVT air inlet I I, C
'I
GEARBOX
Gearbox oil (1) R I :R
Speed sensor C C GEARBOX AND 4 X 4 COUPLING UNIT
4 x 4 coupling unit f I
DRIVE TRAIN ~

Drive shaft boots and protectors I I

Rear propeller shaft joints (1) I I. L
Drive shaft joints I
Wheel bearings I
FRONT DRIVE and REAR DRIVE
Wheel nuts/studs I I
Tire wear and pressure Every ride
Front and rear differentials oil level, seals and
vents I I R

2 vmr2008-041
 Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)

. 10 H()URS'OR300 KM(185 'Illi,

(The initial maintenance is very important and must not
be neglected.) . - .
A: ADJUST
C: CLEAN EVERY 25 HOURS OR 750 KM (470 mi
I: INSPECT EVERY 50 HOURS OR 1500 KM '(930 ml)
L: LUBRICATE
R: REPLACE EVERY 100 HOURS OR 3000 KM (1865 mil
OR 1 YEAR
EVERY-200 HOURS OR 8000 KM
(3730 mi) OR 2 YEAR
PART(TASK REFER TO
;SJEERING SYSTEM
Handlebar fastener
.-

I
,-, "

,
Steering system mechanism (column.
I I
bearing. etc ,) (2) .. STEERING SYSTEM
Tie rod ends L :
Front wheel alignment .I I,A
, n.

SUSPENSION ,

Trailing arms I
REAR SUSPENSION
Trailing arm bearings I
FRONT SUSPENSION and
Shock absorbers I
REAR SUSPENSION
:
A-arms I, L
FRONT SUSPENSION
Ball joints I
~1BRAKES
-. ,,' ... ,,- . .. . ... ,~ .

Brake fi'uid t I R
Brake system (discs, hoses, etc,) I HYDRAULIC BRAKES
Brake pads (1) I
BODY/FRAME
Frame fastener I
Frame I
Hitch/trailer ball condition (if installed) Every ride
Storage cover latches Every ride
Operator's seat and its fasteners Every ride BODY/FRAME
Passenger's seat or storage box and its
Every ride
fasteners (MAX models)
Grab handles (MAX models) Every ride
Vehicle cleaning and protection ] C
(1) More often under severe use such as dusty area, sand. snow. wet or muddy conditions ,
(2) Every 100 hours, check coolant strength,
(3) Make sure that the spark plug gap is correct.
(4) Emission-related component

vm r2008-041 3
 Section 01 MAINTENANCE
Subsection 02 (PRESEASON PREPARATION)

PRESEASON PREPARATION
Prior to use vehicle, proper vehicle preparation is
required after performing the storage procedure.
Any worn, broken or damaged parts found during
the storage procedure should have been replaced.
If not, proceed with the replacement.
Using the maintenance chart, performed items in
the column indicated: EVERY 100 HOURS OR
3000 km (1865 mil OR 1 YEAR.

~=
.......-
1O,,",

.~L
~ ","'lWI

~~=~TUJ: 1--l
."..:..; I~.IIJ.'_

.- ..,--......-
."'
.. I ··
iii
vmr2007·013·00 1_aen

1. Use this column

Furthermore, proceed with the following :

Vehicles Prepared as per Storage Procedure
Remove rags from : CVT inlet and outlet hoses,
engine air intake and muffler.
Test drive vehicle to confirm proper operation.
Vehicles Not Prepared as per Storage Proce-
dure
Replace engine oil and filter.
Drain fuel tank and fill with fresh fuel.
Test drive vehicle to confirm proper operation.

vmr200S-D42 5
 www.midwestmanuals.com

www.midwestmanuals.com
Sales@midwestmanuals.com
 Section 01 MAINTENANCE
Subsection 03 (STORAGE PROCEDURES)

STORAGE PROCEDURES
SERVICE PRODUCTS
Description Part Number Page
BRP heavy duty cleaner ..... ....... ............. ..... .... ................ .... .. 293 110 001 .... ... ........ ... ........................... 8
xP-S Lube .. .. .. ... .... ..... .... ................ ...... ...... ....... ... .... .... .. .. .... . 293600016 ... .. ..... ... .. ..... .. ............ ........... 8
BRP fuel stabilizer .......................................... ..... ........ .... .. .. .. 413 408 600 .... ... ... ... .............. .. ..... ... ........ 7
Vinyl & Plastic Cleaner ..................................... .. ... ...... .... .. .... 413711200 ..... ..... ... ....... ................. ........ 8
storage oil ...... ............................................................. ......... . 413 711 600 ... ... .. ..... ................ ................ 7
storage oil (US) ........ .. .... .... .............. ......... ....... ......... .... .. .. .. .. 41 3 711 900 ... ... ..... ......................... ... ...... 7

If the ATV is not used or is to be stored for an NOTE: For US citizens, use storage oil (US)
extended period of time, more than 4 months, be (PIN 413711900) only.
sure to perform the storage procedures described CAUTION: Do not inject storage oil into throttle
below. body bore to avoid blocking idle bypass valve.
- Press start button, 1 or 2 seconds maximum, to
FUEL STABILIZER lubricate cylinders .
With the new fuel additives, it is critical to use the - Reinstall the spark plugs.
BRP fuel stabilizer (PIN 413 408 600) or an equiva- - Remove the battery. Store it in dry and cool
lent to prevent fuel deterioration and fuel system place out of the sun, refer to BATTERY in
gumming . Follow the manufacturer's instructions CHARGING SYSTEM.
for proper use.
CAUTION: Fuel stabilizer should be added RAGS INSTALLATION
prior to eng ine lubrication to ensure fuel sys-
tem components protection against varnish Using cleans rags, block the following locations:
deposits. CVT inlet and outlet hoses, air intake inlet and muf-
fler. The rags will prevent the intrusion of small
Pour fuel stabilizer in fuel tank . Fill up fuel tank. animals, leaves or other debris.
Do not drain fuel system. CAUTION: Do not forget, these rags must be
removed during preseason preparation before
ENGINE LUBRICATION starting the vehicle.
Engine internal parts must be lubricated to protect To reach the CVT inlet hose and the air intake inlet,
them from rust formation during the storage peri- remove the front inner fender on the left side of
od . vehicle.

& WARNING
This procedure must only be performed in a
well-ventilated area. Do not run engine dur-
ing storage period .

Proceed as follows :
- Start the engine and allow it to run at idle speed
until the engine reaches its operating tempera-
ture .
- Stop the engine .
Change engine oil and filter. Refer to LUBRICA-
TYPICAL - RENEGADE SHOWN
TION SYSTEM. 1. Inner fender
- Remove spark plugs and spray storage oil
(PIN 413 711 600) into each cylinder.

vmr200S.()43 7
Section 01 MAINTENANCE
Subsection 03 (STORAGE PROCEDURES)

DRIVE AND DRIVEN PULLEYS

PROTECTION
Remove drive belt from pulleys.
Inspect and clean pulleys then spray XP-S Lube
(PIN 293 600 016) on pulley faces.
Do not reinstall drive belt. Close CVT cover.

VEHICLE CLEANING
To facilitate the inspection and ensure adequate
TYPICAL - RENEGADE SHOWN
1. CVT inlet hose lubrication of components, it is recommended to
2. Air intake inlet clean the entire vehicle.
The CVT outlet hose is located at the rear of en- Wash and dry the vehicle.
gine, against vertical frame beam. The removal of CAUTION: Never use a high pressure washer
the left side panel is necessary to reach the hose. to clean the vehicle. USE LOW PRESSURE ON-
LY (like a garden hose). The high pressure can
cause electrical or mechanical damages.
Remove any dirt or rust.
To clean the vinyl or plastic parts, use only flannel
clothes with Vinyl & Plastic Cleaner (PIN 413 711
200).
CAUTION: It is necessary to use flannel cloths
on plastic parts to avoid damaging surfaces.
Never clean plastic parts with strong detergent,
degreasing agent, paint thinner, acetone, prod-
ucts containing chlorine, etc.
To clean the entire vehicle, including metallic parts
TYPICAL - RENEGADE SHOWN use BRP heavy duty cleaner (PIN 293 110001).
1. CVT outlet hose
2. CVT cover Inspect the vehicle and repair any damage. Touch
up all metal spots where paint has been scratched
off. Spray all metal parts with XP-S Lube (PIN 293
COOLANT DENSITY 600 016).
Test coolant density using an antifreeze hydrome-
ter. VEHICLE PROTECTION
NOTE: Follow manufacturer's instructions for Protect the vehicle with a cover to prevent dust
proper use. accumulation during storage.
A 50/50 mixture of antifreeze and distilled water CAUTION: The vehicle has to be stored in a
will provide the optimum cooling, corrosion pro- cool and dry place and covered with an opaque
tection and antifreeze protection. tarpaulin. This will prevent sun rays and grime
from affecting plastic components and vehicle
CAUTION: Do not use tap water, straight finish.
antifreeze or straight water in the system.
Tap water contains minerals and impurities
which build up in the system. Straight water
will cause the system to freeze while straight
antifreeze will cause system temperature prob-
lems.
Change coolant if necessary. Refer to COOLING
SYSTEM.

8 vmr2008'{)43
 Section 01 MAINTENANCE
Subsection 04 (SPECIAL PROCEDURES)

SPECIAL PROCEDURES
SERVICE PRODUCTS
Description Part Number Page
XP-SLube ..... ...... ... .................................................. ............. 293600016 ....................................... 9-10

TURN OVER Spray all metal parts with XP-S Lube (P/N 293 600
016).
If the check engine indicator light stays ON after
starting engine and the engine oil level is good, Test drive to confirm all is working well (electrical
check the following: and mechanical components).
- Oil filter for contamination .
ATV Submerged for a Short Time
• Replace oil filter and oil. (fewer one hour)
- Oil pressure regulator valve stays open in the
Check if engine oil is contaminated (oil will be
crankcase due to contamination (metallic parti-
cles) . milky). If so, perform the following instructions .
• Clean and/or replace the valve . Drain engine oil.
- Valve piston stuck in the oil pump housing. Drain air filter housing then clean and dry air filter.
• Repair valve piston . Look for water in fuel tank, in doubt, flush fuel tank
Oil pressure switch for damages. and refill with new gas.
• Replace it if necessary. Drain the CVT housing by removing the bottom
- Oil pump cleanliness and working. rear screw.
• Clean and/or replace oil pump if necessary.
- Oil strainer cleanliness and damages.
• Clean and/or replace oil strainer.

ATV IMMERSION
ATV Submerged for a Long Time
(over one hour)
Disassemble engine and transmission to clean the
internal parts and check if there is no rust or cor-
rosion on any internal parts. Refer to TRANSMIS-
SION and to the specific ENGINE section .
Drain air filter housing then clean and dry air filter.
Remove muffler and empty it. Let muffler dry OUTLANDER SHOWN
1. CVT cover drain plug
then reinstall it on the vehicle .
Flush fuel tank and refill with new gas. Remove the CVT cover then clean and check all
parts of CVT. Refer to CVT.
Lubricate the throttle body. Refer to ENGINE
MANAGEMENT. Lubricate all cables. Check if the cables operate
properly.
Look for water in:
- brake system (replace brake fluid) Remove spark plugs then crank engine several
times.
- differentials (drain oil and check internal parts
for rust or corrosion then refill) . Add a small quantity of engine oil in cylinders
(approximately 2 teaspoonfuls). Do not reinstall
Lubricate all cables. Check if the cables operate
spark plugs at this moment.
properly.
Refill engine at the proper level with the recom-
mended oil. Crank engine several times .
vmr2008{)44 9
Section 01 MAINTENANCE
Subsection 04 (SPECIAL PROCEDURES)

Check condition of spark plugs. If spark plugs ap-

pear good reinstall them, if not install new ones.
Start the engine and allow it to run at idle speed
until the engine reaches its operating tempera-
ture.
Stop the engine.
Change engine oil and filter.
NOTE: Change oil as many times as necessary,
until there is no white appearance in engine oil.
Spray all metal parts with XP-S Lube (PIN 293 600
016).
Test drive to confirm all is working well (electrical
and mechanical components) .

10 vmr2008·044
r .

Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

TROUBLESHOOTING CHART
The following charts are provided to help in diagnosing the probable source of troubles. It should be used
as a guideline. This section pertains to engine mechanical components only. Some related problems can
come from other systems such as ignition system, fuel system etc. and have an impact on the engine.
Ensure to check the other systems before concluding that the engine is faulty.

ELECTRICAL SYSTEM
Symptom: STARTER DOES NOT TURN
1. Ignition switch is in the OFF position.
- Turn switch to the ON position.
2. Engine run/stop switch is in the OFF position.
- Turn switch to the RUN position.
3. DESS key not programmed for the vehicle.
- Refer to DESS SYSTEM.
4. Defective DESS key or switch.
- Check key and switch .
5. Burnt fuse.
- Check main fuse and wiring condition.
6. Transmission is not set to Park or Neutral position or brake switch is not activated.
- Set transmission to PARK or NEUTRAL position or squeeze the brake lever or press on brake
pedal.
7. Weak battery.
- Recharge battery.
8. Poor contact of battery terminal(s) or ground cable connections.
- Clean and tighten terminal(s).
9. Poor contact or open circuit of: start button, engine run/stop switch, ignition switch or
starting solenoid.
- Check and replace defective part.
10. GBPS switch(es) is (are) defective.
- Check GBPS switch(es) and wiring condition. Refer to GEARBOX.
11. Diode incorrectly installed or failure.
- Check diode installation and condition.
12. Defective ECM.
- Check. Refer to ENGINE MANAGEMENT.
13. Multifunction speedometer replaced but not updated with proper coding.
- Use B.U.D.S. and update ECM. Refer to LIGHTS, GAUGES AND ACCESSORIES.
14. Defective brake switch.
- Check brake switch and its connectors. Replace defective part.
15. Engine mechanical problem (ensure that other electric components are good).
- Check and replace defective part.

vmr2009~45 11
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

Symptom: STARTER TURNS, BUT DOES NOT CRANK THE ENGINE

1. Worn sprag clutch.
- Replace.
2. Worn gears.
- Replace.

Symptom: STARTER MOTOR KEEPS RUNNING

1. Shorted starting solenoid switch winding.
- Replace starter solenoid.
2. Melted solenoid contacts.
- Replace starter solenoid.
3. Sticking or defective starter clutch.
- Lubricate or replace electric starter.
4. Start button stock.
- Fix or remove mud/ice/dirt or replace multifunction switch.

COOLING SYSTEM
Symptom: HIGH ENGINE OPERATING TEMPERATURE
1. Check coolant level.
- Coolant level lower than recommended. Refill (refer to COOLING SYSTEM).
2. Check for air bubbles in cooling system.
- Air in cooling system. Refill and bleed cooling system (refer to COOLING SYSTEM).
3. Check temperature sensor for electrical/mechanical failure.
- Temperature sensor defective. Replace.
4. Check thermostat.
- Thermostat defective (does not open when engine gets hot). Replace (refer to COOLING SYS-
TEM).
5. Check leak indicator hole (in crankcase MAG side-water pump housing area) if coolant
leaks.
- Coolant leaking from indicator hole means a damaged water pump rotary seal. Replace rotary
seal (refer to COOLING SYSTEM).
6. Check condition of hoses and hose clamps fixation.
- Hoses are brittle and/or hard. Replace.
- Hose clamps are loose. Retighten clamps.
7. Check condition of impeller located on the water pump shaft.
- Impeller wings broken and/or impeller threads are damaged. Replace (refer to COOLING SYS-
TEM).
8. Check gasket on water pump housing.
- Gasket on water pump housing leaks. Retighten screws and/or replace gasket.
9. Check cylinder head and/or cylinder base gasket.
- Worn out gasket(s) is (are) causing coolant leakage. Replace.
10. Check coolant drain screw on water pump housing MAG side (marked "DRAIN").
- Copper ring on drain screw leaks. Retighten screw and/or replace copper ring.

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 Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

Symptom: HIGH ENGINE OPERATING TEMPERATURE (cont'd)

11 . Check intermediate gear(s) behind of PTO cover.
- Worn out and/or broken gear(s) is/are causing less coolant supply. Replace worn out and/or bro-
ken gear(s) (refer to BOTTOM END).
12. Check if water pump shaft is seized.
- Water pump shaft does not turn. Replace defective part(s).
13. Check cooling fan and connection.
- Fan motor faulty. Replace.
- Wire harness is brittle or hard (no connection). Replace.
14. Check radiator fan switch and fuse 20 A.
- Faulty fan switch and/or faulty fuse. Replace defective part(s).
15. Check radiator condition for leakage.
- Radiator swelled, cracked or deformed. Replace radiator.
16. Check mud/dust in radiator fins.
- Radiator fin obstructed, hard air cooling. Clean radiator fins.
17. Check radiator cap.
- Defective radiator cap relief valve. Replace .
18. Check vent holes in coolant expansion tank cap.
- Inner cap vent hole of coolant expansion tank is clogged. Replace.
- Cap vent hole of coolant expansion tank is clogged. Replace.

MAGI\IETO SYSTEM
Symptom: BATTERY NOT CHARGING OR CHARGING VOLTAGE INADEOUATE
1. Check battery.
- Battery shows less power. Reload battery.
- Battery has electrical failure. Replace.
2. Check magneto for damage and/or electrical failure.
- Radial position of rotor wrong due to broken Woodruff key. Replace Woodruff key.
- Coating on stator winding is damaged. Replace stator.
- Resistance value is out of specification (refer to TECHNICAL SPECIFICATIONS). Replace mag-
neto.
- Connector on magneto is damaged and/or has electrical failure. Repair and clean contacts of
connector.
3. Check voltage regulator/rectifier.
- Refer to CHARGING SYSTEM.
4. Check wiring harness for cracks or other damages.
- Harness shows electrical failure and/or other damages. Replace/repair wiring harness.

vmr200B-045 13
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

LUBRICATION
Symptom: LOW OR NO Oil PRESSURE/HIGH Oil CONSUMPTION
1. Check oil level and search for leakage on crankcase and/or sealing parts.
- Crankcase is leaking due to damage . Rebuild engine with new crankcase and gasket parts. Use
recommended oil (refer to TECHNICAL SPECIFICATIONS) .
- Crankcase is lea king due to loose screws. Retighten screws with recommended torque.
- Sealing rings, O-rings and/or gaskets are brittle, hard or damaged. Replace damaged parts.
- Piston rings worn out (blue colored engine exhaust emission). Replace piston rings (refer to
INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER).
- Piston rings are broken (low compression). Replace piston rings (refer to INTAKE MANIFOLD,
CYLINDER HEAD AND CYLINDER).
- Valve stem seal damaged and/ or sealing lip is hard and/or brittle. Replace all valve stem seals.
2. Check oil filter for contamination.
- Oil filter clogged. Replace oil and oil filter at the same time . Use recommended oil (refer to
TECHNICAL SPECIFICATIONS).
3. Check oil drain plug on engine bottom.
- Plug is loose and/or gasket ring is missing. Retighten the plug and/or place gasket ring.
4. Check leak indicator hole if oil leaks (in crankcase MAG side-water pump housing area).
- Oil leaking from leak indicator hole means a damaged oil seal on water pump shaft. Replace oil
seal (refer to COOLING SYSTEM).
5. Check oil pressure switch function.
- Oil pressure switch damaged. Replace oil pressure switch.
6. Check oil orifice(s) on the oil pump suction side.
- Oil orifice{s) is (are) clogged. Clean from contamination. Replace oil and oil filter if necessary
(refer to LUBRICATION SYSTEM).
7. Check oil pump function.
- Oil pump rotor is out of wear limit. Replace oil pump (refer to LUBRICATION SYSTEM).
- Oil pump seized due to oil leakage and/or air inclusion. Replace oil pump (refer to LUBRICATION
SYSTEM).
- Gears driving oil pump are broken or otherwise damaged. Replace gears.
- Incorrect oil being used. Use recommended oil (refer to TECHNICAL SPECIFICATIONS).
8. Check oil pressure regulator valve (spring) function.
- Valve spring damaged (valve always open). Replace spring.
- Va lve piston is worn or broken. Replace valve piston (refer to LUBRICATION SYSTEM).
- Valve piston stays open due to contamination. Clean or repair valve piston .
9. Check plain bearings in crankcase for heavy wear.
- Plain bearings out of specification (increased clearance). Replace plain bearings (refer to BOT-
TOM END).
10. Check engine oil strainer in crankcase.
- Oil strainer is clogged due to contamination. Clean or replace strainer and diagnose causes.
Rep/ace possible damaged parts (refer to BOTTOM END) .

Symptom : OIL CONTAMINATION (white appearance)

1. Check leak indicator hole (in crankcase MAG side-water pump housing area) if coolant and
oil leaks.
- Leakage of oil/colant mixture from indicator bore means damaged water pump seal ring and
rotary seal. Replace sealing ring, rotary seal and change oil, oil filter and/or coolant (refer to
LUBRICATION SYSTEM, COOLING SYSTEM and BOTTOM END).

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Subsection 01 (TROUBLESHOOTING CHART)

Symptom: OIL CONTAMINATION (white appearance) (cont'd)

2. Check cylinder head and/or cylinder base gasket.
- Gasket damaged or leaking. Retighten cylinder head with recommended torque and/or replace
gasket.
3. Check tightening torque of cylinder head screws.
- Screws not properly tightened. Retighten screws to recommended torque and replace oil.
4. Check oil for particles (may indicate possible engine internal damages).
- Oil contamination due to metal or plastic particles . Replace possibly damaged part(s) including
oil and oil filter. Use recommended oil (refer to TECHNICAL SPECIFICATIONS).

CYLINDER AND HEAD

Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATION
1. Check noise coming from cylinder head area.
- Improper valve clearance adjustment. Readjust valve clearance and/or replace defective part(s).
- Faulty chain tensioner Replace spring and/or mechanism.
- Chain guide worn out. Replace chain guide.
- Stretched chain and/or worn out sprockets. Replace chain and sprockets.
- Sprocket screws got loose. Retighten screws with recommended torque.
- Rocker arm(s) is (are) worn out (valve adjustment). Readjust valve clearance and/or replace rock-
er arm (s).
- Incorrect camshaft timing adjustment. Replace damaged components and readjust camshaft
timing (refer to INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER).

Symptom: OIL CONTAMINATION ON CYLINDER AI\lD/OR HEAD

1. Check screws for torque.
- Loose screws. Retighten screws with recommended torque.
- Gaskets are brittle, hard, worn out or otherwise damaged. Replace damaged gaskets, O-rings
or the V-ring on breather

CRANKSHAFT
Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATIONS
1. Check noise coming from crankshaft area.
- Crankshaft plain bearings are damaged. Replace crankshaft plain bearings (refer to BOTTOM
END).
- Connecting rod plain bearings are damaged. Replace connecting rod plain bearings (refer to
BOTTOM END).
- Magneto rotor got loose. Replace damaged components and retighten rotor retaining screw
with recommended torque (refer to MAGNETO SYSTEM).

GEARBOX
Symptom: UNUSUAL GEARBOX NOISE AND/OR VIBRATIONS
1. Check oil level in gearbox.
- Oil leakage from gearbox. Replace damaged gasket(s) and/or oil seal(s), torque screws and refill
with oil up to specified level (refer to TECHNICAL SPECIFICATIONS and GEARBOX).

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Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

Symptom : UNUSUAL GEARBOX NOISE AND/OR VIBRATIONS (cont'd)

2. Check bearings in the gearbox for free movement.
- Bearing(s) do(es) not move freely. Replace bearing(s).
3. Check for knocking noise.
- Tooth of gears are damaged and/or worn . Replace respective gears.

Symptom: GEAR INDICATION FAILS

1. Check contact screws on gear housing center.
- Check contact screw outside for contamination and wetness. Clean contact screw and screw
for wiring harness.
- Contact(s) is (are) corroded and/or contact screw for wiring harness got loose. Clean contact
surface and retighten contact screw(s) with recommended torque.
- Wiring harness has broken cables. Replace wiring harness.
- Shifting indicator switch(es) pin(s) is (are) worn and/or damaged. Replace shifting indicator
switch(es).

Symptom: GEAR(S) IS (ARE) HARD TO SHIFT

1. Check shift shaft spline and/or shift forks for wear and/or damages.
- Shift shaft is worn out and/or shows damaged splines. Replace shift shaft.
- Shift drum track(s) and/or splines is (are) worn out or damaged. Replace shift drum and damaged
part(s) .
- Shift fork(s) is (are) worn out and/or engagement pins are damaged. Replace shift fork(s).
- Shift fork(s) is (are) worn 'out and/or fork(s) is (are) damaged. Replace shift fork(s).
- Shift gear(s) is (are) worn out. Replace shift gear(s).
- Shifting indicator switch (es) pin(s) is (are) worn out (no roundings on top of pin). Replace shifting
indicator switch(es).
2. Check engine idle speed.
- Check throttle cable and throttle adjustment.
- Check bypass idle valve and connectors.
3. Check CVT one way clutch on drive pulley.
- CVT one way clutch was not lubricated correctly. Lubricate CVT one way clutch (refer to CON-
TINUOUSLY VARIABLE TRANSMISSION (CVT)).
- CVT one way clutch is worn out or damaged. Replace defective part(s) (refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT)).
- Check if friction washer at one way clutch is worn. Replace friction washer (refer to CONTINU-
OUSLY VARIABLE TRANSMISSION (CVT)).
4. Check transmission lever and connecting rod.
- Ball joint and/or ball joint nut is (are) loose. Retighten or replace the ball joint.
5. Check spring on shift shaft in gearbox.
- Broken spring. Replace the spring (refer to GEARBOX).
6. Check for any mud intrusions.
- CVT parts dirty. Clean all CVT parts.

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Subsection 01 (TROUBLESHOOTING CHART)

Symptom: UNUSUAL GEARBOX NOISE AND/OR VIBRATIONS (cont'd)

2. Check bearings in the gearbox for free movement.
- Bearing(s) do(es) not move freely. Replace bearing(s).

3. Check for knocking noise.

- Tooth of gears are damaged and/or worn . Replace respective gears.

Symptom: GEAR INDICATION FAILS

1. Check contact screws on gear housing center.
- Check contact screw outside for contamination and wetness. Clean contact screw and screw
for wiring harness.
- Contact(s) is (are) corroded and/or contact screw for wiring harness got loose . Clean contact
surface and retighten contact screw(s) with recommended torque.
- Wiring harness has broken cables . Replace wiring harness.
- Shifting indicator switch(es) pin(s) is (are) worn and/or damaged. Replace shifting indicator
switch (es) .

Symptom : GEAR(S) IS (ARE) HARD TO SHIFT

1. Check shift shaft spline and/or shift forks for wear and/or damages.
- Shift shaft is worn out and/or show s damaged splines . Replace shift shaft.
- Shift drum track(s) and/or splines is (are) worn out or damaged. Replace shift drum and damaged
part(s).
- Shift fork(s) is (are) worn out and/or engagement pins are damaged. Replace shift fork(s).
- Shift fork(s) is (are) worn 'out and/or fork(s) is (are) damaged. Replace shift fork(s).
- Shift gear(s) is (are) worn out. Replace shift gear(s).
- Shifting indicator s witch (es) pints) is (are) worn out (no roundings on top of pin). Replace shifting
indicator switch(es).
2. Check engine idle speed.
- Check throttle cable and throttle adjustment.
- Check bypass idle valve and connectors.
3. Check CVT one way clutch on drive pulley.
- CVT one way clutch was not lubricated correctly. Lubricate CVT one way clutch (refer to CON-
TINUOUSLY VARIABLE TRANSMISSION (CVT)).
- CVT one way clutch is worn out or damaged. Replace defective part(s) (refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT)).
- Check if friction washer at one way clutch is worn. Replace friction washer (refer to CONTINU-
OUSLY VARIABLE TRANSMISSION (CVT)),
4. Check transmission lever and connecting rod.
- Ball joint and/or ball joint nut is (are) loose. Retighten or replace the ball joint.

5. Check spring on shift shaft in gearbox.

- Broken spring. Replace the spring (refer to GEARBOX).
6. Check for any mud intrusions.
- CVT parts dirty. Clean all CVT parts.

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 Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

COUPLING UNIT
Symptom : 4 WHEEL DRIVE INDICATION FAILS
1. Check contact screw on gear housing right side for damage and/or wear.
- Shifting indicator switch pin is worn and/or damaged. Replace shifting indicator switch (refer to
GEARBOX).
- Contact is corroded and/or contact screw for wiring harness got loose. Clean contact surface
and retighten contact screw with recommended torque.
- Wiring harness has broken cable. Replace wiring harness.

Symptom: 4 WHEEL DRIVE DOES NOT ENGAGE OR DISENGAGE

1. Check actuator and/or actuator shifting fork for wear and/or damages.
- Check if selector works properly. If so, check actuator.
- If selector is out of specifications, check wires, connectors and/or replace selector.
- Actuator shifting fork is worn out and/or damaged. Replace shifting fork of actuator.
- Check function of actuator. Replace if actuator is not turning, refer to GEARBOX.
2. Check shifting sleeve spline and/or shifting fork for wear and/or damages.
- Shifting sleeve shows damaged splines. Replace shifting sleeve (refer to GEARBOX).
- Shifting fork is worn out and/or engagement pin is damaged. Replace shifting fork.

CVT
Symptom: UNUSUAL ACCELERATION BEHAVIOR
1. Check drive belt condition.
- Belt is too narrow (drive belt engagement is higher in drive pulley). Replace belt if width is less
than specified (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT) and/or TECHNICAL
SPECIFICA TlONS).
2. Check lever condition on drive pulley sliding sheave and/or roller(s) on governor cup.
- Lever(s) on drive pulley sliding sheave is (are) worn and/or damaged (refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT)). Replace all levers at the same time (lever kit).
- Roller(s) is (are) worn and/or damaged (refer to CONTINUOUSLY VARIABLE TRANSMISSION
(CVT)) . Replace governor cup assembly.

3. Check drive/driven pulley sliding sheave for free axial movement.

- Sliding sheave is stuck (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)). Replace
damaged part(s).

4. Check condition of drive/driven pulley spring.

- Drive pulley spring tension is too smooth and/or damaged (refer to CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)). Replace spring.
- Driven pulley spring tension is too stiff (refer to CONTINUOUSLY VARIABLE TRANSMISSION
(CVT)). Replace spring.

S. Check if cam of driven pulley is worn.

- Replace if out of specifications; refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT).
6. Check condition of fixed and sliding sheaves (drive and driven pulley).
- Check surface of fixed and sliding sheaves (drive and driven pulley) for grooves or other damages;
refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT).

7. Check with B.U.D.S. at diagnostic communication port for failure.

- Repair or replace defective part.

vmr200S'()45 17
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

Symptom : UNUSUAL ACCELERATION BEHAVIOR (cont'd)

8. Check valve adjustment.
- Intake and/or exhaust valves are not adjusted correctly. Adjust valves .
9. Check engine condition.
- Low engine compression; refer to LEAK TEST in INTAKE MANIFOLD, CYLINDER HEAD AND
CYLINDER.
10. Check ignition condition.
- Faulty spark plug. Install new spark plug(s).
11. Check differentials operation.
- Vehicle on Neutral is hard to move. Repair or replace defective part(s).

Symptom: ENGINE MAXIMUM RPM IS TOO HIGH AND TOP SPEED IS NOT REACHED
1. Check drive/driven pulley area for contamination and/or water intrusion.
- CVT area is contaminated with water, dirt or oil. Clean CVT system and replace damaged part(s).

2. Check items 1 to 3 of UNUSUAL ACCELERATION BEHAVIOR.

3. Check drive/driven pulley spring tension.
- Drive pulley spring tension is too stiff. Replace spring (recommended BRP spring).
- Driven pulley spring tension is too smooth and/or damaged (refer to CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)). Replace spring.

Symptom: DRIVE PULLEY NOISE IN IDLE SPEED

1. Check slider shoes (drive pulley).
- Worn slider shoes (increased clearance between governor cup and drive pulley sliding sheave).
Replace all slider shoes at the same time (slider shoes kit).
2. Check driven pulley sliding mechanism (between driven pulley outer and inner sheave).
- Mechanism is stuck and/or damaged. Replace driven pulley assembly.
3. Check roller(s) and/or levers for wear (located on sliding sheave of drive pulley).
- Roller(s) on governor cup is (are) worn out and/or damaged (refer to CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)). Replace governor cup assembly.
- Lever(s) on drive pulley sliding sheave is (are) worn out and/or damaged (refer to CONTINUOUS-
LY VARIABLE TRANSMISSION (CVT)). Replace all levers at the same time (lever kit).
4. Check drive pulley screw for torque.
- Loose screw. Retighten screw with recommended torque.
5. Check one-way clutch condition on drive pulley sliding sheave.
- Bearing(s) do(es) not move freely. Replace damaged part(s) and lubricate inside of one-way
clutch (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)).
- Spring sleeve(s) inside one-way clutch is (are) worn out. Replace both sleeves and springs and
lubricate inside of one-way clutch (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) .
- Spring(s) inside one-way clutch is (are) worn out. Replace both pins and springs and lubricate
inside of one-way clutch (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)).

Symptom : DRIVE PULLEY NOISE WHEN ACCELERATING/DECELERATING

1. Check items 1 to 5 of DRIVE PULLEY NOISE IN IDLE SPEED.

2. Check if belt runs in dry conditions.
- Drive pulley area is wet/contaminated due to water/dirt intrusion. Clean driven pulley area and/or
drain water out of CVT cover. '

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 Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

Symptom: DRIVE PULLEY NOISE WHEN ACCELERATING/DECELERATING (cont'd)

3. Check drive/driven pulley screw for torque.
- Loose screw on drive and/or driven pulley. Retighten screw with recommended torque.
4. Check cam and driven pulley fixed sheave for wear.
- Cam and/or drive pulley fixed sheave out of wear limit and/or damaged. Replace damaged part(s).
5. Check torque gear fixed in driven pulley sliding sheave for wear.
- Torque gear out of wear limit and/or damaged. Replace torque gear (refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT)).
6. Check for foreign particles in CVT area (stones, dirt, etc.).
- Small particles damaged belt and/or pulley surfacers). Clean system and replace damaged parts
(refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)).

Symptom: VIBRATIONS ORIGINATING FROM DRIVE PULLEY

1. Check tightening torque of drive pulley screw.
- Moving sliding sheave. Retighten screw.
2. Check fixed sheave bushings.
- Excessive gap between bushings and fixed sheave shaft, thus restraining sliding sheave move-
ments. Replace fixed sheave assembly.
3. Check if slider shoes are present and/or placed in correct position.
- Slider shoe(s) is (are) missing and/or damaged. Replace all slider shoes at the same time (slider
shoes kit).

Symptom: VIBRATIONS ORIGINATING FROM DRIVEN PULLEY

1. Check fixed and sliding sheave bushings on driven pulley.
- Excessive gap between bushings and CVT shaft, thus restraining sliding sheave movements.
Replace fixed and/or sliding sheave of driven pulley, polish CVT shaft area with fine emery cloth
and wipe clean with a cloth.

Symptom: PULLEYS DO NOT DOWN/UP SHIFT PROPERLY

1. Check drive pulley bushings (cleanliness, wear, etc.).
- Check items 1 and 2 of UNUSUAL ACCELERATION BEHAVIOR.
- Bushings stick to fixed sheave pulley shaft. Clean or replace.
- Spring seat sticks to sliding sheave pulley bushing. Clean system and/or replace sliding sheave
pulley.
- One-way clutch does not operate properly. Clean system and/or replace damaged part(s).
2. Check driven pulley spring tension.
- Driven pulley spring tension is too weak or broken. Replace.
- Driven pulley cam is worn or damaged. Replace.

Symptom: BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE

1. Check if CVT air intake and/or outlet is clogged.
- CVT area heats up due to contamination. Clean air intake and/or outlet from contamination.
- Fans located on drive pulley fixed sheave are clogged. Clean from contamination.
2. Check if pulley sheaves are clean.
- Oil on pulley surfaces. Clean pulley sheaves and replace belt.
- Water intrusion in CVT area. Find root cause and repair. Drain water and replace belt.

vm r200S-045 19
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

Symptom: BELT WORN EXCESSIVELY IN TOP WIDTH

1. Check drive belt width.
- Considerable wear. Replace belt if narrower than specified (refer to CONTINUOUSLY VARIABLE
TRANSMISSION (CVT) or TECHNICAL SPECIFICATIONS).
2. Check drive belt identification number.
- Wrong type of belt. Replace belt with an appropriate drive belt.
3. Check for localized belt wear caused by belt slippage.
- Localized wear. Replace belt.

Symptom : BELT DISINTEGRATION

1. Check drive belt lifetime is exceeded.
- Clean CVT system and rebuild with a new drive belt.
2. Check drive belt identification number.
- Excessive belt speed. Using unspecified type of belt. Replace belt with proper type of belt (refer
to TECHNICAL SPECIFICATIONS).
3. Check if pulley sheaves are clean.
- Oil on pulley surfaces. Clean pulley surfaces with fine emery cloth and wipe clean using Pulley
Flange Cleaner (P/N 413 711 809) and a cloth.
- Drive/driven pulley sheaves are damaged through stones inside CVT area. Clean pulley surfaces
with fine emery cloth, wipe clean with a cloth or replace drive/driven pulley sheaves and belt.

Symptom : CRACKS BETWEEN COGS

1. Check drive belt condition.
- Considerable use, belt wearing out. Replace.
- Brittle belt condition through aging. Replace belt.

ENGINE GENERAL
Symptom: ENGINE CRANKS BUT FAILS TO START
1. Check if spark plug connectors fit on spark plugs (refer to IGNITION SYSTEM).
2. Check spark plugs.
- Define spark plugs (no spark) or wrong spark plug gap. Readjust gap and clean spark plugs or
replace.
3. Check for fuel on spark plugs.
- Flooded engine (spark plugs wet when removed). Activate engine drowned mode and crank
engine with rags over the spark plug holes (refer to OVERVIEW in EMS SYSTEM).
4. Check battery voltage.
- Battery is discharged and starter works not properly. Charge battery.
5. Check fuel level in fuel tank and fuel pressure. Ensure fuel pump was not disabled by
B.U.D.S.
- Low or no fuel pressure . Replace defective part(s} (refer to FUEL TANK AND FUEL PUMP).
6. Check fuel injectors.
- Plugged or faulty injector(s}. Replace defective part(s} (refer to ENGINE MANAGEMENT).
7. Check idle bypass valve.
- Stuck or defective. Refer to ENGINE MANAGEMENT.

20 vm(2008-045
 Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

Symptom: ENGINE CRANKS BUT FAILS TO START (cont'd)

8. Check encoder wheel.
- Bent tooth. Refer to MAGNETO SYSTEM.
9. Check engine compression.
- Insufficient engine compression. Replace defective part(s) (refer to LEAK TEST in INTAKE MAN-
IFOLD, CYLINDER HEAD AND CYLINDER).
10. Check fault codes in B.U.D.S system.
- Check if electrical actuator(s) is/are defective. Replace defective part(s) (refer to ENGINE MAN-
AGEMENT).

Symptom: ENGINE DOES NOT START

1. Electrical problem.
- Determine if the electrical system works correctly (fuse(s), battery, wiring harness, etc.). Refer
to IGNITION SYSTEM.
2. Problem with fuel system (carburetor, fuel pump, hoses, etc.).
- Clean, inspect, repair or replace defective parts. Refer to FUEL SYSTEM.
3. Check engine compression.
- Insufficient engine compression. Replace defective parts.
- Valve seat worn and/or damaged. Repair by performing valve guide procedure (refer to INTAKE
MANIFOLD, CYLINDER HEAD AND CYLINDER). Readjust valve clearance.
4. Internal engine problem.
- Overhaul engine to find defective parts. refer to the appropriate section in ENGINE.

Symptom: ENGINE HARD TO START

1. Check idle bypass valve.
- Stuck or defective. Refer to ENGINE MANAGEMENT
2. Check closed throttle and idle actuator with B.U.D.S.
- Wrong TPS zero setting/idle bypass valve reset. Refer to ENGINE MANAGEMENT
3. Check throttle cable adjustment.
- Wrong adjustment (likely too tight). Refer to ENGINE MANAGEMENT
4. Check engine compression.
- Insufficient engine compression. Replace defective part(s) (refer to LEAK TEST in INTAKE MAN-
IFOLD, CYLINDER HEAD AND CYLINDER).
5. Verify spark plug condition.
- Defective, improperly set, worn out, fouled. Identify source of problem and correct. Replace
spark plug.
6. Check fuel level in fuel tank and fuel pressure.
- Low or no fuel pressure. Replace defective part(s) (refer to FUEL TANK AND FUEL PUMP).
7. Check CAPS (camshaft position sensor).
- Defective sensor/wiring. Refer to ENGINE MANAGEMENT

Symptom: ENGINE SUDDENLY TURNS OFF

1. Perform engine leak test. Refer to INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER.
- Damaged head gasket and/or seal and/or leaking inlet/exhaust valve (s) . Replace and/or repair
defective parts.

vmr200B'()45 21
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

Symptom: ENGINE SUDDENLY TURNS OFF (cont'd)

2. Check spark plugs condition and/or gap.
- Fouled spark plugs or wrong spark plug gap. Readjust gap and clean spark plugs or replace.
3. Piston seizure.
- Spark plugs heat range is too hot. Install spark plugs with appropriate heat range (refer to TECH-
NICAL SPECIFICATIONS)
- Compression ratio is too high. Install genuine parts.
- Poor oil quality. Use recommended oil.
- Leaks at air intake manifold (engine gets too lean). Retighten screws or replace air intake mani-
fold gasket.
- Snow/water intrusion through intake system into combustion chamber. Clean intake system and
replace defective part(s)
4. Melted and/or perforated piston dome; melted section at ring end gap.
- Spark plugs heat range is too hot. Install recommended spark plugs (refer to TECHNICAL SPEC-
IFICATIONS)
- Coolant less than recommended level (engine gets too hot). Repair cooling circuit and/or refill
with recommended liquid.
- Poor quality and/or wrong fuel. Clean from contamination and use appropriate fuel (refer to
TECHNICAL SPECIFICATIONS).
5. Piston color is dark due to seizure on intake and exhaust sides.
- Cooling system leaks and lowers coolant level. Tighten clamps or replace defective parts. Add
antifreeze in cooling system until appropriate level is reached. Replace damaged parts.
6. Cracked or broken piston.
- Cracked or broken piston due to excessive piston/cylinder clearance or engine overreving. Re-
place piston. Check piston/cylinder clearance (refer to INTAKE MANIFOLD, CYLINDER HEAD
AND CYLINDER).
7. Check piston rings and cylinder surface for grooves.
- Poor oil quality. Use recommended oil.
- Contamination through engine intake. Replace defective part(s) and use new air filter.
S. Check crankshaft, rocker arms movement.
- Oil pump failure due to lack of oil. Repair and replace defective parts and use recommended oil.
- Oil contamination due to clogged oil filter/oil strainer. Replace oil and oil filter at the same time,
replace defective part(s) (refer to LUBRICATION SYSTEM).
9. Check valve springs exhaust/intake.
- Broken valve spring damages the cylinder head, valve (s), rocker arm(s), piston, piston rings and
connecting rod. Replace defective part(s).
10. Check if fuel supply is sufficient.
- Low fuel level.
- Clogged fuel filter or fuel injector filter.
- Fuel line is contaminated and/or bent. Clean and/or replace defective part(s).
11. Check fault codes in B.U.D.S. system.
- Check if electrical actuator(s) is/are defective. Replace defective part(s) (refer to ENGINE MAN-
AGEMENT).

Symptom: ENGINE BACKFIRES

1. Check spark plugs.
- Carbon accumulation caused by defective spark plugs. Replace spark plugs.

22 vmr20 08-045
 Section 02 TROUBLESH001"ING
Subsection 01 (TROUBLESHOOTING CHART)

Symptom: ENGINE BACKFIRES (cont'd)

2. Check leakage on intake manifold.
- Air leak on intake system. Retighten screws and/or replace intake manifold gasket.
3. Check exhaust air leaking.
- Exhaust gasket is leaking. Retighten screws and/or replace exhaust gasket.
4. Check intake valve(s) for leaking.
- Intake valve(s) is (are) leaking. Repair or replace valve(s).
5. Check if fuel supply is sufficient.
- Fuel line is contaminated and/or bent (engine gets lean). Clean and/or replace defective part(s).

6. Check engine ground.

- Poor engine ground. Clean .
7. Check fault codes in B.U.D.S. system.
- Check if electrical actuator(s) is/are defective. Replace defective part(s) (refer to ENGINE MAN-
AGEMENT).

Symptom: ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH
MAXIMUM OPERATING RPM
1. Check spark plugs condition and/or gap.
- Fouled spark plugs or wrong spark plug gap. Readjust gap and clean spark plugs or replace.
2. Check spark plugs type.
- Improper spark plugs heat range. Install recommended spark plugs (refer to TECHNICAL SPEC-
IFICATIONS).
3. Perform engine leak test. Refer to LEAK TEST procedure in INTAKE MANIFOLD, CYLINDER
HEAD AND CYLINDER.
- Damaged head gasket and/or seal and/or leaking intake/exhaust valve(s). Replace and/or repair
defective parts.
4. Check for water in fuel (wrong fuell.
- There is water in fuel or wrong fuel. Drain fuel system, search for leakage and refill it with ap-
propriate fuel.
5. Check engine compression.
- Worn piston(s) and/or piston ring(s). Replace defective part(s) (refer to INTAKE MANIFOLD,
CYLINDER HEAD AND CYLINDER).
6. Check fuel pressure.
- Low fuel pressure. Perform fuel pressure test (refer to FUEL SYSTEM).
7. Check air intake system.
- Air filter is clogged due to contamination. Replace air filter.
S. Check if EMS (engine management system) is in limp home mode. Check fault codes in
B.U.D.S system.
- Check if electrical actuator(s) is/are defective. Replace defective part(s) (refer to ENGINE MAN-
AGEMENT).
9. Check drive belt.
- Worn . Replace belt if its width is less than specified (refer to CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)).

Symptom: HIGH ENGINE OPERATING TEMPERATURE

1. Check if cooling system shows any failure (see COOLING SYSTEM).
- System is leaking. Repair and/or replace damaged part(s).
vmr200~45 23
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)

Symptom: HIGH ENGINE OPERATING TEMPERATURE (cont'd)

2. Check function of lubrication system (see LUBRICATION SYSTEM).
- Lubrication is not working properly. Repair and/or replace damaged part(s).
3. Check condition and heat range of spark plugs.
- Melted spark plug tip or inadequate heat range, Replace,
4. Check air leakage on engine intake.
- Leakage causes overheating, Replace/repair damaged part(s).
5. Check air inlet and outlet of the CVT cover.
- Air circulation is clogged (overheating), Clean air circulation from contamination,
- Drive belt worn and/or damaged. Replace belt with an appropriate drive belt (refer to TECHNI-
CAL SPECIFICATIONS).

,:,-, ,",
. . . :

rft
,

. 111...
: ,: . I .·

, ,
· . lmidwe:str SiiCOm

24 vmr200B'()45
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

ENGINE REMOVAL AND INSTALLATION

SERVICE TOOLS
Description Part Number Page
engine lifting tool " ..." ......... " ........ ......... " ... .. .... " .. .... .... " ... ... 529036022 "" .. ..... " .. .. ......... .. .. " .. .... " ... 31

7N'm
A
~-~~
(62 Ibfoin)~

10 Nom
(89 Ibfoin)

/~

~r~
I~ --J

L~ 61 Nom
(45 Ibfoft)

24 Nom
(18Ibfoft)

vmr200S'{)46 25
Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

GENERAL
& WARNING
To avoid potential burns, let engine and ex-
haust system cool down before servicing.

During assembly/installation , use the torque val-

ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

& WARNING
Torque wrench t ightening specifications 1. Oil drain plug
must strictly be adhered to. 2. Brake pedal
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc.) must be installed or replaced with new
one where specified. If the efficiency of a
locking device is impaired, it must be re-
newed.

PROCEDURES
ENGINE REMOVAL
Vehicle and Engine Preparation
Place vehicle on a workstation that will have ac-
cess to an engine-lifting hoist. Then start with ini-
tial preparation of vehicle by doing the following .
Se lect 4WD position then place transmission lever 1. Cooling dra in plug
to PARK . 2. Bra ke pedal

Using B.U .D.S., remove fuel pressure in the fuel Remove :

system. Refer to ENGINE MANAGEMENT. - seat
Disconnect the BLACK (-) cable from battery, then - both side panels . Refer to BODY
the RED (+) cable. - both foot rests . Refer to BODY
& WARNING - central panel. Refer to BODY
- air f ilter housing cover. Refer to AIR INTAKE
Always disconnect battery cables exactly in
the specified order, the BLACK (-) cable first.
SYSTEM.
It is recommended to disconnect electrical
connections prior to disconnecting fuel lines.

Drain oil and coolant from engine .

NOTE: Drain engine oil only if engine overhaul
is necessary. To work on gearbox the engine re-
moval is necessary but not engine oil drain .

26 vmr2008-046
 Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

CVT OUTLET HOSE (UNSCREW BOTTOM CLAMP AND BOLT)

On Left Side of Vehicle, Remove the

Following Parts:

CRANKCASE VENT TUBE FROM ENGINE

MUFFLER - OUTLANDER SHOWN

FRONT SPARK PLUG CABLE

CVT INLET HOSE CLAMP

LOWER BOLTS FROM UPPER ENGINE SUPPORT

vmr2008-046 27
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

SHIFTING PLATE (UNSCREW BOLT TO REMOVE SHIFTING

BOLTS RETAINING AIR FILTER HOUSING
PLATE)

AIR FIL TER HOUSING BOL T

DART HOLDING AIR INTAKE INLET

On right side of vehicle, remove or

disconnect the following:

CONNECTORS FROM THROTTLE BODY AND INTAKE

MANIFOLD

FRONT AND REAR ENGINE COVERS

28 vm(2008 -046
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 01 (ENGII\IE REMOVAL AND INSTALLATION)

THE OTHER SPARK PLUG CABLE

UPPER THROTTLE BODY CLAMP

OUTLET ENGINE COOLANT HOSE

AIR FILTER HOUSING AND PLACE IT ON FRONT RACK (ON

RENEGADE MODELS, REMOVE IT COMPLETEL YJ

~ ~,.
\,;;
..

FUEL INJECTOR CONNECTORS

vmf2006-01 1-01B

FUEL SUPPLY LINE

INTAKE MANIFOLD

vmr200S-{)46 29
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

COUPLING UNIT CONNECTOR STARTER CABLE

MAGNETO CONNECTOR

2WD/4WD SWITCH CONNECTOR THEN REMOVE HOUSING

FROM BRACKET

ENGINE GROUND B.U.D.S. CONNECTOR THEN REM OVE HOUSING FROM

BRACKET

30 vmr200B-0 46
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

FRONT PROPELLER BOLT

IGNITION COIL CONNECTOR THEN CUT THE LOCKING TIE

vmr2006-011-033_8

REAR PROPELLER BOLT

Lifting Engine

CONNECTOR "A" FROM ECM

vmr2006-011-031

INLET ENGINE COOLANT HOSE

INSTALL THE ENGINE LIFTING TOOL (PIN 529 036 022)

vmr2008-046 31
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 01 (ENGII\IE REMOVAL AI\ID INSTALLATION)

REMOVE THE REAR ENGINE MOUNTING BOLT

vmr2006.{) 1 1-038

MOVE ENGINE FORWARD AND DISCONNECT REAR

PROPELLER SHAFT

Lift engine to clear mounting brackets.

Turn engine 90°, cylinder head towards right side
of vehicle.
Remove engine from vehicle.

ENGINE INSTALLATION
THEN THE FRONT ENGINE MOUNTING BOL T
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following .
NOTE: Prior to install engine, inspect condition of
engine mounts.
Install the rear engine mounting bolt. Do not
torque yet.
Install the rear propeller shaft onto engine output
shaft.
Connect the front propeller shaft to engine output
shaft while lowering engine.
LIFT ENGINE ANO DISCONNECT THE FRONT PROPELLER Install front engine mounting bolt then torque all
SHAFT FROM ENGINE
mounting bolts.
Install and connect all other removed parts.

Final Assembly Procedure

Make sure coolant and oil drain plugs are reIn-
stalled and tight.
Fill cooling system. Refer to COOLING SYSTEM.
Fill engine with the recommended oil and quantity.
Refer to LUBRICATION.
Reconnect battery.

& WARNING
Connect RED (+) cable then BLACK (-) cable.
Always connect RED (+) cable in first.

Start engine and let it reach its operating temper-

ature.
32 vm r2 008-046
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

Stop engine and check coolant and oil levels. Re-

fill as necessary.
Test drive vehicle to confirm proper operation.

ENGINE MOUNT REPLACEMENT

NOTE: Use the same procedure for the front and
rear engine mounts.

Removal
Insert a punch in any engine mount bushing and
push the other bushing out.

TYPICAL

Use punch from the other side to remove the re-

maining bushing.

V07C1GA

TYPICAL

Installation
The installation is the reverse of the removal pro-
cedure.

vmr200S'()46 33
 I

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www.lm idwestlm aln uas.com
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 02 (AIR INTAKE SYSTEM)

AIR INTAKE SYSTEM

SERVICE PRODUCTS
Description Part Number Page
air f ilter clea ning solution ........ .............................. ......... .. .. . 219700341 .. ........ ...... .. ...... .. .. .. .. .... .... .. . 37
Loctite 59 10 .... ...... .. .. .. . 293800081 .... ..... .... .. ...... .. ..... .. .. ........... 39

vmr200a-Q47 35
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 02 (AIR INTAKE SYSTEM)

AIR FILTER HOUSING

6 Nom
(53IbNn)

• .-"n-- 10 Nom
(89Ibfoin)

- :_~_____
l ___________ _
European Community '
Outlander 500 series I

2.5Nom~
(22 Ibfoin) ~
Renegade 500:

vmr2008.()47-001_a

36 vmr200B-047
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 02 (AIR INTAKE SYSTEM)

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure .

& WARNING
Torque wrench tightening specifications
must strictly be adhered to. 1. Clamp
Locking devices (e .g.: locking tabs, elastic 2. Air filter
stop nuts, cotter pin , etc.) must be replaced
with new ones. NOTE: If vehicle is used in dusty area, inspect
more frequently than specified in MAINTENANCE
CHART.
PROCEDURES If liquid/deposits are found, squeeze and dry the
foam filter. Replace filter element if damaged.
AIR FILTER CAUTION: Do not start engine if liquid or de-
posit are found. If there is oil in the air filter
Air Filter Removal housing, check engine oil level. Oil level may
be too high.
CAUTION: Never remove or modify any com-
ponent in the air filter housing. The engine Pour air filter cleaning solution (P/N 219 700 341)
management system is calibrated to operate or an equivalent into a bucket. Put the foam filter
specifically with these components. Other- in to soak. Do not wash filter element.
wise, engine performance degradation or
damage can occur. While filter soaks, clean inside of air filter housing .
Remove seat, side panels, central panel and dash- Rinse foam filter with warm water and let it dry
board . Refer to BODY. completely.
Release clamps and remove air f ilter housing cov- Blow low pressure compressed air on filter ele-
er. ment to clean it.

Air Filter Installation

Properly reinstall removed parts in the reverse or-
der of their removal.

AIR FILTER HOUSING

Air Filter Housing Removal
Remove seat. side panels, central panel and dash-
board. Refer to BODY.
Set shifter lever to PARK.
Disconnect ball joint from shifting plate.
NOTE: If you prefer to remove the shifting plate
from transmission shaft, refer to SHIFTER section
for the procedure .
1. Clamps
2. Cover

Loosen clamp and remove air filter.

vmr2008.()47 37
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 02 (AIR INTAKE SYSTEM)

1. Shifting plate
2. Shifter link rod

Detach throttle cable from shifter panel.

Remove retaining fasteners .

Remove dart.

Disconnect vent tube.

38 vmr2008·047
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 02 (AIR INTAKE SYSTEM)

Remove the water deflector.

Pull the restrictor.

Pull air filter housing out.

Air Filter Housing Installation 1. Inlet tube of air filter housing

2. Water deflector
For installation, reverse the removal procedure but 3. Restrictor
4. CVT air inlet
pay attention to the following.
If the baffle is removed, reseal it with Loctite 5910
(PIN 293 800 081) and replace rivets by screws Restrictor Installation
(M4 x 12 mm) and elastic stop nuts.
The installation is the reverse of the removal pro-
Set shifter lever to PARK then reinstall shifter to cedure .
transmission shaft. Check its operation and adjust
as necessary. Refer to GEARBOX.
Secure throttle cable to shifter panel.
Gently pull throttle cable toward rear to have a gap
between cable and shifter mechanism .

GAP HERE

& WARNING
Ensure shifter mechanism does not touch
throttle cable. Depress throttle lever several
times to ensure it properly returns.

RESTRICTOR
Outlander 500 and Renegade 500 (European
Community Models)

Restrictor Removal
The restrictor is installed on the inlet tube of the
air filter housing.
vmrlOOS-D47 39
 I

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 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 03 (EXHAUST SYSTEM)

EXHAUST SYSTEM
SERVICE TOOLS
Description Part Number Page
exhaust spring tool.......... ...... .... ... ........ ...... ..... ........ ... .......... 529 035 983 .... ... .... .. .... ........... ............ ... 42

- - - - - - - - - 6 N:m - - - - - - - - - - - -
It [(53 Ibfoin)

cl -"'_
3.5 Nom
(31 Ibfoin)

?-/
I
--- -------_ .-' /
MAX series

1 13 Nom
23 Nom (115 Ibfoin)

~
(17 Ibfoft)

6 Nom
(53 Ibfoin)

vm r2008-04B-00 1_a

vmr2008.Q4 8 41
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 03 (EXHAUST SYSTEM)

GENERAL Using the exhaust spring tool (P/N 529 035 983),
remove exhaust springs.
&. WARNING
529035983

-I
To avoid potential burns, never touch exhaust
system components immediately after the
engine has been run because these compo-
nents are very hot. Let engine and exhaust
system cool down before performing any
servicing.

Du ring assemb ly/installation, use the torque val-

ues and service products as in the exploded
views.
Clean threads before applying a thread locker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

&. WARNING
Torque wrench tightening specifications Unscrew exhaust pipe nuts.
must strictly be adhered to .
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a iocking device is impaired, it must be re-
newed .

PROCEDURES
FRONT EXHAUST PIPE
Move front exhaust pipe forward then remove it.
Inspection
Remove exhaust gasket no. 1 from engine ex-
Check for cracks, bending or other damages. Re- haust port.
place if necessary.
Installation
Removal
Install a new exhaust gasket on front exhaust pipe
Remove LH side panel. end.
Unscrew heat shield clamps. Loosely install front exhaust pipe on cylinder head
with exhaust nuts.
Ma ke sure front exhaust pipe end is properly
aligned inside ball socket of "Y" exhaust pipe.
Install exhaust springs.

7. Heat shield clamps

2. Heat shie ld of front exhaust pipe

42 vmr2008-048
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 03 (EXHAUST SYSTEM)

"Y" EXHAUST PIPE

Inspection
Check for cracks, bending or other damages. Re-
place if necessary.

Removal
Remove heat shield no. 3.
1. "Y" exhaust pipe ball socke t

Torque exhaust pipe nuts.

Reinstall all other removed parts .

MUFFLER
Removal
Unscrew muffler clamp.

Remove muffler.
Remove front exhaust pipe .
Disca rd the gasket no. 2.
Unscrew exhaust pipe nuts then remove "Y" ex-
Remove muffler sc rews then pull muffler to re- haust pipe.
move it.

Discard the gasket no. 2 at the end of "Y" exhaust

pipe.
Remove exhaust gasket no. 4 from engine ex-
Inspection haust port.
Check muffler for cracks or other damages. Re-
place if necessary. Installation
Install a new gasket on each end of Y-exhaust pipe
Installation end and another on the end of "Y" exhaust pipe
For the installation, reverse the removal proce- (cylinder side) .
dure.
vmr2008.Q48 43
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 03 (EXHAUST SYSTEM)

While sliding the "Y" exhaust pipe end over the

front exhaust pipe end, align its other end with the
studs on cylinder head.
Secure the front exhaust pipe on cylinder with ex-
haust nuts.
Torque exhaust nuts and exhaust clamp.
Reinstall all other removed parts.

FUEL TAI\IK PROTECTOR

Inspection
Check for wear, cracks or other damages. Re-
place if necessary.

Removal
Remove muffler.
Unscrew front bolt.

Unscrew upper bolts.

Remove fuel tank protector.

Installation
The installation is the reverse of the removal pro-
cedure but pay attention to the following.
First, loosely install front bolt then instal l remain-
ing bolts. Torque all bolts as per installation se-
quence.

44 vmr2008·048
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 04 (LUBRICATION SYSTEM)

LUBRICATION SYSTEM
SERVICE TOOLS
Description Part Number Page
adapter hose ........................................................................ . 529 035 652 .......................... .. ............... 49
oil pressure gauge ......................................... .. .................... . 529 035 709 ........................................... 49
disconnect tool .................................................................... . 529035714 ........................................... 49

SERVICE PRODUCTS
Description Part Number Page
XP-S 5W30 mineral oil .......... .. ...... ....... .. ....... ....... .. ...... .. .. ..... 219700706 ......... ........ ........ ........ .......... 48
Loctite 243 (blue) .................................................................. 293800060 .......... .................. ...... ......... 51

vmr2007.()49 45
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 04 (LUBRICATION SYSTEM)

COMPONENTS
20 Nom
(15 Ibfoft)
2

~
12 Nom
(106 Ibfoin)

3~~/"
1
..J ~Loctite _ - - - & Super Lube grease
~ 243
5 6 (PIN 293550030)

/~
10 Nom
(89Ibfoin)

Super Lube grease

(P/I\I 293550030)
~, .... ---~
~
~--- '",,-
,/, ------- -~ '~
I ~ '\
( "'-- "'-- \
"'-- mD---o M12 x 1.5
\ '",-- ~ 20 Nom \
\ "'-- . - - (15 Ibfoft) 'j
Loctite 243 '", "'-- "'-- '
~ "'-- "'-- /
\ "'-- "'-- '---- /
5Nom -~ ------- /
(44Ibfoin) ---------- - -- --

vm r2006·042·001 _b

46 vmr2007-Q49
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 04 (LUBRICATION SYSTEM)

ENGINE LUBRICATION

1. Camshaft bearings
2. Oil pressure switch
3. Oil filter
4. Oil pressure regulator valve
5. Oil strainer
6. Oil pump
7. Crankshaft main bearings
8. Crankshaft support bearing
9. Connecting rod bearings

vmr2007<l49 47
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 04 (LUBRICATION SYSTEM)

GENERAL Oil Level Verification

During assembly/installation, use the torque val- NOTE: Strictly follow this procedure, otherwise
ues and service products as in the exploded view. wrong oil level may be indicated.
Clean threads before applying a threadlocker. Re- Ensure vehicle is on a level surface.
fer to SELF-LOCKING FASTENERS and LOCTITE Start engine and let idle for a few minutes.
APPLICATION at the beginning of this manual for Stop engine. Wait a few minutes to allow oil to
complete procedure. flow down to crankcase then check oil level.
& WARNING Fully screw in dipstick to check oil level.
Torque wrench tightening specifications Remove dipstick and read oil level.
must strictly be adhered to. Oil level must be between minimum and maxI-
Locking devices (e.g.: locking tabs, elastic mum marks on dipstick.
stop nuts, self-locking fasteners, etc.) must
be installed or replaced with new ones where
specified. If the efficiency of a locking device
is impaired, it must be renewed.

MAINTENANCE
ENGINE OIL
Recommended Oil
Use 4-stroke engine oil that meets or exceeds the
requirements for API service classification SM, SL
or SJ. Always check the API service label certifi-
cation on the oil container, it must contain at least
one of the above standards.

Oil Viscosity
TYPICAL - FULLY SCREW DIPSTICK TO CHECK OIL LEVEL
XP-S 5W30 mineral oil (P/N 219 700 706) is rec- 1. Maximum
ommended for all seasons. 2. Minimum

Refer to the following chart for other viscosity There is a capacity of 300 mL (10 U.S. oz) between
grades. the two marks.
Refill oil as necessary. Do not overfill.
XP-S5W40 Synthetic Qil (PIN 293 6.00 039)
Reinstall dipstick.
XP-S 5W30Minerai Oil (PIN 219700706)
Oil and Filter Change
XP-S 10W40 Mineral Oil (PIN 219 700 346)
Prior to change the oil, ensure vehicle is on a level
Temperature Range
surface.
50°C 1122°F)
4DoC 11 D4°F) Oil and oil filter must be replaced at the same
3DoC 186°F)
time. 011 change and oil -filter replacement should
2DoC 168°F)
be done with a warm engine.
1DOC 15DOF)
DOC 132°F)
& WARNING
-IDoC IWF) The engine oil can be very hot. Wait until en-
- 2DoC 1- 4°F) gine oil is warm.
- 3DoC 1- 22°F]
Place a drain pan under the engine drain plug area.
Clean the drain plug area.
Unscrew drain plug and discard the gasket ring.
48 vmr2007-049
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 04 (LUBRICATION SYSTEM)

Remove the oil pressure switch . See procedure

below.
Install oil pressure gauge (PIN 529 035 709) and
adapter hose (PIN 529035 652).

529035709

1 ~.
vm ,2006-00B-003_a

1. Drain plug
2. Gasket ring

Remove dipstick.
Allow oil to drain completely from crankcase .
NOTE: Oil condition gives information about the
529035652
engine condition. See TROUBLESHOOTING sec-
tion.
Clean the magnetic drain plug from metal shavings
and residue. Presence of debris gives an indica-
tion of failure inside the engine. Check engine to
correct the problem. The engine oil pressure should be within the fol-
lowing values.
Install a NEW gasket ring on drain plug. Torque
drain plug to 20 N.m (15 Ibf·ft).
OIL
1250 RPM 6000 RPM
CAUTION: Never use the gasket ring a second PRESSURE
time. Always replace by a new one.
70 kPa 350 kPa
Replace oil filter. Refer to OIL FILTER further in MINIMAL
(10 PSI) (51 PSI)
this section.
180 kPa 420 kPa
Refill engine with recommended engine oil. NOMINAL
(26 PSI) (61 PSI)
See RECOMMENDED OIL and OIL VISCOSITY
300 kPa 550 KPa
CHART above. MAXIMAL
(43 PSI) (80 PSI)
Oil change capacity with filter: 2 L (2 .11 qt).
After filling, check the 011 level with the dipstick. If the engine oil pressure is out of specifications,
Refer to OIL LEVEL CHECK above. check the points described in TROUBLESHOOT-
ING section .
Run engine to ensure oil filter and drain plug areas
are not leaking. Remove oil pressure gauge and adapter hose.
Dispose oil and filter as per your local environmen- NOTE: To remove adapter hose from oil pressure
tal regulations . gauge, use the disconnect tool (PIN 529035714) .
Reinstall the oil pressure switch.
INSPECTION
PROCEDURES
ENGINE OIL PRESSURE
NOTE: The engine oil pressure test should be OIL FILTER
done with a warm engine 90°C (194°F) and the
recommended oil.
Oil Filter Removal
Remove oil filter screws.

vmr2 007.Q49 49
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 04 (LUBRICATION SYSTEM)

Remove oil filter cover.

Remove oil filter.

vmr2006.()Oa.OO I_a

1. Slightly oil
2. Slightly grease

Install the cover on the engine.

Torque screws to 10 N-m (89 Ibf-in).
vmr2006-00S-004_a

1. Oil filter screw

2. Oil filter cover OIL PRESSURE SWITCH (OPS)
3. a-ring
4. Oil filter

Oil Filter Inspection

Check and clean the oil filter inlet and outlet area
for dirt and other contaminations.

1. Oil pressure switch

Oil Pressure Switch Activation

Oil pressure switch works when engine oil pres-
sure is between 20 and 40 kPa (2.9 and 5.8 PSI).
To check the function of the oil pressure switch,
an oil pressure test has to be performed. Refer to
ENGINE OIL PRESSURE.
1. Inlet bore from the oil pump to the oil filter
2. Outlet bore to the engine oil providing system If the engine oil pressure is good, check the resis-
tance of the oil pressure switch while engine is off
and while engine is running .
Oil Filter Installation
Install a NEW a-ring on oil filter cover. Oil Pressure Switch Resistance Test
Install the filter into the cover. Disconnect the connector from the oil pressure
switch .
Apply engine oil on a-ring and grease on the end
of filter. Use a multimeter to check the resistance between
as shown.

50 vmr200H)49
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 04 (LUBRICATION SYSTEM)

OPS ENGINE NOT ENGINE

CONNECTOR RUNNING RUNNING
PIN RESISTANCE (n)
Infinitely
Engine
Close to 0n . high when
1 (normally pressure reaches
ground
closed switch) 20 - 40 kPa
(2.9 - 5.8 PSI)

1. Engine oil pressure regulator

NOTE: The oil pressure regulator system works

when the oil pressure exceeds 450 kPa (65 PSI).

Removal
Remove plug screw no. 2 and pull oil pressure
If resistance values are incorrect, replace the oil regulator out.
pressure switch .
If the values are correct, check the continuity of
the wiring harness.
Disconnect the connector" A" from the ECM and
check continuity of circuit 10.

Oil Pressure Switch Removal

Unplug then unscrew the 011 pressure switch
no. 1, mounted on the crankcase.

Oil Pressure Switch Installation

Torque switch to 12 N-m (106 Ibf-in) .
NOTE: Install oil pressure switch with Loctite 243
(blue) (PIN 293 800 060) .

1. Plug screw
ENGINE OIL PRESSURE 2. Gasket ring
REGULATOR 3.
4.
Pressure regulator housing
Spring
5. Pressure regulator valve
The 011 pressure regulator is located on the engine
magneto side (inside magneto cover) .
Inspection
Inspect pressure regulator housing no. 4 and valve
no. 6 for scoring or other damages.
Check spring no. 5 for free length.

vm r2007.Q49 51
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 04 (LUBRICATION SYSTEM)

SPRING FREE LENGTH

NEW NOMINAL 39 mm (1.535 in)
SERVICE LIMIT 37 mm (1.457 in)

NOTE: Replace worn or damagEld components.

Clean bore and thread in the magneto housing
from metal shavings and other contaminations .

Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: At installation, always replace the gasket
ring no. 3 of the plug screw.

OIL PUMP
2
The oil pump is located on the engine PTO side vmr2006-{)42-0 lO_a

(behind cover). 1. Retaining ring

2. Oil pump gear
3. Needle pin
4. Thrust washer

- oil pump cover screws and pull oil pump cover

- oil pump shaft with inner rotor and outer rotor.

vmI 2006-042·009_a

1. Oil pump

vmr2006-04 2-01 1_a

Removal
1. Retaining scre ws
Remove parts to access the engine crankcase 2. Oil pump cover
PTO cover.
Remove the engine crankcase PTO cover. Refer
Inspection
to BOTTOM END section.
Inspect oil pump for marks or other damages.
Remove :
Check for scratches in crankcase between outer
- retaining ring rotor and oil pump bore. If so, replace damaged
- oil pump gear parts.
- needle pin
- thrust washer

52 vmr200 7-049
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 04 (LUBRICATION SYSTEM)

If clearance of inner and outer rotors exceeds the

tolerance, replace oil pump shaft assembly. En-
sure to also check oil pump cover. If damaged,
replace the complete oil pump assembly.
If clearance between outer rotor and its bore
in crankcase exceeds the tolerance, replace
the complete oil pump assembly and/or the
crankcase.
Using a depth gauge, measu re the axial clearance
of the 011 pump as shown .

1 2 3 5
vmr2006·().12·0 12 ~a

1. Oil p ump bore

2. Outer rotor
3. Oil pump shaf t
4. Needle pin
5. Inne r rotor

Check inner rotor for corrosion pin holes or other

damages. If so, replace 011 pump shaft assembly.

OIL PUMP - MEASUREMENT " A "

vm r2006-()4 2·013 _a

1. Pittin gs on the teeth

Using a feeler gauge, measure the clearance of

inner and outer rotors as shown.

vmr2006-042-0 16

OIL PUMP COVER - MEASUREMENT " 8"

Difference between measurements should not

exceed 0.2 mm (.008 in). ' If so, replace the com-
plete oil pump assembly.
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure de-
1. Outer ro tor creases .
2. Inner ro tor
A. Service lim it: 0.25 m m (.009 in)
Installation
For installation, reverse the removal procedure .

vmr2007'()49 53
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 04 (LUBRICATION SYSTEM)

Pay attention to the following details.' Cleaning and Inspection

NOTE: The outer rotor and inner rotor are marked. Clean engine oil strainer with a part cleaner then
When installing, make sure both markings are on use an air gun to dry it.
the upper side.
& WARNING
Always wear eye protector. Chemicals can
cause a rash break out and injure your eyes.

Check engine oil strainer for cracks or other dam-

age . Replace if damaged.

Installation
Refer to BOTTOM END section.
Rl004motr51A

TYPICAL REED VALVE

1. Markings
The engine is equipped with a reed valve no. 8
After reinstallation of the remaining parts, check which prevents accumulation of larger oil quanti-
for smooth operation of the oil pump assembly. ties in the crankcase. The reed valve is fitted into
the crankcase.
Final Test
After engine is completely reassembled, start en-
gine and make sure oil pressure is within specifi-
cations (refer to ENGINE OIL PRESSURE above) .

ENGINE OIL STRAINER

The engine oil strainer no. 7 is located between
both crankcase halves.

1. Reed valve
2. Stopper
3. Scre ws

Valve Removal
Remove:
- PTO cover (refer to PTO COVER)
- reed valve retaining screws
- stopper plate
3 - reed valve.
vm I2006·()42·017 _a

1. Engine oil strainer

2. Retaining plate Valve Inspection
3. Screws
Check reed valve for cracks or other damage.
NOTE: Replace reed valve if damaged.
Removal
Refer to BOTTOM END section. Valve Installation
The installation is the reverse of the removal pro-
cedure.

54 vmr2007-0 49
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

COOLING SYSTEM
SERVICE TOOLS
Description Part Number Page
installer handle ..................................................................... . 420 877 650 ........................................... 68
pressure/vacuum pump ... .... .................... .... ..................... .. .. 529021 800 ...... ..................................... 58
large hose pincher .... ...... ................. ......... ................ ........ .. .. 529 032 500 ... ............................ .. .......... 59
oil seal pusher ............. .. ...... ....... ... .. ................. .................... . 529035757 ... ........ .. ...... .. ....... ........ .. .. ... 68
rotary seal installer. ........... ......... .................. ......... ... .. .......... . 529 035 766 ... ..... ................................... 69
Fluke 111 multi meter ........ .... ............. ... ...... ..... ... .... .......... .. . 529 035 868 ........................................... 62
test cap ...................... ... ........ ... .............. .. .................... ........ . 529 035 991 ............................ .. ... .. ........ 58
puller kit ............... ...... ......... .. .. ..... ..... ........... .. .. .... ..... ... .... .. .. 529 036 056 ...... ..................................... 68

SERVICE PRODUCTS
Description Part Number Page
BRP premixed coolant.. .... ..... ......... ....... .. ......... ....... ... .......... 219700362 ................................. .. .. ...... 59
Molykote 111 ......................... .. ........ .... ......... .... ......... ... ........ 413707 000 ........ .. ...... .... ............ ..... .. .. .. 69

vmr200S'{)50 55
Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 05 (COOLING SYSTEM)

RADIATOR

7 Nom
~ (62.lbfoin)
12 I
:r""'~AlY~
~7
11-
5.5 Nom
(49 Ibfoin) i
~

vmt2006·Q09-002_8

56 vmr2008-050
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

WATER PUMP

~
Engine
oil

vmf2006-04Q-001 _b

vmr200B{)50 57
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

GENERAL
& WARNING
Never start engine without coolant. Some
engine parts such as the rotary seal on water
pump shaft can be damaged.

During assembly/installation, use the torque val-

ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

& WARNING
Torque wrench tightening specifications
must strictly be adhered to. V07CONA
Locking devices (e.g.: locking tabs, elastic
TYPICAL
stop nuts, self-locking fasteners, etc.) must 1. Special radiator cap
be installed or replaced with new ones where
specified. If the efficiency of a locking device Check all hoses, radiator no. 3 and cylinder(s)/base
is impaired, it must be renewed. for coolant leaks or air bubbles.

Inspection
INSPECTION Check general condition of hoses and clamps
tightness.
COOLING SYSTEM LEAK TEST Check the leak indicator hole if there is 011 or
coolant.
& WARNING
NOTE: Leaking coolant indicates a defective ro-
To avoid potential burns, do not remove the tary seal. Leaking oil indicates a defective inner
radiator cap or loosen the cooling drain plug oil seal. If either seal is leaking, both seals must
if the engine is hot. be replaced at the same time. Refer to WATER
PUMP SHAFT AND SEALS in this section.
Open the access panel and remove the radiator
cap no. 1.
Install the test cap (P/N 529035991) on filler neck.

,
.,..
t
I

I-. - .-::- 529035991

~~ ~
IIIIIIII!...
~ ~ 1. Leak indicator hole

Using pressure/vacuum pump (P/N 529021 800), Another leak indicator hole is visible on the PTO
pressurize system to 103 kPa (15 PSI) . side . It indicate if the PTO gasket is in good con-
dition . If a liquid leaks by this hole, the PTO gasket
replacement is necessary.

58 vmr2008'()50
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

MAINTENANCE
vmo2006-007-019_B

COOLANT REPLACEMENT UNDER RH FOOTREST

1. Cooling drain plug
.& WARNING 2. Brake peda l

To avoid potential burns, do not remove the When cooling system is drained completely, re-
radiator cap or loosen the cooling drain plug move cooling drain plug completely and install a
if the engine is hot. new gasket ring. Screw the cooling drain plug and
torque it to 10 N-m (89 Ibf-in) .

Recommended Coolant Refilling the System

Use BRP premixed coolant (PIN 219 700 362) or a Remove the RH side panel.
blend of 50% antifreeze with 50% water. Pinch radiator inlet hose no. 4 between radiator
To prevent antifreeze deterioration, always use and thermostat housing with a large hose pincher
the same brand. Never mix different brands (PIN 529 032 500).
unless cooling system is completely flushed and
refilled.
CAUTION: To prevent rust formation or freez-
ing condition, always replenish the system
with the BRP premixed coolant or with 50%
antifreeze and 50% water. Do not use tap wa-
ter, straight antifreeze or straight water in the
system. Tap water contains minerals and im-
purities which build up in the system. During
cold weather, straight water causes the system
to freeze while straight antifreeze thickens and
does not have the same efficiency. Always
use ethylene glycol antifreeze containing cor-
rosion inhibitors specifically recommended for
aluminum engines.
1. Place hose pincher here
Draining the System
Unscrew bleeding screws on top of thermostat
.& WARNING housing.
Never drain or refill cooling system when en-
gine is hot.

Remove radiator cap no. 1.

Partially unscrew cooling drain plug located below
water pump housing .

vm(200S-050 59
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

PROCEDURES
THERMOSTAT
The thermostat is a single action type.

Thermostat Removal
NOTE: The thermostat is located on the top of
cylinder head, on intake side (front cylinder) .
Install a hose pincher on both radiator hoses.
Remove:
1. Bleeding screws
- thermostat housing screws and pull thermostat
cover
NOTE: Both cylinders must be bled.
With vehicle on a flat surface, engine cold, refill
radiator no. 3. When the coolant comes out by
the thermostat housing hole, install the bleeding
screw with its gasket ring and torque to 5 N-m
(44 Ibf-in).

. ~

vmr2006.Q09-0 11_a

1. Thermostat cover
2. Screws

TYPICAL
- thermostat with gasket out of the hole.
1. Gasket ring
2. Bleeding screw

Remove hose pincher, fill up the radiator then in-

stall radiator cap.
Refill coolant tank no. 5 up to cold level mark. In-
stall the coolant tank cap. Run engine until ther-
mostat opens then stop engine .
When engine has completely cooled down,
recheck coolant level in radiator and coolant tank
and top up if necessary. The level in the coolant
tank should be between MIN. and MAX. marks .
NOTE: Each year or every 100 hours or when ve-
hicle reaches 3000 km (1865 mil, check coolant 1. Thermostat with gasket
concentration (freezing point) with proper tester.

60 vmr2008-050
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

Thermostat Test
To check thermostat. put in water and heat water.
Thermostat should open when water temperature
reaches 65°C (149°F) .
Check if the gasket is brittle, hard or damaged. If
so, replace gasket.

Thermostat Installation
For installation, reverse the removal procedure,
pay attention to the following details.
Install the thermostat cover then torque screws to
6 N.m (53 Ibf.in).
Check coolant level in radiator and coolant tank
and top up if necessary.
CAUTION: Do not forget to bleed the cooling
system. Refer to COOLANT REPLACEMENT.

RADIATOR CAP V07CORA

TYPICAL
Using a pressure cap tester, check the efficiency 1. Radiator mounting bolts
of radiator cap no. 1. If the efficiency is feeble,
install a new 110 kPa (16 PSI) cap (do not exceed Unplug radiator fan no. 8.
this pressure). Remove radiator no. 3.

RADIATOR Radiator Installation

For installation, reverse the removal procedure.
Radiator Inspection Pay attention to the following detail.
Check radiating fins for clogging or damage.
Install rubber bushings no. 10 between the bot-
Remove insects, mud or other obstructions with tom of radiator and radiator supports .
compressed air or low pressure water.
Fill up the radiator. Refer to COOLANT REPLACE-
MENT, in this section.
Radiator Removal
Drain cooling system. Check for any coolant leakage from radiator and
hoses.
Remove front fascia and radiator shroud, refer to
BODY. COOLANT TANK
Remove:
radiator inlet no. 4 and radiator outlet no. 6 The coolant expands as the temperature (up to
100 - 11 ooe (212 - 230°F)) and pressure rise in the
hoses
system. If the limiting system working pressure
- overflow hose no. 2 cap is reached 110 kPa (16 PSI), the pressure relief
- mounting bolts no. 7. valve in the pressure cap is lifted from its seat and
allows coolant to flow through the overflow hose
into the overflow coolant tank no. 5.
Ensure ventilation holes are not obstructed.

vmr200S-050 61
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

RADIATOR FAN RELAY (R1)

Relay Installation
NOTE: Relay may be inverted by 1800 at installa-
tion and it will work correctly. Ensure to align tabs
of relay with terminals of fuse holder at installa-
tion .

1. Ourer cap vent

2. Inner cap vent

Tank Removal A

Remove :
- LH inner fender (refer to BODY)
- coolant tank support bolt no. 11 IImr2006.Q2O-Q03

Rl: Radiator fan relay

Relay Operation Test

The easiest way to check the relay is to remove
it and bypass it with a jumper. If the radiator fan
is activated, replace the relay. See illustration to
find where to bypass the relay.

V07COSA

TYPICAL

- overflow hose no. 2

- support no. 12 and coolant tank no. 5.
Empty coolant tank .
RELAY R1 (RADIATOR FAN)

Tank Installation
The installation is the reverse of the removal pro- Relay Continuity Test
cedure. Remove relay.
Use the Fluke 111 multimeter (PIN 529035868),
COOLANT TEMPERATURE and select the It position.
SENSOR (CTS) Probe relay as follows .
Refer to ENGINE MANAGEMENT section for test-
ing and replacement procedures of the coolant TERMINAL RESISTANCE
temperature sensor (CTS).
Open circuit
30
I 87 (OU

62 vmr200B-0 50
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

s mr2007-027-050_a

Connect battery as shown and probe relay again

as follows.

TERMINAL RESISTANCE
0.5 [1 max .
30 87
t (continuity)

smr2007-027-060_a

If relay failed any test, replace it.

RADIATOR FAN
Radiator Fan Operation
The ECM controls the radiator fan via the input
of the coolant temperature sensor (CTS) and the
manifold air pressure and temperature sensor
(MAPTS).
The radiator fan should turn on when coolant tem-
perature reaches 98°C (208°F) and should turn off
when the coolant cools down at 95°C (203°F) .

vmr200S'()50 63
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

CHECK MESSAGE IN
ENGINE INTAKE COOLING LlIVIP HOIVIE
ENGINE MULTIFUI\lCTION
TEMPERATURE TEMPERATURE FAN MODE
LIGHT GAUGE
88°C
Turns ON
(190°F)
85°C
Turns OFF
(185°F)
98°C
Turns ON
(208°F)
95°C
Turn OFF
(203°F)
115°C - Check engine
ON Turns ON
(239°F) - Hi Temp

- 118°C Engine RPM

ON Flashes Limp Home
(244°F) limited to 4000

Radiator Fan Test

Connect the vehicle to B.U.D.S. Refer to ENGINE
MANAGEMENT for procedure and connector lo-
cation.
In ACTIVATION folder, press COOLANT FAN but-
ton.
If fan turns, check CTS, wiring harness and con-
nectors. If all parts are good, replace the ECM.
If fan does not turn when COOLANT FAN button is
pressed, use the following troubleshooting chart
to resolve the problem.

64 vmr2008-050
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

yes
Is fan working? Everything is OK
no
Check accessories fuse
(30 A) and fan fuse (20 AI. yes
16 fuse burned? Rep/sce (use(s)
no

Check relav no. 1

Replace relay

Apply 12 Volts on fan connector

Fan tums? Replace fan

yes
CheckCTS

CTSworks7 ReplseeeTS
yes
Cbeck wiring harness
and connectors

All work well? Repair or replsee

defiH:tive part(s)
yes
Try a newECM
vm r2006-009-005_aen

Radiator Fan Removal Water Pump Housing Removal

Remove radiator shroud.
Remove bolts no. 13.
& WARNING
To avoid potential burns, do not remove the
Remove the radiator fan. radiator cap or loosen the cooling drain plug
if the engine is hot.
Radiator Fan Installation
For the installation, reverse the removal proce- Drain cooling system.
dure.
Remove radiator outlet hose from water pump
housing.
WATER PUMP HOUSING
Remove screws retaining water pump housing.
It is located on the engine MAG side.

vmr200S'()50 65
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

3 WATER PUMP IMPELLER

Impeller Removal
Remove water pump housing.
Unscrew impeller.

vmr2006-040-008_b

TYPICAL
7. Cooling drain plug
2. Sealing ring 1
3. Screws vmr2006-040-010_b
4. Water pump housing
1. Turn clockwise to unscrew

Pull water pump housing to remove it. CAUTION: Water pump shaft and impeller have
right-hand threads. Remove by turning coun-
Water Pump Housing Inspection terclockwise and install by turning clockwise.
Check if gasket is brittle, hard or damaged and
replace as necessary. Impeller Inspection
Check impeller for cracks or other damage. Re-
place impeller if damaged.
1
Impeller Installation
The installation is the opposite of the removal pro-
cedure.
CAUTION: Be careful not to damage impeller
wings during installation.

WATER PUMP SHAFT AND SEALS

vm f2006-040-009_a

TYPICAL Shaft/Seal Removal

1. Gasket
NOTE: It is not required to split crankcase to re-
place the water pump shaft and seals, but engine
Water Pump Housing Installation removal is necessary.
The installation is the opposite of the removal pro- Drain engine oil. Refer to LUBRICATION SYS-
cedure . TEM.
CAUTION: To prevent leaking, take care that the Drain gearbox oil. Refer to GEARBOX AND 4X4
gasket is exactly in groove when you reinstall COUPLING UNIT.
the water pump housing. Remove CVT and inner cover. Refer to TRANS-
Tighten screws of water pump housing in a criss MISSION section.
cross sequence.

66 vmr2008·050
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

Remove engine from vehicle. Refer to ENGINE

REMOVAL AND INSTALLATION section.
Detach gearbox from engine. Refer to GEARBOX
AND 4X4 COUPLING UNIT.
Remove engine drive shaft and engine PTO cover.
Refer to BOTTOM END.
Remove water pump housing and impeller. See
procedures in this section.
Pullout water pump gear to disengage the inner
drive gear.

1. Thrust washer here

CAUTION: If thrust washer is not on water

pump shaft, use a magnet to retrieve it inside
crankcase.
Using appropriate pliers, remove and discard the
retaining ring securing water pump gear on water
pump shaft.
To remove plastic gear from water pump shaft,
place gear between your fingers and briskly tap
shaft end.

1. Water pump gear

2. Inner drive gear

Sharply strike water pump shaft out with a plastic

hammer.

Using 2 screwdrivers, pry out inner part of the ro-

tary seal.

Pullout water pump shaft through the engine

drive shaft opening.
NOTE: Pay attention to hold thrust washer to pre-
vent it from falling in crankcase.

vmr200S-D50 67
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

To remove outer part of rotary seal, use an ex-

pander from puller kit (PIN 529 036 056).
Install expander snugly against outer part and pull
1. Inner oil seal
rotary seal out. 2. Rotary seal surface

CAUTIOI\!: Be careful not to damage the rotary

seal surface in crankcase.

Part Inspection
Inspect water pump gear for wear and damage on
the snap mechanism to the needle pin . Replace
if damaged .

Shaft/Seal Installation
For installation, reverse the removal procedure .
However, pay attention to the following.
NOTE: For installation use the torque values in
the exploded view. Ensure to use mUltipurpose
grease for oil seal.
CAUTION: Always replace rotary seal and wa-
Remove inner oil seal. ter pump shaft together. Also, install a new
inner oil seal (behind rotary seal) at the same
time.
Apply engine oil on the water pump shaft and in-
termediate shaft.
NOTE: Never use oil in the press fit area of the oil
seal and rotary seal.
Use the oil seal pusher (PIN 529035 757) and the
installer handle (PIN 420 877 650) to install inner
oil seal.

68 vmr2008·050
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

Slide water pump shaft with the new ro tary seal

int o crankcase.
To properly insta ll water pump shaft with rotary
seal , use the rotary seal installer (PIN 529 035
766) .
1 2
1. Handle
2. Pusher

Apply Molykote 111 (PIN 413 707 000) inside lips 529035766
of oil seal.
When installing the oil seal on the pusher, make
sure sealing lip points outside .
Push inner oil seal in place .

R400motr 150A

1. Surface where rotary seal is pushed bV tool

Use a plastic hammer and drive rotary seal into

crankcase .

1. Inner oil seal

2. Installer handle with oil seal p usher

From engine drive shaft opening, insert thrust

washer on water pump shaft in crankcase .
Using a flashlight and a mirror, position shaft hole
so that pin can be installed.
Position pin between your fingers, push in water
pump shaft to fully expose hole then install pin.
Position pin at equal distance out of shaft hole so
gear can be installed .

vm,200B-050 69
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 05 (COOLING SYSTEM)

Install water pump shaft gear.

NOTE: Ensure gear properly snaps on pin. A
screwdriver may have to be used to push gear in
place.
Use a 45° snap-ring pliers and install a NEW retain-
ing ring on pump shaft end.
CAUTION: Never use the retaining ring a sec-
ond time. Always install a new one.
After installation, water pump shaft with rotary
seal must rotate freely.
Carefully push in water pump gear while turning
to mesh with the inner drive gear.

1. Water pump gear

2. Inner drive gear

Tighten screws of the water pump housing cross-

wise.
Properly reinstall remaining parts. Refer to appro-
priate sections.
Refill all fluids.

70 vmr200S'()SO
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 06 (MAGNETO SYSTEM)

MAGNETO SYSTEM
SERVICE TOOLS
Description Part Number Page
crankshaft locking bolt ...... ...................... ..... .. ... ... ..... .... .... .... 529035617 .... .. ...... ........ .... .. .......... .. ..... 75
magneto puller .. .. ............ ..... .. ....... ...... ... ........ ............ .. ......... 529035748 ...... .................... .. .. .... ......... 75
crankshaft protector.... .... ............ .... .... .... .. ...... ..... .. .......... .. .. 529 036 034 ........................ .. ........ .... ..... 75

SERVICE PRODUCTS
Description Part Number Page
Loctite 767 (antiseize lubricant) ....... .. .............. .. ...... .... .. .. .... . 293 800 070 ...... .. ...... ...... ... ..... .. ............. 78
pulley flange cleaner .. ... ..... ... ... ........ .. .. .. .. ............. .. ..... ....... .. 413 701 809 ......................... ............ ...... 75
Loctite Chisel (gasket remover) ............. ...... ..... .. ................. . 413 708 500 ......................... .......... .. .. .... 73
Loctite 648 (green) .......... ................ .. ................... ............... . 41 3 711 400 ... .................. ... .. .... ....... .. ... . 77
Drei Bond sealing compound .................... .. ................ ........ . 420 297 906 ........................... .... ...... .... .. 73

sa,les@.mildwe, manrUI,a s.c,o,m

id .
WWW"lm l · ·· westlmalnua 5.COm 1

vmr200S-D51 71
Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 06 (MAGI\IETO SYSTEM)

~
Molykote
111

Loctite 767
(antiseize lubricant)
~

150 Nom
(111 Ibfoft)

30 Nom
(22Ibf°ft)

~ 25 Nom
Engine oil (18Ibf°ft)

vm r2006-0A 1-0Dl_b

72 vmr200B-051
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 06 (MAGNETO SYSTEM)

GENERAL
Always perform the electric tests before removing
or installing whatever component.
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

& WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a locking device is impaired, it must be re- 1. Magneto cover
2. Retaining screws
newed. 3. Crankshaft position sensor

Pull out magneto cover.

PROCEDURES
Magneto Cover Inspection and
Cleaning
MAGNETO COVER
Check magneto cover for cracks or other damage .
Magneto Cover Removal Replace if necessary.
Drain engine oil (refer to LUBRICATION SYSTEM) . NOTE: Clean all metal components in a non-
ferrous metal cleaner. Use Loctite Chisel (gasket
Remove plastic cover.
remover) (PIN 413 708 500), or suitable equiva-
Remove crankshaft position sensor (CPS) and cut lent.
tie raps.
Disconnect magneto connector. & WARNING
Remove dipstick. Wear safety glasses and work in a well
ventilated area when working with strong
Remove magneto cover retaining screws . chemical products. Also wear suitable
non-absorbent gloves to protect your hands.

Magneto Cover Installation

For installation, reverse the removal procedure .
However, pay attention to the following.
NOTE: At installation replace magneto cover gas-
ket.
Apply Drei Bond sealing compound (PIN 420 297
906) on stator cable grommet as shown in next
illustration.

vm r200a.Q51 73
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 06 (MAGNETO SYSTEM)

1. Apply Orei Bon d sealing compound

Tightening sequence for screws on magneto cov-

er is as per following illustration. 1. Stator
2. Stator retaining screw s
3. Holding strip
4. Holding strip screws

Stator Inspection
Check stator condition . If damaged replace it.
Check if stator wi res are brittle, hard or otherwise
damaged.
For electrical inspe ction, refer to CHARGING SYS-
TEM.

Stator Installation
For installation , reverse the removal procedure .
However, pay attention to the following .
CAUTION: When installing the stator take care
that the cable is in place (guide for the wire).
TIGHTENING SEQUENCE
NOTE: There is only one position for the stator
(notch in the magneto housing cover) .
Refill engine with recommended oil.

STATOR
Stator Removal
Remove magneto cover (refer to MAGNETO COV-
ER above).
Remove screws securing holding strip.
Remove stator retaining screws then the stator.

vmr2006-041-006_a

1. Threads for cable holdin g strip

2. Notch for s tator

74 vmr200S-Q51
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 06 (MAGf\IETO SYSTEM)

ROTOR
Rotor Removal
Lock crankshaft with crankshaft locking bolt
(PIN 529035 617) (refer to BOTTOM END).
Remove magneto cover. Refer to MAGNETO
COVER above .
Remove screw and washer securing rotor to
crankshaft.

1. Rotor
2. Magneto puller

Screw magneto puller bolt to remove rotor.

Rotor Inspection
Check inner side of rotor for scratches or other
damage.
Check keyway of the rotor for wear or damages .
Check if trigger wheel teeth are bent or otherwise
1. Screw M16 damaged.
2. Washer
3. Rotor

Install magneto puller (PIN 529 035 748) and

crankshaft protector (PIN 529 036 034) then re-
move rotor.

vm r2006-041-008

MAGNETO PULLER

vmr 2006-041-01i_a

1. Rotor with trigger wheel

Check woodruff key and keyway on the crankshaft

for wear or damages.
Replace parts as necessary.

Rotor Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
vmr 2006.()4 1-009
Clean crankshaft taper and rotor with pulley flange
CRANKSHAFT PROTECTOR cleaner (PIN 413 701 809) .

NOTE: Use grease to place protector on crank- CAUTION: Taper on crankshaft and rotor must
be free of grease.
shaft end prior to screw on the magneto puller.
vm,200S-051 75
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 06 (MAGNETO SYSTEM)

Oil sprag clutch in sprag clutch housing and install Remove sprag clutch gear.
sprag clutch gear. Remove sprag clutch housing screws and sprag
clutch housing .

1 2 3 4

vmr2006-04 1-013 _a
vmr20 06 -041 -0 15_b
1. Sprag clutch housing scre ws
1. Sprag clutch 2. Rotor
2 . Sprag clu tch housing 3. Sprag clutch
3. Sprag clutch gear 4. Sprag clutch housing
4. Apply engine oil here

Slide rotor onto crankshaft. The woodruff key and

the keyway must be aligned .
Sprag Clutch Inspection
Inspect sprag clutch and sprag clutch housing for
Rotate starter double gear counterclockwise to
wear and damage .
align intermediate gear teeth with sprag clutch
gear. Also chec k the collar of the sprag clutch gear.
Perform a functional test of the sprag clutch. To
do so, rotate sprag clutch gear in sprag clutch.
NOTE: Sprag clutch must lock in counterclock-
wise direction .

1. Starter doub le gear

2. Sprag clutch gear
3. Intermediate gear

vmr2006..()i.ll.Q14 _a

SPRAG CLUTCH SPRAG CLUTCH FUNCTIONAL TEST

1. Lock

Sprag Clutch Removal NOTE : Sprag clutch , housing and gear must be
Remove magneto cover (refer to MAGNETO COV- replaced at the same time , if damaged .
ER above).
Loosen sprag clutch housing screws located in- Sprag Clutch Installation
side rotor. For installation, reverse the removal procedure .
Remove rotor (refer to ROTOR above) . Pay attention to the following details.

76 vmr200B'()Sl
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 06 (MAGNETO SYSTEM)

Apply Loctite 648 (green) (PIN 413 711 400) on Check needle bearing condition. Replace sprag
threads of sprag clutch housing screws. clutch gear if necessary.
Install screws but do not torque yet.
Apply engine oil on sprag clutch and inside sprag
clutch gear hole.

vmr2006-041-0 16_8

INSPECT
1. Teeth
vmr2006-041-015_b
2. Collar
3. Needle bearing
1. Sprag clutch
2. Sprag clutch housing
3. Sprag clutch gear
4. ApplV engine oil here Sprag Clutch Gear Installation
The installation is the reverse of the removal pro-
Install rotor then torque sprag clutch housing cedure.
screws to 30 N-m (22 Ibf-ft).
NOTE: Apply engine oil on needle bearing and col-
lar of sprag clutch gear.
SPRAG CLUTCH GEAR
Sprag Clutch Gear Removal STARTER DRIVE GEARS
Remove rotor (refer to ROTOR above). The starter drive gears are located on the engine
Pull sprag clutch gear from the rotor. MAG side behind the magneto cover.

1
vmr2006-041-015_a vmr2006-041-017 _a

1. Rotor 1. Intermediate gear

2. Sprag clutch gear 2. Starter double gear
3. Starter gear
4. Location pins
Sprag Clutch Gear Inspection
Inspect gear, especially teeth and sprag clutch col-
lar, for wear and other damage.
vmr200S'()51 77
Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 06 (MAGNETO SYSTEM)

Gear Removal
Remove magneto cover (refer to MAGNETO COV-
ER above).
Remove location pins, starter double gear and in-
termediate gear.

Gear Inspection
Inspect gears and location pins for wear and dam-
age.
Replace parts as necessary.

Gear Installation
The installation is the reverse of the removal pro-
cedure. Pay attention to the following details.
Apply Loctite 767 (antiseize lubricant) (PIN 293
800 070) on starter gear before installing the
starter double gear.
Apply engine oil on location pins.

78 vmr2008·051
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

INTAKE MANIFOLD, CYLINDER

HEAD AND CYLINDER
SERVICE TOOLS
.Description Part Number Page
dial gauge ......... ............. ... .... .. .. ... .... ..... .... .. ..... .... ....... .. .. ..... . 41 4 104 700 ... ...... ..... ....... .... .. .... .... ........ 86
crankshaft locking bolt ... .... ... ......... ... .. .. ........... .. ...... ..... .. ..... . 529 035 617 .... .... .... ...... ........ ........ . 97 , 106
valve spring compressor clamp ... .... ....... .. .. .... .... .. .... .. .... .... .. 529 035 724 ......... .... ...... ............... ...... . 100
valve spring compressor cup .............. .... ....... ... .. ....... .. ..... .. .. 529 035 764 ...... .... .... ... .. ... .... ... .... .. .. .... 100
valve guide installer ........ ... .. .. ................. .. .... .... .... ............... . 529 035 853 .. .. .. .. ...... .. .... .. .. .. .... ... .. ...... 104
Piston ring compressor .......... ....... .. .. ....... .. .. ..... .... .. .. .. ........ .. 529035919 .. ..... .............. .. .. .. .... .. .... .... 106
Circlip installer .............. ... ... ..... ........ ..... ... .... .. .. ..... .. .. .......... .. 529 035 921 .. .... .............. .. ... .... .... .... .... 110
valve guide remover ........ ........ ........ .. .. .. .... .. ..... .. .. .. .. ... ........ . 529 035 924 ...................... .. .. .... ........... 104
camshaft locking tool. ......... ... .... .. .... ... ... ... .. .. ........ ... ... ...... ... . 529 035 926 ....... .. .... .. ..... ... .. ........ ... . 86, 90
Piston ring compressor. .. .. ....... .... ...... ... .... .. .. ... .. .. .... ............ . 529 035 977 ....... .. .. ............ .. .... ..... .. .. ... 106
Circlip installer .. .. .. .. .. ................. .. .. .. .... ..... ....... .. .. ..... ........... . 529036058 ...... .. .... .. .. .. ....................... 110

SERVICE TOOLS - OTHER SUPPLIER

Description Part Number Page
Snap-on pliers.. .. .. .. ... ..... .. .. ........... .... .. .. ........ .. .. .. ..... .... ....... .. YA 8230 .. .. ..... .. ..... ... .. ... .. .... ........... 102

SERVICE PRODUCTS
Description Part Number Page
Loctite 767 (antiseize lubricant) ......... .. .. .. .. ...... .. ............. .. .. .. 293 800 070 ... ...... .. ........... .... ..... .......... 104

vmr200S'{)52 79
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

INTAKE MANIFOLD

0.5 Nom
(5 Ibfoin)

6 Nom
(53Ibfoin)

I
Loctite&--f
243
6 Nom
(53Ibfoin)
~

& Engine oil

20 Nom
(15Ibfoft)

vmr2008-04 7-o0 2_a

80 vmr2008·052
 Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

CYLINDER HEAD NO. 1

T5-A
... ~ Loctite
648

t1 60 Nom (44 Ibfoft) t7 6 Nom (53 Ibfoin)

T2 30 Nom (22 Ibfoft) T8 4.5 Nom (40 Ibfoin)
,T3 20 Nom (15 Ibfoft) T9 0.1 Nom (0.89 Ibfoin)
14 12 Nom (106 Ibfoin) T10 16 Nom (141 Ibfoin)
'T5 10 Nom (89 Ibfoin) ,T11 5 Nom (44 Ibfoin)
T&; 7 Nom (62 Ibfoin)
vmr2007-OJ6-001_a

vmr200S-052 81
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

CYLINDER HEAD NO.2

Ta~

I
T9~
n~

t &Engine oil

& Loctit. 243

1nl~·t\Loctite 243

no

T1 60 Nom (44 Ibfoft) .Ti'i 6 Nom (53 Ibfoin)

T2. 30 Nom (22 Ibfoft) :ral 4.5 Nom (40 Ibfoin)
20 Nom (15Ibfoft) .T9. 0.1 Nom (0.89 Ibfoin)
12 Nom (106/bfoin) -nO 16 Nom (141 Ibfoin)
10 Nom (89 I bfoin) T11 5 Nom (44 Ibfoin)
T6: 7 Nom (62 Ibfoin)

82 vmr200S-Q52
 www.midwestmanuals.com
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

CYLINDERS AND PISTONS

Engine oil
Engine oil

'--~"'Engine oil

vmr2006-043-003_b

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 www.midwestmanuals.com
Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

GENERAL .& WARNING

Components which are identical for both Torque wrench tightening specifications
cylinders/cylinder heads are identified in the must strictly be adhered to.
two exploded views by the same number. Com- Locking devices (e.g.: locking tabs, elastic
ponents which are different or which are, for stop nuts, cotter pin, etc.) must be replaced
instance, present of one of the cylinders/cylinder with new ones.
heads but not on the other, have different num-
bers. The information given below always relates When disassembling parts that are duplicated in
as a general rule. the engine, (e .g.: valves), it is a strongly recom-
mended to note their position (PTO/MAG side,
Special reference is made in the text to work in-
front/rear cylinder) and to keep them as a "group ".
structions which are not the same for cylinder
If you find a defective component, it would be
no. 1 and cylinder no. 2.
much easier to find the cause of the failure among
its group of parts (e.g. : you found a worn valve
guide. A bent spring could be the cause and it will
be easy to know which one among the springs is
the cause to replace it if you grouped them at dis-
assembly). Also, since used parts have matched
together during the engine operation, they will
keep their matched fit when you reassemble them
together within their" group" .

MAINTENANCE
VALVE ADJUSTMENT
NOTE: Check and adjust valve clearance only
when engine is cold .
Remove valve covers.
Before checking or adjusting the valve clearance,
vm r2006-0 12·003 _a turn crankshaft to TDC ignition of the respective
1. Cylinder 1 (front) cylinder, see CAMSHAFT.
2. Cylinder 2 (rear)
Using feeler gauge, check the valve clearance.
When diagnosing an engine problem, always per-
form a cylinder leak test. VALVE CLEARANCE

Always place the vehicle on level surface. 0.11 to 0.19 mm

EXHAUST
(.0043 to .0075 in)
NOTE: For a better understanding, the many illus-
trations are taken with engine out of vehicle . To 0.06 to 0.14 mm
INTAKE
perform the following instructions, it is not neces- (.0024 to .0055 in)
sary to remove engine from vehicle.
Always disconnect BLACK H cable from the bat- If the valve clearance is out of specification, adjust
valves as follows.
tery, then RED (+) cable before working on the en-
gine. NOTE: Use mean value of exhaust/intake to en-
Even if the removal of many parts is not neces- sure a proper valve adjustment.
sary to reach another part, it is recommended to Hold the adjustment screw at the proper position
remove these parts in order to check them . and torque the locking nut.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a thread locker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
84 www.midwestmanuals.com vm r2008·052

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 www.midwestmanuals.com
Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MAf\IIFOLD, CYLlf\IDER HEAD AND CYLINDER)

Remove any parts to have access to engine cylin-

der heads.
Unplug spark plug cable.
Clean spark plug area and remove spark plug from
cylinder head.

1. Adjustment screw
2. Locking nut TYPICAL
3. Feeler gauge 7. Spark plug cable
2. Spark plug
Repeat the procedure for each valve .
Remove valve cover.
Before installing valve covers, recheck valve clear-
ance.

INSPECTION
LEAK TEST
Before performing the cylinder leak test, verify the
following:
- clamp(s) tightness
- radiator and hoses.
NOTE: For best accuracy, the leak test should be
done with the engine at normal operating temper-
ature .

Prevent burning yourself on hot engine parts.

Preparation 7. Valve cover screws

2. Valve cover
Disconnect battery.

& WARNING Rotate crankshaft until piston is at ignition TDC.

Always respect this order for disassembly; To turn crankshaft, there are two possible proce-
disconnect BLACK (-) cable first. dures.
Fi rst Procedu re
Remove radiator cap. - Turn the drive pulley.
& WARNING Second Procedure
To prevent burning yourself only remove the - Remove plug screw with O-ring from magneto
radiator cap by wearing the appropriate safe- cover.
tyequipment. - Use a 14 mm Allen key and turn crankshaft.
vm r2008-052
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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

CAUTION: Turn only clockwise to avoid loosen-

ing of magneto flywheel Allen screw.
Using the dial gauge (PIN 414 104 700). turn the
crankshaft and set the piston to precisely ignition
TDC.

529 035 926

CAMSHAFT LOCKING TOOL

Leak Test
TYPICAL
1. Dial gauge Connect to adequate air supply.
Set needle of measuring gauge to zero .
NOTE: If a dial gauge is not available, use a screw-
driver or another similarly suitable tool. NOTE: All testers have specific instructions on
gauge operation and required pressure.
CAUTION: Do not scratch or damage pistonl
cylinder surface. Install gauge adapter into previously cleaned spark
plug hole.
NOTE: At ignition TDC the marks on the camshaft
timing gear have to be parallel to cylinder head Supply combustion chamber with air pressure.
base as per following illustration.

TYPICAL
1. Leak Tester
2. Air supply hose

1. Marks on camshaft timing gear Note the amount or percentage of leakage (de-
2. Cylinder head base pending on tester).
3. Camshaft locking tool

Lock camshaft at TDC by using camshaft locking

tool (PIN 529035926).

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

Mofttoong
... . !. A<1Iv0li; ;' J.. F_
- -,
LEAKAGE
PERCENTAGE
ENGINE
CONDITION
I~_:_.
HstOoy IF..;,iP\.rr4>./ .
o [nib/.d e Oil\alllod .
0% to 15% Excellent condition A<f!veI.- .
16% to 25% Good condition ~~~_R,,* I
._._~~--.J
26% to 40%
Fair condition; reduced ___.__~---.J
engine performance Rti.fl I
Poor condition, diagnose
..SQr\ s.f.T9it I
41 % and higher
and repair engine -
·~F1mMOOstf_ .
'. ~.~ '
Diagnosis
Listen for air leaks.
- air escaping on intake port/throttle body means mmr2007-10&-008_c

leaking intake valve(s)

- air escaping on exhaust port means leaking ex- Release fuel pressure by running engine until it
haust valve(s) runs out of gas.
- air bubbles out of radiator means leaking cylin-
der head gasket
& WARNING
The fuel hose may be under pressure. Cov-
- air/oil escaping from crankcase means dam-
er the fuel line connection with an absorbent
aged gasket and/or loosened screws (refer to
shop rag. Slowly disconnect the fuel hose
BOTTOM END)
to release the pressure. Wipe off any fuel
- air/coolant escaping from cylinder/head means spillage.
damaged gasket(s) and/or loosened screws (re-
fer to INTAKE MANIFOLD, CYLINDER HEAD
Remove seat, both side panels, central panel and
AND CYLINDER)
dash board. Refer to BODY.
- air escaping into crankcase area means exces-
sively worn cylinder and/or broken piston rings Remove the cover of the air filter housing.
(refer to INTAKE MANIFOLD, CYLINDER HEAD Remove the air filter.
AND CYLINDER) . Unscrew bolts securing the air filter housing to
NOTE: For all the checkpoints mentioned above, frame .
see the appropriate engine section to diagnose Unscrew the lower clamp retaining the manifold
and repair the engine. adapter between throttle body and intake mani-
fold.
Reassembly
Reverse the preparation procedure . Ensure to
respect torque values and use of appropriate
products/lubricants . Refer to exploded views in
other sections of this manual as required.

PROCEDURES
INTAKE MANIFOLD
Intake Manifold Removal
Disable fuel pump using B.U.D.S . Look in the Ac-
tivation tab.
1. Manifold adapter
2. Throttle body
3. Air filter housing

Remove the manifold adapter.

Unplug fuel lines from injectors.

vmr2008'()52
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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

Disconnect both injectors and the manifold air VALVE COVER

pressure temperature sensor (MAPTS).
Cover Removal
Remove distance screws of valve cover.

1. MAPTS
2. Fuel lines
3. Injectors connectors

Unscrew intake manifold from cylinders.

Remove intake manifold from vehicle.
NOTE: To remove fuel injectors from intake man-
ifold, refer to ENGINE MANAGEMENT. vmr2006-039-002_a

1. Distance screws
Intake Manifold Inspection 2. Valve cover
Check intake manifold for cracks, warping at
flanges or any other damage. Replace if neces- Remove valve cover and gasket.
sary.

Intake Manifold Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Torque manifold screws to 20 N-m (15 Ibf-ft) one
cylinder at a time.
Re-enable fuel pump using B.U.D.S.

F_ " , ,HlIiIOI'{ .!
.... ~
,. . ~

~~:~f .O O~.d
'

'. •
R400motr53A

1. Valve cover
r ., ' fuel Pross Ro~ I 2. Gasket

~, ~~­ Repeat the procedure for the other valve cover if

-,-~E!_. J required .
~2 I,
s..i Sol·TO<! -.J. '
I · Cover Inspection
~IOr FIOW __ Check the gasket on the valve cover if it is brittle,
--!.~ . cracked or hard. If so, replace the gasket.

Cover Installation
mmr2007-106-QOB_b
For installation, reverse the removal procedure.
Torque the valve cover distance screws in a criss-
cross sequence.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

TIMING CHAIN TENSIONER

I'JOTE: Before removal and installation, make sure
that the respective cylinder is set to TDC ignition.
Refer to CAMSHAFT.

Tensioner Removal
& WARNING
Timing chain tensioner is spring loaded. Nev-
er perform this operation immediately after
the engine has been run because the exhaust
system can be very hot. Wait until exhaust
system is warm or cold.

Remove chain tensioner plug.

1. Chain tensioner screws
Unscrew chain tensioner plug . 2. Chain tensioner housing
3. O-ring
Remove a-ring, spring and chain tensioner
plunger.
Tensioner Inspection
Check the housing for cracks or other damages.
Replace if necessary.
Check chain tensioner plunger for free movement
and/or scoring.
Check if O-rings are brittle, cracked or hard. Re-
place if necessary.
Check spring condition . Replace if broken or
worn .

Tensioner Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
NOTE: Before installing the chain tensioner make
sure, that the camshaft timing gear can be moved
1. Chain tensioner plug
2. O-ring back and forth.
3. Spring
4. Chain tensioner plunger

Unscrew screws retaining chain tensioner hous-

ing.
Remove chain tensioner housing with O-ring.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

529 035 926

MOVE GEAR BACK AND FORTH

Apply engine oil on the plunger before installing.

NOTE: Slightly screw in the plunger until the tim-
ing chain allows no more back and forth move-
ment of the camshaft timing gear. Then screw in
the plunger an additional 1/8 turn to reach the re-
quired torque of 0.1 N-m (.9 Ibf-in).
CAUTION: Improper adjustment of the timing
chain will lead to severe engine damage.
Fit the spring on one side into the slot of the plug
screw and on the other side into the plunger. Turn 1. Camshaft locking tool
spring only clockwise in order to fit the spring end 2. Camshaft timing gear screw
3. Camshaft timing gear
into the notch of the plunger and to avoid loosen- 4. Trigger wheel (cylinder head 1 only)
ing the plunger during spring installation . Do not
preload the spring . Remove the camshaft timing gear.
NOTE: Do not forget to place the O-ring on chain NOTE: Secure timing chain with a retaining wire.
tensioner plug .
Gear Inspection
Then compress the spring and screw in the plug
screw. Check camshaft timing gear for wear or deteriora-
tion.
Finally, tighten the plug screw to 4.5 N-m
(40 Ibf-in). If gear is worn or damaged, replace it as a set
(camshaft timing gear and timing chain) .
CAMSHAFT TIMING GEAR For crankshaft gear, refer to BOTTOM END sec-
tion, see CRANKSHAFT.
Gear Removal
Remove the valve cover. Gear Installation
Turn crankshaft to TDC ignition of the respective For installation, reverse the removal procedure .
cylinder, see CAMSHAFT. Pay attention to the following details .

Unscrew timing chain tensioner. Clean mating surface and threads of camshaft pri-
or to assemble camshaft timing gear.
Remove camshaft timing gear screw.
To prevent timing chain stretching during removal
of camshaft timing gear screw, use the camshaft
locking tool (PIN 529 035926).

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

R400motr63A

1. Mating surface on camshaft

2. Threads for camshaft screw

Camshaft timing gear and crankshaft must be at

TDC ignition position before installing the timing
chain .
CAUTION: Crankshaft and camshaft must
be locked on TDC ignition position to place
camshaft timing gear and timing chain in the
proper position.
Install camshaft timing gear so that the timing gear
1. Printed marks on camshaft timing gear
tabs are located into the flat zone of the camshaft. 2. Cylinder head base
3. Camshaft tim ing gear
The printed marks on the camshaft tim ing gear 4. Timing gear tab
must be parallel to the cylinder head base. See
the following illustration for a proper positioning. Install trigger wheel on camshaft timing gear of
cylinder 1.

1. Camshaft locking tool

2. Camshaft screw
3. Camshaft timing gear
4. Trigger wheellcylinder head 1 only)

When the camshaft timing gear and the timing

chain are installed, remove the crankshaft locking
bolt as well as the camshaft locking tool.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

NOTE: Before installing the camshaft screw ad-

just the chain tension (see CHAIN TENSIONER be-
low) and check again if marks on the timing gear
are parallel to cylinder head base .
Reinstall all other removed parts.

ROCKER ARM
Rocker Arm Removal
Remove valve cover.
Remove chain tensioner and camshaft timing gear
no. 1.
Remove Allen screw and camshaft retaining plate .

3
7. Rocker arm shaft
2. Rocker arm (exhaust side)
3. Rocker arm (intake side)
4. Adjustment screw
5. Locking nut

Remove thrust washers no. 2.

CAUTION: Pay attention not to lose thrust
washers or drop them into the timing chain
2 compartment.
R400mo(r65A
1
7. Cylinder head
2. Allen screw
3. Camshaft reta ining plate

Remove rocker arm shafts.

I
Remove rocker arm assembly (exhaust side and
intake side) with adjustment screws and nuts .

R400motr67A 4
7. 2 thrust washers
2. Rocker arm (exhaust side)
3. Cylinder head - spark plug side
4. Big taper to spark plug side

Rocker Arm Inspection

Inspect each rocker arm for cracks and scored fric-
tion surfaces . If so, replace rocker arm assembly.
Check the rocker arm rollers for free movement,
wear and excessive radial play. Replace rocker
arm assembly if necessary.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

ROCKER ARM SHAFT DIAIVIETER

12.000 to 12.018 mm
NEW
(.4724 to .4731 in)
SERVICE LIMIT 11.990 mm (.4720 in)

Any area worn excessively will require parts re-

placement.

Rocker Arm Installation

R400motr6BA
NOTE: Use the same procedure for exhaust and
1. Rocker arm (exhaust side) intake rocker arm.
2. Roller
A. Bore for rocker arm shaft Apply engine oil on rocker arm shaft.
Measure rocker arm bore diameter. If diameter is Install the rocker arm shafts with the chamfered
out of specification, change the rocker arm assem- edge first and use following procedure .
bly. Insert a rocker arm pin through rocker arm pin
bore.
ROCKER ARM BORE DIAMETER
Install a thrust washer no. 2 then the proper rocker
12 .036 to 12.050 mm arm no. 3 (exhaust side) or no. 4 (intake side) .
NEW
(.4739 to .4744 in)
Push in rocker arm shaft until its chamfer reaches
SERVICE LIMIT 12.060 mm (.4748 in) the end of rocker arm bore.

Check adjustment screws for free movement,

cracks and/or excessive play.

R400motr69A

1. Free movement of adjustment screw top

Rocker Arm Shaft

Check for scored friction surfaces; if so, replace
parts. 1. Rocker arm shaft
2. Thrust washer (timing chain side)
Measure rocker arm shaft diameter. 3. Thrust washer (spark plug side)

Place the other thrust washer and push rocker arm

shaft to end position.
Install the camshaft retaining plate no. 5.

R400motr70A A
TIMING CHAIN
A. Measure rocker arm shaft diameter here Refer to BOTTOM END, see TIMING CHAIN.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

CYLINDER HEAD
Cylinder Head Removal
The removal procedure is the same for both cylin-
der heads.
Drain coolant (refer to COOLING SYSTEM) .
NOTE: Before removing cylinder head, blowout
remaining coolant by air pressure. During cylinder
head removal, the remaining coolant in cylinder
head could overflow into the engine and a little
quantity of coolant could drop into the engine. In
this case, the engine 011 will be contaminated.
Disconnect spark plug wire.
Disconnect temperature sensor connector, locat-
ed at rear cylinder head . 1. Cylinder head screws MIG
2. Cylinder head screws M6
Disconnect camshaft sensor, located at front cylin-
der head. Pull Up cylinder head.
Remove both side panels and both inner fenders Remove chain guide.
(refer to BODy).
Remove the cylinder head gasket and scrap it.
Remove exhaust pipe springs or exhaust pipe
clamp .
Unscrew exhaust pipe nuts .
Unplug radiator inlet hose .
Remove air filter housing. 4
Remove throttle body.
2

Remove the intake manifold (see INTAKE MANI-

FOLD above.
Remove the chain tensioner (see CHAIN TEN-
SIONER above).
Remove the valve cover and its gasket (see VALVE
COVER above).
Remove the camshaft timing gear.
R400motr72A 3
Unscrew cylinder head screws M6 and M10 re-
taining cylinder head and cylinder to cylinder base. I. Cylinder head
2. Tim ing chain
3. Chain guide
4. Cylinder head gasket

Cylinder Head Inspection

Inspect timing chain guide for wear, cracks or oth-
er damages. Replace if necessary.
Check for cracks between valve seats, if so, re-
place cylinder head .
Check mating surface between cylinder and cylin-
der head for contamination. If so, clean both sur-
faces .
Clean oil support through the cylinder head from
contamination.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MAI\JIFOLD, CYLINDER HEAD AND CYLINDER)

1. Oil port to lubrica te camshaft lobes intake/exhaust

2. Oil supply to camshaft bearing jo urnal timing chain side
3. 0,1 supply to camshaft bearing journal spark plug side

1. Cylinder head screws M 10

Cylinder Head Installation 2. Cylinder head screws M 6

NOTE: The cylinder heads are not identical in de- Check chain guide for movement.
sign. Do not invert the cylinder heads at assem-
bly. Remove crankshaft locking bolt and reinstall plug
screw with sealing ring .
For installation, reverse the removal procedure.
Pay attention to the fo llowing details.
CAMSHAFT
Ensure dowel pins no. 9 are in place.
NOTE: The engine is equipped with two different
CAUTION: Chain guide has to be fixed between camshafts.
cylinder and cylinder head.

1 2

R400motr74A 1. Camshaft of cylinder 1

2. Camshaft of cylinder 2
1. Chain guide (fixed between cylin der an d cylinder head)
2. Chain tensioner guide (mounted in crankcase)

Install a NEW cylinder head gasket.

Camshaft Timing
NOTE: If a piston (of cylinder 1 or 2) is set to TDC
First. torque cylinder head screws M 10 in criss-
ignition, the camshaft timing gear of the opposite
cross sequence to 20 N-m (15 Ibf-ft) then finish
cylinder must be in the following position .
by tightening to 60 I\J-m (44 Ibf-ft).
Install cylinder head screws M6 .

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Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

TYPICAL
1, Marks on timing gear of the opposite cylinder
2, Cylinder head base
1, Crankshaft position sensor
Camshaft Timing Cylinder 2 2, Screw

Turn crankshaft until piston is at TDC ignition as Use a 14 mm Allen key to turn crankshaft until
follows , piston 2, rear is at TDC ignition ,
Remove spark plug of both cylinders,
Remove valve covers of both cylinders,
Remove the plug screw and O-ring of magneto
cover,

1, Allen key 14 mm

When rear piston is at TDC ignition, marks on mag-

neto flywheel "2" and on the magneto cover are
aligned.

1, Plug screw
2. O-ring

Remove the crankshaft position sensor (CPS) ,

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

1. Plug screw
2. Sealing ring
3. Crankcase PTO side, front side
1. Mark "2" on magneto flywheel
2. Notch on magneto cover Lock crankshaft with the crankshaft locking bolt
3. Crankshaft position sensor location
(PIN 529 035 617) .
At TDC ignition, the printed marks on the camshaft
timing gear have to be parallel to cylinder head
base .

1. Crankshaft locking bolt

NOTE: Make sure the locking bolt engages in the

groove of the crankshaft.
Camshaft Timing Cylinder 1
Turn cylinder 2 to TDC ignition, see CAMSHAFT
TIMING CYLINDER 2.
1. Printed marks on camshaft timing gear NOTE: Do not lock crankshaft.
2. Cylinder head base
Using a 14 mm Allen key, turn crankshaft 280 0
counterclockwise, until marks on magneto fly-
To lock crankshaft at TDC ignition, proceed as fol-
wheel" 1 " and magneto cover are aligned.
lows.
Remove from crankcase plug screw with sealing
ring.

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Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AI\JD CYLINDER)

1. Allen key 14 mm
2. Turn crankshaft 280 0 counterclockwise

TYPICAL
1. Printed marks on camshaft timing gear
2. Cylinder head base

CAUTION: Crankshaft can not be locked at

cylinder 1 TDC ignition.

Camshaft Removal
The removal procedure is the same for both
camshafts.
Each camshaft is different in design . Thus, it is
important not to mix up any parts of the camshaft
assembly with that of the other cylinder. Keep
parts as a group.
Remove valve cover (see VALVE COVER above) .
1. Mark "1" on magneto flywheel Remove the chain tensioner (see CHAIN TEN-
2. Notch on magneto cover
3. Location of crankshaft position sensor SIONER above).
Remove the camshaft timing gear (see
NOTE: At TDC ignition, the printed marks on the
CAMSHAFT TIMING GEAR above) .
camshaft timing gear have to be parallel to cylinder
head base as per following illustration. Remove the camshaft retaining plate.

2
R400motr65A

1. Cylinder head
2. Allen screw
3. Camshaft retaining plate

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

Remove rocker arms (see ROCKER ARM above). V490

Remove the camshaft. CAMSHAFT LOBE (exhaust)
NOTE: For removal rotate camshaft so that 31.730 to 31.930 mm
intake/exhaust lobe shows to upper side of cylin- NEW
(1.2492 to 1.2571 in)
der head.
SERVICE LIMIT 31.710 mm (1.2484 in)
2 CAMSHAFT LOBE (intake)
31.830 to 32.030 mm
NEW
3 (1.2531 to 1.2610 in)
SERVICE LIMIT 31.810 mm (1.2524 in)

V660N810
CAMSHAFT LOBE (exhaust)
31.940 to 32.140 mm
NEW (1.2575 to 1.2654 in)
R400motr75A

SERVICE LIMIT 31.920 mm (1.2567 in)

1. Area for camshaft lobes
2. Camshaft CAMSHAFT LOBE (intake)
3. Camshaft retaining plate
32.110 to 32.310 mm
NEW
(1.2642 to 1.2721 in)
Camshaft Inspection
SERVICE LlIVIIT 32.090 mm (1.2634 in)
Check each lobe and bearing journal of camshaft
for scoring, scuffing, cracks or other signs of wear.
ALL ENGINES
Measure camshaft journal diameter and lobe
height using a micrometer. CAMSHAFT JOURNAL
(timing chain side)
34.959 to 34.975 mm
NEW
(1.3763 to 1.3770 in)
SERVICE LlIVIIT 34.950 mm (1.3760 in)
CAMSHAFT JOURNAL
(spark plug side)
21.959 to 21.980 mm
NEW
(.8645 to .8654 in)
SERVICE LIMIT 21.950 mm (.8642 in)

Measure clearance between both ends of

A. Camshaft lobe (exhaust valves) camshaft and cylinder head.
B. Camshaft lobe (intake valves)
C. Camshaft journal (timing chain side)
O. Camshaft journal (spark plug side)

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

R4QOmotr75B

1. Camshaft retaining plate position

2. Slot retaining camshaft
3. Direction of movement

A. Camshaft bearing (timing chain side) For other parts, refer to proper installation proce-
B. Camshaft bearing (spark plug side)
dure.
ALL ENGINES
VALVE SPRING
CAMSHAFT BEARING
(timing chain side)
Valve Spring Removal
35.000 to 35.025 mm Remove rocker arms (see ROCKER ARM above).
I\JEW
(1.3780 to 1.3789 in)
Remove cylinder head (see CYLINDER HEAD
SERVICE LIMIT 35.040 mm (1.3795 in) above).
CAMSHAFT BEARING Compress valve spring no. 6; use valve spring
(spark plug side) compressor clamp (PIN 529 035 724) and valve
22.000 to 22.021 mm spring compressor cup (PIN 529035 764).
I\JEW
(.8661 to .8670 in)
SERVICE LIMIT 22.040 mm (.8677 in)
& WARNING
Always wear safety glasses when disassem-
Replace parts that are not within specifications. bling valve springs. Be careful when unlock-
ing valves. Components could flyaway be-
Camshaft Installation cause of the strong spring preload.
For installation, reverse the removal procedure.
Pay attention to the following details.
CAUTION: The camshafts are not identical in
design. Do not invert the camshafts during as-
sembly. Any mix-up of the components will
lead to engine damage.
Place the camshaft retaining plate in the slot of the
camshaft.

vmr2006-043-019

vmr2006-043-020

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

R400m ot r80A

A. Valve spring le ng th
R400m otr79A

LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF VALVE SPRING FREE LENGTH
THE VALVE
NOMINAL NEW 40 .81 mm (1 .607 in)
Remove valve cotters . SERVICE LIMIT 39 .00 mm (1.535 in )
3 2
Replace valves springs if not within specifications .

Valve Spring Installation

For installation, reverse the removal procedure .
Pay attention to the following details.
Colored area of the valve spring must be placed
on top .
To ease installation of cotters, apply oil or grease
on them so that they remain in place while releas-
ing the spring.
NOTE: Valve cotter must be properly engaged in
valve stem grooves.

1. Valve spring compressor clamp

2. Valve spring compressor cup
3. Valve co tter

Withdraw valve spring compres sor, valve spring

retainer no. 7 and valve spring no. 6.

Valve Spring Inspection

Check valve spring for visible damages . If so, re-
place valve spring.
Check valve spring for free length and stra ight-
ness . 1. Position of the valve spring
2. Valve cotter

After spring is installed, ensure It IS properly

locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
times.
CAUTION: An improperly locked valve spring
will cause engine damage.

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Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 07 (INTAKE MANIFOLD, CYLlt\IDER HEAD AND CYLlt\IDER)

VALVE Valve Inspection

Valve Stem Seal
Valve Removal
Always install new seals whenever valves are re-
Remove valve spring, see VALVE SPRING above .
moved .
Push valve stem, then pull valves (intake and ex-
haust) out of valve guide. Valve
Inspect valve surface, check for abnormal stem
wear and bending . If out of specification, replace
by a new one .

VALVE OUT OF ROUND

(intake and exhaust valves)
NEW 0 .005 mm (.0002 in)
SERVICE LIMIT 0.06 mm (.0024 in)

Valve Stem and Valve Guide Clearance

Measure valve stem and valve guide in three
places using a micrometer and a small bore
gauge.
NOTE: Clean valve guide to remove carbon de-
posits before measuring.
vmr2006-043-021_a
Change valve if valve stem is out of specification
1. Intake valves 31 mm
2. Exhaust valves 27 mm or has other damages such as wear or friction sur-
face.
Remove valve stem seal no. 8 with Snap-on pliers
(PIN YA 8230) and discard it.

vm r2006-043-022

A. Valve stem diameter

VALVE STEM DIAMETER

EXHAUST VALVE
4.956 to 4.970 mm
NEW
(.1951 to .1957 in)
SERVICE LIMIT 4.930 mm (.1941 in)
INTAKE VALVE
4.966 to 4.980 mm
NEW
(.1955 to .1960 in)
SERVICE LIMIT 4.930 mm (.1941 in)

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

Replace valve guide out of cylinder head if valve If valve seat contact width is too wide or has dark
guide is out of specification or has other damages spots, replace the cylinder head.
such as wear or friction surface (see VALVE GUIDE
PROCEDURE belowl.

VALVE GUIDE DIAMETER

(intake and exhaust valves)
4.998 to 5.018 mm
NEW (.1968 to .1976 in)
SERVICE LIMIT 5.050 mm (.1988 in)

Valve Face and Seat

V01C1HA

A. Valve face contact width

B. Valve seat contact width
3

Valve Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
A400motr84A Install a NEW valve stem seal. Make sure thrust
1. Valve seat
washer is installed before installing seal.
2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seat)
Apply engine oil on valve stem and install it.
CAUTION: Be careful when valve stem is
Check valve face and seat for burning or pittings passed through sealing lips of valve stem seal.
and replace valve or cylinder head if there are signs
of damage. 2
Ensure to seat valves properly. Apply some lap-
ping compound to valve face and work valve on its
seat with a lapping tool (see VALVE GUIDE PRO-
CEDURE belowl.
Measure valve face contact width.
NOTE: The location of contact area should be in
center of valve seat.
Measure valve seat width using a caliper. R400motr85A

1. Thrust washer
VALVE SEAT CONTACT WIDTH 2. Sealing lips of valve stem seal

EXHAUST VALVE To ease installation of cotters, apply oil or grease

1.25 to 1.55 mm on them so that they remain in place while releas-
NEW ing the spring.
(.049 to .061 in)
SERVICE LIMIT 2.00 mm (.078 in) After spring is installed, ensure it is properly
locked by tapping on valve stem end with a soft
INTAKE VALVE hammer so that valve opens and closes a few
1.05 to 1.35 mm times.
NEW
(.041 to .053 in) CAUTION: An improperly locked valve spring
SERVICE LIMIT 1.80 mm (.070 in) will cause engine damage.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

VALVE GUIDE
Valve Guide Removal
Remove cylinder head (see CYLINDER HEAD
above).
Remove valves (see VALVE above).
NOTE: Clean valve guide area from contamination
before removal.
Using the valve guide remover (P/I\J 529035 924)
and a hammer, drive the valve guide out of cylinder
head.
1. Valve guide installer
2. Valve guide

NOTE: Apply Loctite 767 (antiseize lubricant)

(PIN 293800 070) on valve guide prior to install it
vmr2006·043-024 into the cylinder head.
CAUTION: Push valve guide in the cold cylinder
head as per following illustration.

1. Valve guide remover

R4QOmotr878
2. Valve guide
1. Thrust surface of cylinder head
2. Valve guide
A. Measurement from thrust surface to valve guide top
Valve Guide Inspection
Always replace valve stem seals whenever valve VALVE GUIDE
guides are removed. (measurement "A")
Clean the valve guide bore before reinstalling the 14.00 to 14.40 mm
NEW
valve guide into cylinder head.
I (.5512 to .5669 in)

Valve Guide Installation Valve guide to be adjusted in diameter by using a

For installation, reverse the removal procedure. reamer.
Pay attention to the following details.
Use the valve guide installer (PIN 529035 853) to VALVE GUIDE DIAMETER
(intake and exhaust valves)
install valve guide.
4.998 to 5.018 mm
NEW
I (.1968 to .1976 in)

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

R400motr88A

1. Valve guide
A. Valve guide diameter
R400motr90A

NOTE: Ensure to turn reamer in the right direction. 1. Cylinder

2. Piston assembly
Use cutting oil and make brakes to clean ream- 3. Cylinder base gasket
er/valve guide from metal shavings. 4. Camshaft timing chain

Apply some lapping compound to valve face and

work valve on its seat with a lapping tool. Cylinder Inspection
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder. If so, re-
place cylinder.
Cylinder Taper
Measure cylinder bore and if it is out of specifica-
tions, replace cylinder and piston rings.
Measure cylinder bore at 3 recommended POSI-
tions. See the following illustration.

R400motr89A

1. Valve seat
2. Valve face (contact surface to valve seat)
3. Turn valve while pushing against cylinder head
A. Valve seat angle 45°

NOTE: Ensure to seat valves properly. Apply

marking paste to ease checking contact pattern.
Repeat procedure until valve seat/valve face fits 2~------------ ----------
together. R400motr91A

1. First measuring of diameter

2. Second measuring of diameter
CYLINDER 3. Third measuring of diameter
A. 7 mm (.276 in) from cylinder bottom
B. 68 mm (2.68 in)
Cylinder Removal C. 32 mm (1.260 in)
Remove chain tensioner (see CHAIN TENSION-
ER). CYLINDER TAPER IN DIAMETER
Remove the camshaft timing gear (see NEW (maximum) 0.038 mm (.0015 in)
CAMSHAFT TIMING GEAR). 0.090 mm (.0035 in)
SERVICE LIMIT
Remove the cylinder head (see CYLINDER HEAD).
Pull cylinder. Distance between measurements should not ex-
ceed the service limit mentioned above.
Discard cylinder base gaskets.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

Cylinder Out of Round

Measure cylinder diameter in piston axis direction
from top of cylinder. Take another measurement
90° from first one and compare.
NOTE: Take the same measuring points like de-
scribed in CYLINDER TAPER above.

vmr2006-043-026

R4QOmotr92A

A. Perpendicular to crankshaft axis

B. Parallel to crankshaft axis

CYLINDER OUT OF ROUND

NEW (maximum) 0.015 mm (.0006 in)
SERVICE LIMIT 0.020 mm (.0008 in)

Cylinder Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
CAUTION: Always replace cylinder base gasket
before installing the cylinder.
First mount cylinder 2. Then remove the crank-
shaft locking bolt (PIN 529035 617). Crank the en- 1. Piston ring compressor tool
gine further and position piston 1 at TDC. Mount 2. Piston
3. Cylinder
cylinder 1. The cylinder can not be pushed fully
over the piston unless the piston is located at TDC. NOTE: Put timing chain through the chain pit then
Apply engine oil in the bottom area of the cylinder put the cylinder in place.
bore and also on the band of the piston ring com-
CAUTIOI\!: Chain guide has to be fixed between
pressor tool. cylinder and cylinder head.
ENGII\IE TOOL NOTE: After both cylinders are installed, turn
crankshaft until piston of cylinder 2 is at TDC igni-
Piston ring compressor tion and lock crankshaft. Refer to CAMSHAFT.
V490N660
(PIN 529 035 977)
Install cylinder head and the other parts in accor-
Piston ring compressor dance with the proper installation procedures.
V810
(P/I\j 529 035 919)

PISTON
Piston Removal
Remove cylinder head (see CYLINDER HEAD
above).
Remove the cylinder (see CYLINDER above).

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

Place a rag under piston and in the area of timing

chain compartment.

Remove one piston circlip and discard it.

1. Measuring perpendicularly (90°) to piston pin

A. 8 mm (.315 in)

The measured dimension should be as described

in the following tables. If not, replace piston.

PISTON MEASUREMENT
V490/V660
81.950 to 81.966 mm
NEW
(3.2264 to 3.2270 in)
R4QOmotr94A SERVICE LIMIT 81.850 mm (3.2224 in)
1. Piston circiip V810
NOTE: The removal of both piston circiips is not 90.950 to 90.966 mm
NEW
necessary to remove piston pin. (3.5807 to 3.5813 in)

Push piston pin out of piston. SERVICE LIMIT 90.850 mm (3.577 in)

Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston dimen-
sion.

R400motr95A

1. Piston
2. Piston pin

Detach piston from connecting rod.

fOOB08A

Piston Inspection 1. Micrometer set to the piston dimension

Inspect piston for scoring, cracking or other dam-
ages. Replace piston and piston rings if neces- With the micrometer set to the dimension, adjust
sary. a cylinder bore gauge to the micrometer dimen-
sion and set the indicator to a (zero).
Using a micrometer, measure piston at 8 mm
(.315 in) perpendicularly (90°) to piston pin.

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Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

If clearance exceeds specified tolerance, replace

pisto n by a new one and measure piston/cylinder
clearance again.
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same pos ition as with the
2 micrometer, otherwise the reading will be false.
Connecting Rod/Piston Pin Clearance
Using synthetic abrasive woven, clean piston pin
from deposits .
Inspect piston pin for scoring . cracking or other
damages .
Measure piston pin . See the following illustration
FOO B09A for the proper measurement positions .
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge

R400m otr30A A
A. Piston pin diameter

PISTON PIN DIAMETER

V490
17.996 to 18.000 mm
NEW
(.7085 to .7087 in)
FOQB OAA
SERVICE LIMIT 17.980 mm (.7079 in)
TYPICAL
1. Indica tor set to 0 (zero) V660/V810
19.996 to 20 .000 mm
Position the dial bore gauge 20 mm (.787 in) above NEW
(.7872 to .7874 in)
cylinder base , mea suring perpendicularly (90°) to
piston pin axi s. SERVICE LIMIT 19.980 mm (.7866 in)
Read the measurement on the cylinder bore
gauge . The result is the exact piston/cylinder wall Replace piston pin if diameter is out of specifica-
clearance . tions .
Measure inside diameter of connecting rod small
PISTON/CYLINDER CLEARANCE end bushing .
V490/V660
0 .057 to 0.087 mm
NEW
(.0022 to .0034 in)
SERVICE LIMIT 0.130 mm (.0051 in)
V810
0 .027 to 0.057 mm
NEW
(. 0011 to .0022 in)
SERVICE LIMIT 0.100 mm (.0040 in)

NOTE: Ma ke sure used piston is not worn.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

Front cylinder: Mark on top of piston must show

to exhaust side.
Rear cylinder: Mark on top of piston must show
to exhaust side.

R1004motrl1A

1. Bore gauge
2. Connecting rod

CONNECTING ROD SMALL END DIAMETER

V490
18.010 to 18.020 mm
NEW
(.7091 to .7095 in)
SERVICE LIMIT 18.060 mm (.7110 in)
V660/V810
20.010 to 20.020 mm
NEW
(.7878 to .7882 in)
1. Piston of cylinder 1
SERVICE LIMIT 20.060 mm (.7898 in) 2. Mark on piston must show to exhaust side of cylinder 1
3. Piston of cylinder 2
4. Mark on piston must show to exhaust side of cylinder 2
Replace connecting rod if diameter of connecting
rod small end is out of specifications. Refer to V810 Engines
BOTTOM END for removal procedure. For each cylinder, install piston with the punched
Compare measurements to obtain the connecting arrow on piston dome is pointing toward the rear
rod/piston pin clearance. side of the engine.

CONNECTING RODI Front cylinder: Mark on top of piston must show

PISTON PIN CLEARANCE to intake side.
ALL ENGINES Rear cylinder: Mark on top of piston must show
to exhaust side.
SERVICE LIMIT I 0.080 mm (.0035 in)

Piston Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
CAUTION: The mounting direction of the pis-
tons is different between the V490N660 and the
V810.
V490 and V660 Engines
For each cylinder, install piston with the punched
arrow on piston dome is pointing toward the ex-
haust side.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

u
3

1
2

R400motr100A

1. Circilp
2. Sleeve
3. Assembly jig from piston clip installer

Push taper side of assembly jig until circlip reaches

middle of sleeve.
Align sleeve with piston pin axis and push assem-
1. Piston of cylinder 1
2. Mark on piston must show to intake side of cylinder 1 bly jig until circlip engages in piston.
3. Piston of cylinder 2
4. Mark on piston must show to exhaust side of cylinder 2

Use the piston appropriate circiip installer to as-

semble the NEW piston circiip as per following
procedure:

ENGINE TYPE TOOL

Circ/ip installer
V490
(PI/\] 529 036 058)
Circiip installer
V660 and V810
(PIN 529 035 921)

vmr2007.{)36-008_a

1. Hold piston while pushing circiip in place

2. Sleeve
3. Assembly jig
4. Direction to push circlip

'1m r2006~043-o30
NOTE: Take care that the hook of the piston circlip
CAUTION: Always replace disassembled pis- is positioned properly.
ton circlip(s) by new ones. Place a rag on cylin-
der base to avoid dropping the circlip inside the
engine.
Place circlip in sleeve as per following illustration.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLlI\JDER)

/ 2

1. Piston
2. Feeler gauge

Ring End Gap

R400motr102A
RING END GAP
CORRECT POSITION OF THE PISTON CIRCLIP
UPPER COMPRESSION RING
0.20 to 0.40 mm
PISTON RINGS NEW
(.008 to .016 in)
SERVICE LIMIT 1.50 mm (.059 in)
Ring Removal
Remove the piston (see PISTON above). LOWER COMPRESSION RING
0.20 to 0.40 mm
Ring Inspection NEW (.008 to .016 in)
Ring/Piston Groove Clearance SERVICE LIMIT 1.50 mm (.059 in)
Using a feeler gauge measure each ring/piston OIL SCRAPER RING
groove clearance. If the clearance is too large, the
0.20 to 0.70 mm
piston and the piston rings should be replaced. NEW
(.008 to .028 in)
RINGJPISTON GROOVE CLEARANCE SERVICE LIMIT 1.50 mm (.059 in)
UPPER COMPRESSION RING
To measure the ring end gap place the ring in the
0.030 to 0.070 mm cylinder in the area of 8 to 16 mm (5/16 to 5/8 in)
NEW
(.0012 to .0028 in) from top of cylinder.
SERVICE LlIVIIT 0.150 mm (.0059 in) I\JOTE: In order to correctly position the ring in the
LOWER COMPRESSION RING cylinder, use piston as a pusher.
Using a feeler gauge, check ring end gap. Replace
0.020 to 0.060 mm
NEW (.0008 to .0024 in) ring if gap exceeds above described specified tol-
erance.
SERVICE LIMIT 0.150 mm (.0059 in)
OIL SCRAPER RING Ring Installation
For installation, reverse the removal procedure.
0.010 to 0.180 mm
NEW Pay attention to the following details.
(.0004 to .0071 in)
NOTE: First install spring and then rings of oil
SERVICE LIMIT 0.250 mm (.0098 in)
scraper ring.
Install the oil scraper ring first, then the lower com-
pression ring with the word "N and TOP " fac-
ing up, then the upper compression ring with the
word" N and TOP" facing up.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

( I'" 1

-_-_-_-lJj'" 2

vmr2007 -036-009_3

1. Upper compression rin g

2. Low er compression ring
3. Oil scraper rin g

CAUTION: Ensure thattop and second rings are

not interchanged.
NOTE: Use a ring expander to prevent breakage
during installation . The oil ring must be installed
by hand.
Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120 0 apart and do
not align the gaps with the piston pin bore or the
thrust side axis.

A3 1C20A

1. DO NOT align ring gap with piston thrust side axis

2. DO NOT align ring gap with piston pin bore axis
A. 120·

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOnOM END)

BOTTOM END
SERVICE TOOLS
Description Part Number Page
crankshaft locking bolt ... ................ ... ........ ...... .... ...... .. .. ...... .. 529035617 .. .... .. ........ ................ ......... 129
plain bearing remover/installer .. ..... ... ... .......... ... .. ..... .... ....... .. 529 035 917 .. ...... .... ... .......................... 126
oil seal installer .. .......................... ........ ........ .. ... ............... ... .. 529 036 028 .......... ............ .. .. .. ..... .. ...... 118
oil seal protection sleeve .... ......... .... .. ................................. .. 529 036 029 .... ........ ........ ........... .......... 118
crankcase support sleeve .... ......... ....... .. .... ...................... ... .. 529 036 031 ..... .... .. .... .... .. .. .. ................ 126
plain bearing remover/installer ...... ........ .................... .. .. .. ..... . 529036032 ............... ... .. ....... .. .... 120-121
oil seal installer .. ... .......... .. ..... .. ........ ..... ......... ............. ..... .... . 529 036 033 ......................................... 119

SERVICE PRODUCTS
Description Part Number Page
Loctite 591 0 .... ......... ....... ..... .. ...... .. ............. ... .... ......... .. .. ...... 293800081 .. .. ........ .. .. ............. .. ..... ..... 118
Loctite chisel .. .. ........ ....... .......... .. .... ............ ...... .. .. ... .. .......... 413 708 500 .... ..... .. .. ...... .. ............. .. .. ... 118

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

ENGINE DRIVE SHAFT

Engine
oil
~

Loctite 767
(antiseize lubricant)

~
Loctite
5 5910

Loctite
5910

Engine
oil

~
Super Lube
grease

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOnOM END)

CRANKCASE AND PTO COVER

25 Nom
(18 Ibf°ft)

"
Engine
oil

~
10 Nom
(89 Ibfoin) grease

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

CRANKSHAFT

10 Nom
(89Ibfoin)
I <\Loctite 243
~
<\Engine oil
~<\Engine oil

< Engine oil

~<\

) 10 Nom
<\ (89 Ibfoin)
Engine oil Loctite
243

vm r2007-Q3 7-001 _0

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOnOM END)

GENERAL
During assembly/installation, use the torque val-
ues and service products as shown in the explod-
ed view(s).
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION in INTRODUCTION section.

& WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc.) must be replaced with new ones where
specified.
vmr2006 -022-104_a

1. Bearing cover
PROCEDURES 2. G-ring

Pullout drive shaft no. 1.

ENGINE DRIVE SHAFT
CAUTION: Check ends of the circlip for sharp
Oil Seal Removal edges or burr before removing the drive shaft,
to avoid damaging the oil seal.
To remove the front 011 seal no. 4, no need to re-
move the engine. Lift the front of vehicle to avoid
engine oil spillage. Separate the front propeller
shaft from engine, refer to FRONT DRIVE.
For the rear oil seal no. 7 the gearbox removal is
necessary.
For oil seal installation, refer to ENGINE DRIVE
SHAFT INSTALLATION.

Engine Drive Shaft Removal

NOTE: The engine drive shaft no. 1 is located in-
side the engine and comes through it to drive the
front differential.
Separate gearbox from engine.
To the rear of engine, remove the bearing cover
1. Bearing cover gearbox side
and its a-ring. 2. Drive shaft
3. Circ/ip

Remove the other bearing cover no. 3 at the front

of engine.

Engine Drive Shaft Inspection

Replace oil seals no. 4 and no. 7 and/or O-ring
no. 8 if they are brittle, hard or damaged.
Check drive shaft bearings no. 2 and no. 5 for con-
tamination and/or metal shavings. Check if bear-
ings turn freely and smoothly. Replace if neces-
sary.
Check drive shaft for cracks, bend, pitting or other
visible damages.
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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

Check drive shaft splines for wear or damages.

Check oil seal running surface of the drive shaft
for scratches. Replace if necessary.

Engine Drive Shaft Installation

The installation is the reverse of removal proce-
dure . Pay attention to the following details .
Clean all metal components in a solvent.
Crankcase surfaces and bearing covers are best
cleaned using a combination of Loctite chisel
(PIN 413 708 500) and a brass brush. Brush a
first pass in one direction then make the final
brushing perpendicularly (90°) to the first pass
cross (hatch).
CAUTION: Do not wipe with rags. Use a new
clean hand towel only. Do not apply in excess as it will spread out inside
Then install drive shaft oil seals no. 4 and no. 7 crankcase .
with the oil seal installer (PIN 529036028) . NOTE: It is recommended to apply this specific
sealant as described here to get a uniform appli-
cation without lumps. If you do not use the roller
method, you may use your finger to uniformly dis-
tribute the sealant (using a finger will not affect
the adhesion) .
To install bearing cover no. 6, fit oil seal protection
sleeve (PIN 529 036 029) into oil seal.

529036028

Use a suitable installer for installing bearings .

Use Loctite 5910 (PIN 293 800 081) on mating
surfaces.
IMPORTANT: When beginning the application of
the bearing cover sealant, the assembly and the
first torquing should be done within 10 minutes.
It is suggested to have all you need on hand to
save time.
Use a plexiglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in)). 529036029

available in arts products suppliers for printing, and

roll the sealant to get a thin uniform coat on the
plate (spread as necessary) . When ready, apply
the sealant on bearing cover surfaces.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

vmr2006{)44-0 10

OIL SEAL INSTALLER

Vmr2007·037 -OO7 _8

1. Protection sleeve
2. Bearing cover
3. a-ring
4. Drive shaft

Install bearing cover then place the a-ring no. 8

inside cover.
Finally check for axial play of the drive shaft.

PTa COVER OIL SEAL

To replace oil seal no. 9 it is not necessary to re-
move engine from vehicle .

PTO Oil Seal Removal

Remove CVT cover, drive and driven pulleys and vmr2007-o37-o05_a

air guide.
1. PTa co ver
Remove oil seal no. 9 with a small flat screwdriver. 2. Oil seal
3. Oil seal installer
CAUTION: Avoid scoring surfaces with tool.

PTO Oil Seal Inspection PTa COVER

Check oil seal running surface of crankshaft PTa
side for grooves. Replace if necessary. PTO Cover Removal
Remove :
PTO Oil Seal Installation - CVT and air guide . Refer to TRANSMISSIOM
The installation is the reverse of the removal pro- - disconnect vent hose
cedure. - PTa cover screws and pull PTa cover.
Pay attention to the following details.
CAUTION: Oil seal must be installed with seal-
ing lip toward the engine.
Push oil seal in place by using the oil seal installer
(PIN 529 036 033).

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

1. Oil breather bore

Check plain bearings no. 10 for scorings or other

damages .
NOTE: Measure plain bearing inside diameter and
compare to crankshaft journal diameter (PTO sup-
port bearing). Refer to CRANKSHAFT in this sec-
tion. Replace if the measurement is out of speci-
fication.
1. PTO cover
2. PTO cover screws
3. Vent hose nipple

PTO Cover Inspection

Check the PTO cover for cracks or other damage.
Replace PTO cover if damaged .
Clean oil breather bore in PTO cover from contami-
nations with part cleaner then use an air gun to dry
it.
& WARNING
Always wear eye protector. Chemicals can 1. Plain bearing
cause a rash break out and injure your eyes. 2. Oil bore
A. Measure plain bearing inside diameter

PLAIN BEARING INSIDE DIAMETER

(PTO side support bearing)
SERVICE LIMIT I 34.120 mm (1 .3433 in)
Plain Bearing Replacement Procedure
Plain Bearing Removal
Carefully remove the oil seal no. 9 with a screw-
driver, without damaging the PTO cover.
Push-out the plain bearings from the outside
towards the inside using the plain bearing re-
mover/installer (P/N 529036 032) .

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

vmr2006-044-006

PLAIN BEARING REMOVER/ INSTALLER - PTO COVER

The PTO cover has to be supported from below

with suitable support with straight surface, in or-
der to prevent damage of the sealing surface.
1. Mark position of oil bore on PTO cover
2. Mark position of oil bore on plain bearing remover/installer

NOTE: Wrong oil bore position will stop oil supply

to plain bearings and will damage the engine.
CAUTION: The partition of the plain bearings
must be positioned near to oil bore in counter-
clockwise direction (refer to no. 3 in next illus-
tration).

1. PTO cover
2. Plain bearing remover/installer

Plain Bearing Installation

CAUTION: Unless otherwise instructed, never
use hammer to install plain bearings. Use
press only. 1. PTO cover (inside )
2. Partition
Install plain bearings with the proper plain bearing 3. Oil bore
remover/installer (P/N 529036 032) in a cool PTO
cover. Do not lubricate plain bearings and/or PTO
cover for installation. PTO Cover Installation
Carefully press-in the plain bearings in the same For installation, reverse the removal procedure.
direction as during disassembly, from the outside Pay attention to the following details .
towards the inside. Support PTO cover with suit-
NOTE: At installation, replace PTO cover gasket
able support with straight surface, in order to pre-
and oil seal.
vent damage of the sealing surface .
Tightening sequence for screws on PTO cover is
CAUTION: Mark position of oil bore on PTO as per following Illustration .
cover and on plain bearing remover/installer.
Align mark on plain bearing remover/installer
with mark on PTO cover.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

Drive Gear Removal

Remove:
- PTO cover (refer to PTa COVER)
- intermediate gear no. 11
- oil pump gear no. 12 (refer to OIL PUMP in
LUBRICATION SYSTEM)
- water pump gear no. 13.
To remove water pump gear, pull the shaft assem-
blya bit out and turn it about one teeth until it stays
out.
Now you can push water pump gear down. Re-
move needle pin no. 14 and pull water pump gear
out.
Remove breather gear no. 15.

Drive Gear Inspection

Intermediate Gear/Oil Pump Gear/Water
Pump Gear
Inspect gears for wear or other damage. Replace
if damaged.
Breather Gear
TIGHTENING SEQUENCE The engine is equipped with a breather gear which
prevents engine oil coming out through the breath-
ing system into the air box.
DRIVE GEARS
The drive gears are located on the engine PTO side 1
behind the PTO cover.
2

"mrZ006..Q44-015_a

1. Breather gear
2. V·ring

Inspect gear for wear or other damage.

Check ball bearing for excessive play and smooth
operation . Replace breather gear assembly if nec-
essary.

Drive Gear Installation

The installation is essentially the reverse of the re-
moval procedure, but pay attention to the follow-
1. Intermediate gear
2. Oil pump gear ing details.
3. Water pump gear
4. Breather gear
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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

NOTE: At installation replace the V-ring no. 16 of Carefully pull the timing chain sideward and down
the breather gear. from the crankcase.
Adequately oil the ball bearing of the breather gear. NOTE: Mark the operating direction of the timing
chain before removal.
TIMING CHAIN
Timing Chain Inspection-
The engine is equipped with two timing chains. Inspection is the same for both timing chains.
One of the timing chain is located on engine MAG
side behind the magneto cover. The second tim- NOTE: Check timing chain on camshaft timing
ing chain is located on engine PTO side behind the gear for excessive radial play.
PTO cover. Check chain condition for wear and teeth condi-
tion.
Timing Chain Removal (Magneto Side)
Remove:
- valve cover, chain tensioner and camshaft tim-
ing gear (refer to INTAKE MANIFOLD, CYLIN-
DER HEAD AND CYLINDER)
magneto cover and rotor (refer to MAGNETO
SYSTEM)
- timing chain guide and lower timing chain guide.

1
vmr2006-Q44-0 18 _a

1. Tim ing chain

If chain is excessively worn or damaged, replace

it as a set (camshaft timing gear and timing chain).

Timing Chain Installation

Installation is the same for both timing chains .
The installation is essentially the reverse of the re-
moval procedure, but pay attention to the follow-
ing details.
NOTE: Ensure to perform proper valve tim-
ing . Lock crankshaft (see CRANKSHAFT) and
camshaft at TOC ignition (refer to INTAKE MAN-
1. Timing chain
2. Timing chain guide
IFOLD, CYLINDER HEAD AND CYLINDER sec-
3. Lower timing chain guide tion) .
Install timing chain with camshaft timing gear
Carefully pull the timing chain sideward and down
then, adjust chain tension (refer to INTAKE
from the crankcase.
MANIFOLD, CYLINDER HEAD AND CYLINDER
NOTE: Mark the operating direction of the timing section).
chain before removal.
CAUTION: Improper valve timing will damage
Timing Chain Removal (PTO Side) engine components.
Remove :
- valve cover, chain tensioner and camshaft tim-
ing gear (refer to INTAKE MANIFOLD, CYLIN-
DER HEAD AND CYLINDER section)
- PTO cover (refer to PTO COVER)
- intermediate gear and breather gear (refer to
DRIVE GEARS)
- timing chain guide and lower timing chain guide
(see illustration above) .
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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

TIIVIING CHAIN GUIDE ,

~

vmr2006-<J44-020_a

1. Electric starter
2. Screw

magneto cover and rotor (refer to MAGNETO

7. Timing chain guide
2. Bearing screw SYSTEM section)
- electric starter drive gears (refer to MAGNETO
SYSTEM section)
Chain Guide Removal - water pump housing (refer to COOLING SYS-
Refer to TIMING CHAIN above. TEM section)
- oil filter (refer to LUBRICATION SYSTEM sec-
Chain Guide Inspection tion)
Check timing chain guide for wear, cracks or other - cylinder head and cylinder (refer to INTAKE
damage. Replace if necessary. MANIFOLD, CYLINDER HEAD AND CYLIN-
DER section)
Chain Guide Installation - timing chains and timing chain guides (refer to
The installation is the reverse of the removal pro- TIMING CHAIN and TIMING CHAIN GUIDE!.
cedure. Remove retaining screws of crankcase.

CRANKCASE
NOTE: Before disassembly, drain engine oil and
engine coolant.

Crankcase Disassembly
I\lOTE: Before splitting the crankcase, measure
crankshaft axial play. Refer to CRANKSHAFT.
Remove:
- drive shaft (refer to ENGINE DRIVE SHAFn
- PTO cover (refer to PTO COVER)
- drive gears (refer to DRIVE GEARS)
I\lOTE: Oil pump removal from crankcase is not
necessary, but recommended to see condition of
oil pump (refer to LUBRICATION SYSTEM sec-
tion).
- electric starter

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

1. Water pump intermediate shaft

2. Water pump gear

Remove engine oil strainer.

vmr2006-044-034_b

1. Four screws M8 x 65
2. 12 screws M6 x 75
3. One screw M6 x 35

~
Carefully split crankcase halves by using a screw-
driver and a soft hammer.

1
3 2
v m r2006-044-024 _a

1. Engine oil strainer

2. Retaining plate
3. Screws

Crankcase Cleaning

Use safety goggles to avoid eye injuries.

Clean crankcase using a part cleaner.

NOTE: During disassembly, do not damage the Dry crankcase using compressed air.
sealing surfaces of the crankcase halves. Blow the oil supply lines.
Pull crankshaft out of crankcase. Oil Strainer
Remove the water pump intermediate shaft and Clean the engine oil strainer (same procedure as
the water pump gear. for the cran kcase).

Crankcase Inspection
Check crankcase halves for cracks or other dam-
age. Replace if damaged.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

Check plain bearings no. 17 and no. 18 for scor- NOTE: Place the proper crankcase support sleeve
ings or other damages . (P/N 529036031) under crankcase halves before
NOTE: Measure plain bearing inside diameter and removing plain bea ri ngs .
compare to PTa/MAG side journal diameters of
crankshaft (refer to CRANKSHAFn, Replace if the
measurements are out of specification .

" mf 2006-044-028

CRANKCASE SUPPORT SLEEVE (P/ N 529036031)

NOTE: During disassembly, make sure not to

damage the sealing surfaces of the crankcase
halves.

2 - ---=

1. Plain bearing
2. Oil bore
A. Measure plain bearing ins ide diameter

PLAIN BEARING INSIDE DIAMETER (PTO/MAG)

SERVICE LIMIT I 42.100 mm (1 .6575 in)
Plain Bearing Replacement
Plain Bearing Removal
CAUTION: Always support crankcase halves
properly when ball bearings or plain bearings vm r2006-044-029 _a
are removed. Damages to crankcase halves
PUSH PLAIN BEARINGS OUTSIDE
may occur if this procedure is not performed 1. Crankcase half
correctly. 2. Plain bearing rem over/installer
3. Crankcase support slee ve (P/N 529 036 031)
NOTE: Always use a press for removal of plain
bearings. Plain Bearing Installation
Remove plain bearings no. 17 and no. 18 with CAUTION: Unless otherwise instructed, never
the proper plain bear ing remover/installer (PIN 529 use hammer to install ball bearings or plain
035 917). bearings. Use press only.
Insta ll plain bearings with the proper plain bear-
ing remover/installer (P/N 529 035 917) in a cool
crankcase. Do not lubricate plain bearings and/or
crankcase for installation.
NOTE : Place the proper crankcase support sleeve
under crankcase halves before installing the plain
bearings (refer to BEARING REMOVAL PROCE-
DURH
vm r 20C6 -C4~26

PLAIN BEARING REMOVER/ INSTALLER (P/N 529 035 917)

Carefully press-in the plain bearings in the same di-
rection as during disassembly, from the crankcase
Carefully push the plain bearings out, from the inside towards the outside.
crankcase half inside towards the outside .
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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOnOM END)

During reassembly, make su re not to damage the CAUTION: The partition of the plain bearings
sealing surfaces of the crankcase halves . in crankcase half PTO side must be positioned
near to oil bore in counterclockwise direction
CAUTION: Mark position of oil bore on (refer to no. 3 in next illustration).
crankcase half and on plain bearing remover/
installer. Align mark on plain bearing
remover/installer with mark on crankcase
half.

1. Crankcase half PTa (inside)

2. Oil bore
3. Partition

NOTE: Use an O-ring (0 42 x 1 to 1.5 mm (.04

to .06 in) th ickness) to hold plain bearing s in place
1. 0 11 bore position marked on crankcase
2. Oil bore position marked on plain bearing remover/ins taller
during installation . The O-ring will disappear in the
groove of the plain bearing remover/instal ler.
NOTE: Wrong oil bore position will stop oil supply
to plain bearings and will cause engine damage. Crankcase Assembly
CAU1"ION: The partition of the plain bearings The assembly of crankcase is essentially the re-
in crankcase half MAG side must be positioned verse of removal procedure. However, pay atten-
near to oil bore in clockwise direction (refer to tion to the following details.
no. 3 in next illustration). Clean oil passages and ma ke sure they are not
clogged.
Clean all metal components in a solvent.
Install a new crankcase gasket.
Oil the plain bearings before mounting the crank-
shaft.
CAUTION: Correctly reinstall crankshaft (refer
to CRANKSHAFn,
Properly reinstall engine oil strainer and screws.
Reinstall water pump shaft shafts/gears (refer to
COOLING SYSTEM section).
Tightening sequence for screws on crankcase is
as per following illustration .

1. Crankcase half MAG (inside)

2. Oil bore
3. Partition

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM EI\ID)

Crankshaft Locking Procedure

NOTE: When crankshaft is locked, the rear piston
(cylinder 2, rear) is at TDC ignition. Crankshaft can
not be locked at cylinder 1 (front) TDC.
Remove :
- spark plug cable and spark plug of both cylinders
- valve covers of both cylinders
- plug screw and O-ring of magneto cover

vmr20C6-044-034_3

TIGHTENING SEQUENCE

1. Plug screw
CRANKSHAFT 2. a-ring

- crankshaft pos ition sensor

1. Crankshaft position sensor

2. Screw

- plug screw with sealing ring .

1. Crankshaft
2. Crankcase MAG

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

1, Plug screw
2, Sealing ring 1. Mark "2" on magneto flywhee l
3, Crankcase PTO side, front side 2, Notch on magneto cover
3, Cranks haft position sensor location
Use a 14 mm Allen key to turn crankshaft until
piston 2, rear is at TDC ignition, Use a screwdriver to check if the groove in the
crankshaft is aligned with the hole .

1, AI/en key 14 mm 1, Screwdriver

When rear piston is at TDC ignition, marks on mag- Lock crankshaft with crankshaft locking bolt
neto flywheel "2" and on the magneto cover are (PIN 529 035 617),
aligned .

vmr2006.()43-Q 13

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

CRANKSHAFT AXIAL PLAY

0.200 to 0.500 mm
NEW
(.008 to .020 in)
SERVICE LIMIT 0.6 mm (.024 in)

If play is out of specification, replace crankcase

and/or crankshaft.
Connecting Rod Big End Axial Play
Using a feeler gauge, measure distance between
butting face of connecting rods and crankshaft
counterweight. If the distance exceeds specified
1. Crankshaft locking bolt tolerance, replace the crankshaft.

Crankshaft Removal
Refer to CRANKCASE.

Crankshaft Inspection
NOTE: Check each bearing journal of crankshaft
for scoring, scuffing, cracks or other signs of wear.
NOTE: Replace crankshaft if the gears are worn
or otherwise damaged .
CAUTION: Components with less than the ser-
vice limit always have to be replaced. If this is
not observed, severe damage may be caused
to the engine.

vmr2006-044-037 _8

1. Crankshaft
2. Connecting rods
3. Feeler gauge

COI\lI\lECTING ROD BIG END AXIAL PLAY

0.200 to 0.500 mm
NEW
(.008 to .020 in)

vmI2006-044-036_a
SERVICE LIMIT 0.6 mm (.024 in)
1. Crankshaft timing gears
Connecting Rod/Piston Pin Clearance
Crankshaft Axial Play Refer to INTAKE MANIFOLD, CYLINDER HEAD
NOTE: Axial play needs to be measured before AND CYLINDER section .
splitting the crankcase . Connecting Rod Big End Radial Play
Measure play on PTO end, using a dial indicator. NOTE: Prior to remove connecting rod from the
crankshaft, mark big end halves together to en-
sure a correct reinstallation (cracked surface fits
in only one position).
Remove connecting rods from crankshaft.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

CAUTION: Always replace connecting rod OUTLANDER 500

screws no. 19 if removing the connecting rod.
It is recommended to replace plain bearings CRANKSHAFT PIN DIAMETER
no. 20, in case of installing the connecting rod. 35.064 to 35.080 mm
NEW
(1.3805 to 1.3811 in)
SERVICE LIMIT 35 .050 mm (1.3800 in)
CONNECTING ROD BIG END DIAMETER
SERVICE LIMIT 35 .150 mm (1 .3839 in)
CONNECTING ROD BIG END RADIAL PLAY
SERVICE LIMIT 0.09 mm (.0035 in)
vmr2007-037-003_a

1. Connecting rod screw s

OUTLANDER 650/800
Measure crankpin . Compare to inside diameter of CRANKSHAFT PIN DIAMETER
connecting rod big end.
40 .009 to 40 .025 mm
NEW
(1 .5752 to 1.5758 in)
SERVICE LIMIT 39.990 mm (1 .5744 in)
CONNECTING ROD BIG END DIAMETER
SERVICE LIMIT 40 .100 mm (1 .5787 in)
CONNECTING ROD BIG END RADIAL
CLEARANCE
SERVICE LIMIT 0.09 mm (.0035 in)

Crankshaft Radial Play MAG/PTO Side

Measure crankshaft on MAG/PTO side . Compare
to inside diameter of MAG/PTO plain bearing (refer
to CRANKCASe.

1. Microm eter
2. Crankpin area for plain bearin g

To measure the connecting rod big end diameter,

use the OLD screws no. 19 .
Install the OLD plain bearings no. 20 as they were
mounted initially.
Do the torque procedure as described further.

1. Micrometer
2. Crankshaft area for M AG plain bearing

vmr2006·Q44-039_a

A. Connecting rod big end plain bearing

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

vmr2006-044-041_8

7. Micrometer
2. Crankshaft area for PTO plain bearing

CRANKSHAFT MAG/PTO SIDE DIAMETER 7. Micrometer

2. Crankshaft Journal (PTO support bearing)
42.024 to 42.040 mm
NEW
(1.6545 to 1 .6551 in) CRANKSHAFT JOURNAL DIAMETER
(PTO support bearing)
SERVICE LIMIT 42.000 mm (1.6535 in)
34.024 to 34.040 mm
NEW
(1.3395 to 1.3402 in)
CRANKSHAFT MAG/PTO SIDE RADIAL
CLEARANCE SERVICE LIMIT 34.010 mm (1.3390 in)

SERVICE LIMIT I 0.07 mm (.0031 in)

CRANKSHAFT PTO SUPPORT BEARING
Crankshaft Radial Play RADIAL CLEARANCE
(PTa Side Support Bearing) SERVICE LIMIT I 0.10 mm (.0039 in)
Measure crankshaft journal of PTO support bear-
ing. Compare to inside diameter of PTO support Crankshaft Assembly
bearing in PTO cover (refer to PTO COVER).
For assembly, reverse the disassembly procedure.
Pay attention to following details.
NOTE: Use NEW plain bearings no. 20, when con-
necting rod big end diameter is out of specifica-
tion.
Put plain bearings correctly in place and clean the
split surface on both sides (cracked area) carefully
with compressed air.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 08 (BOTTOM END)

R1004mott20A

1. Half plain bearing of connecting rod big end

2. Split surface of the connecting rod
3. Nose of plain bearing in line with connecting rod groove

NOTE: Oil the plain bearing surface of the con-

necting rod and crank pin before installation .
Torque NEW connecting rod screws no. 19 as per
following procedure:
1. Angle torque wrench
Outlander 500:
CAUTION: Failure to strictly follow this proce-
- First. install screws with half of the recom- dure may cause screw to loosen and lead to
mended torque. Do not apply any thread engine damage. The plain bearing tapered end
locker. must be against the counterweight. Besides,
- Secondly, torque screws to 12 N.m as the "crankpin" screw has been stretched
(106 Ibf·in). from the previous installation, it is very impor-
Finish tightening the screws with an additional tant to use a new screw at assembly.
70° turn using an angle torque wrench. NOTE: The running direction of the big end bear-
ings and of the piston pins must not change.
Outlander 650 and 800:
First. install screws with half of the recom- Crankshaft Installation
mended torque. Do not apply any thread
For installation of crankshaft in crankcase reverse
locker.
the removal procedure . Pay attention to the fol-
- Secondly, torque connecting rod screws to lowing details.
20 N·m (15 Ibf·ft).
Do not mix up the connecting rods of cylinders 1
- Finish tightening the screws with an additional
and 2 during installation .
60° turn using an angle torque wrench.
CAUTION: Observe the correct installation po-
sition when fitting the crankshaft with the con-
necting rods. The connecting rod MAG side
has to face to cylinder 1.

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Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 08 (BOTTOM END)

1. Crankcase half MAG side

2. Connecting rod cylinder 1
3. Connecting rod cylinder 2

CAUTION: Install CRANKSHAFT LOCKING

BOLT to put crankshaft in TDC position before
installing the camshaft and rocker arms (refer
to CRANKSHAFT LOCKING PROCEDURE.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

GEARBOX AND 4X4 COUPLING UNIT

SERVICE TOOLS
Description Part Number Page
installer handle ... ... ......... ............ ... ..... ...... ........ ..................... 420 877 650 ..... .. ... ... ... .. ...... .... .... . 142, 160
oil seal installer .. ... .. .. .... ... ...... .... ...... ... ...... ... .. .......... .... ........ . 529035758 .. ... .. ......... ..... .. .... .... ... ....... 142
main shaft needle bearing installer ... .... .. ...... .. .. .. ...... ..... .... ... 529035762 .... ........ ... ...... ..... ... .. .... ...... 160
bevel gear needle bearing installer ......... .. .. .. ... .... ... ... ....... .. .. 529 035 763 .... ... .. ........ .......... .. ...... ...... 160
Fluke 111 multimeter ..... ... ... ... ....... ... .... ... .. ..... ... .. ..... ...... ... .. 529 035 868 ... .... ......... .... .. .. .... .. .. ... ...... 142
oil seal installer ......... .. ........ .... .. ... ... ..... ...... ... ... .... ..... .. ..... .. ... 529036028 .... ..... ... ..... ... .... .. ........ ...... . 141
backlash measurement tool ..... .. ....... ..... ..... ... ..... ..... .. ....... .. . 529 036 030 .. ....... ... ..... .... .. .. ... .... .... .... . 144

SERVICE PRODUCTS
Description Part Number Page
Super Lube grease .................................. ............................ . 293 550 030 ... ... ..... .. .. .. ..... ..... ... .. . 143, 149
Loctite 591 0 ... ... ...... ........... ....... ... .. .. .. .... ...... .. ...................... . 293800081 ... .... .. 139- 140,148-149,164
Loctite chisel (gasket remover) .. ....... .. ................................ . 413 708 500 ... ..... ... .. .. ....... .. . 148, 156, 164
XP-S chaincase oil. .... ....... .. .... ............ ............................. ..... . 413801 900 ... ....... .... ....... .... ...... ... .... .. . 139
XP-S synthetic chaincase oil .... .................... .. ..... .. ....... .... .... . 413 803 300 ........ .. .. ......... ... .. ..... ..... .... . 139

sa,les@.mil dwe, manrUI,a s.c,o,m

id .
WWW"lm l · ·· westlmalnua 5.COm 1

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AI\ID 4X4 COUPLING UI\IIT)

GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM

20 Nom .
(15Ibfoft)- ~ &Loctlte 243

(lLJ
28-'~

10

I Engine oil

9
Bevel gear
backlash shim
11

14
2(
22
)1"
aa.J&
"
18
23

Engine oil

Engine oil&

16
17
Bevel gear
axial play shim

vmr2006-022-001_b

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

GEARBOX HOUSING AND 4X4 ACTUATOR UNIT

Super Lube grease
(PIN 293550030)
1,5 Nom
~
(13Ibfoin)

Y'
41
Loctite 5910
I ~
Loctite 591 0 ~~ 25 Nom
'-(18Ibtoft)

20l\lom
(15 I bt°ft) L t't Loctite
/ ~ oc I e 5910
~ 243 ~
~

Loctite 243
4:.:
r"
~

35~
~
34

Engine 10 Nom
oil (89 Ibfoin)

~
10 Nom Engine
(89 Ibfoin) oil

25 NO;--~ ~
5 Nom Ibtoft)-~::,~,
(18
/
Super Lube
grease
(44 Ibfoin) 1,5 Nom '~~ '" (PIN 293 550 030)
44 (13Ibtoin) //' ~
..( 40 /'

20 Nom
•

(15Ibt°ft) /
~
Loctite I
5910
'~ ~-=-t '~~fIII
/~
,/
~
10 Nom
39 ~ 42-~ 45 25 Nom I (89Ibtoin)
Super Lube ~ (18Ibt ft) ,

e1
grease /" - --- ~
0
33
(PIN 293550030) 43 ~~ ..... .. +"-
~
Loctite W ....
243 ,~ ,
~
10 Nom~' / ' Engine
(89 Ibfoin)
'" , ~ ,
/ A
' ~
\JI
'v Loctite
oil

243 6 Nom
(53Ibtoin)
vmr2006-022-002_b

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Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

GENERAL MAINTENANCE
During assembly/installation, use the torque val-
ues and service products as in the exploded GEARBOX OIL CHANGE
views.
Draining Procedure
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE Prior to change the 011, ensure vehicle is on a level
APPLICATION at the beginning of this manual for surface.
complete procedure. Oil change should be done with a warm engine.

& WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic Place a drain pan under the gearbox drain plug
stop nuts, self-locking fasteners, etc.) must area.
be installed or replaced with new ones where Clean drain plug area and remove magnetic drain
specified. If the efficiency of a locking device plug no. 42 with its sealing ring no. 43 to drain
is impaired, it must be renewed.
gearbox oil.

Always drain the gearbox before working on it. Remove oil filler screw no. 44 including its a-ring
no. 45.
To remove gearbox, the engine removal is neces-
sary. Refer to ENGINE REMOVAL AND INSTAL- CAUTIOI\!: Pay attention not to loose O-ring on
LATION. drain plug screw.
Remove drive and driven pulley and CVT air guide, Wait a while to allow oil flow out of gearbox.
refer to CVT.

Overview
7

3 2 1
vmr2006-022-D05_a

3 2 5 1 1. Magnetic drain plug

'1m r2006-02 2-004_a 2. Sealing ring
3. Oil filler screw
1. Right housing
2. Center housing
3. Left housing Dispose gearbox oil as per your local environmen-
4. Output shaft
5. Bearing cover
tal regulations.
6. Counters haft
7. Shift shaft Inspection
8. Actuator
Oil condition gives information about the teeth
condition inside the gearbox. See TROU-
BLESHOOTING section.
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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

Clean the magnetic drain plug from metal shavings Unscrew switch.
and dirt. Presence of debris gives an indication
of failure inside the gearbox. Check gearbox to Test
correct the problem. Check if gearbox position indicator switches work
Change gasket ring no. 43 on the magnetic drain properly as per following procedure:
plug if damaged. Disconnect wires from switches.
Replace a-ring no. 45 if brittle, hard or otherwise NOTE: Remove insulating paint to obtain correct
damaged. readings.
Filling Procedure Put gearbox in park, reverse, neutral, high and low
position.
Make sure that magnetic drain plug no. 42 is rein-
stalled and tight. Use a multimeter to measure the resistance from
the indicator switch to engine ground. Compare
With the vehicle on a level surface, fill the gearbox results with the logic table below.
through the oil filler hole with XP-S chaincase oil
(P/N 413 801 900) or XP-S synthetic chaincase oil CORRESPONDING SWITCH WIRES
(P/N 413 803 300) or with an equivalent product SHIFTER
until the oil reaches the lower threads of the oil POSITION BROWN/ WHITE/ ORANGE/
filler hole (around 400 mL (13.5 oz U.S.)). GREY GREY GREY
L X X
PROCEDURES H X
N X X
GEARBOX POSITION INDICATOR
SWITCHES R X
P X X
NOTE: The gearbox removal is not necessary to
reach the gearbox position indicator switches.
An "X" indicates switch is making ground contact,
Removal thus there should be continuity (R is close to 0
Ohms).
To reach the gearbox position indicator switches
no. 41, remove the rear engine cover. A blank space indicates switch is not making con-
tact, there should be no continuity (R = infinite).
Remove screw retaining indicator switch wire.
If the indicator switch is good, check the vehicle
harness and/or indicator lights.

I nsta lIation
For installation, reverse the removal procedure.
Pay attention to the following details.
Take care do not damage shifting indicator switch-
es threads during installation.
Apply carefully some Loctite 5910 (P/N 293 800
081) on threads of shifting indicator switches.
CAUTIOI\!: Do not apply Loctite 5910 on switch
plunger, as it will lead to switch malfunction.
If all switches are removed, make sure to put the
wires back in the right location.

1. Gearbox position indicator switches

2. BROWN/GREY wire
3. WHITE/GREY wire
4. ORANGE/GREY wire

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Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

1. 4 WD indicator switch
1. Indicator switches 2. BLACK/YELLOW wire for contact to 4WD
2. BROWN/GREY wire 3. Actuator
3. WHITE/GREY wire 4. Speed sensor
4. ORANGE/GREY wire

Spray a layer of electrical insulating paint or varnish Test

over switches to prevent shorts and corrosion. Measure switch resistance as follows.

SWITCH
SWITCH WIRE RESISTANCE
POSITION

2WD BLACK/
YELLOW
I ground
Engine Infinite (Ol)

If the resistance is out of specification, replace the

4WD indicator switch.

Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Take care do not damage indicator switch threads
during installation.
Apply carefully some Loctite 5910 (PIN 293 800
081) on threads of indicator switch.
4WD INDICATOR SWITCH
CAUTION: Do not apply Loctite 5910 on switch
NOTE: The gearbox removal is not necessary to plunger, as it will lead to switch malfunction.
reach the 4WD indicator switch. Spray a layer of electrical insulating paint or varnish
over switch to prevent shorts and corrosion.
Removal
To reach the 4WD indicator switch no. 40, remove OIL SEALS
the rear engine cover.
Remove screw retaining 4WD indicator switch Removal
wire. Replace oil seals if they are brittle, hard or dam-
aged.
A small flat screwdriver can be used to remove
most of these 011 seals.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

CAUTION: Avoid scoring housings, bearing

cover, shift shaft, distance sleeve of counter-
shaft or output shaft during oil seal removal.
Countershaft Oil Seal
The countershaft oil seal no. 47 can be removed
without removing gearbox from vehicle . Remove
drive and driven pulley and CVT air guide .
NOTE: When oil seal is removed also inspect
O-ring no. 31 .

vmr2006"()22-007 ~a

1. Shift shaft oil seal

2. Output shaft oil seal

Inspection
Check bearings behind each oil seal for contami-
nation and/or metal shavings .
Check oil seal running surfaces for scratches . Re-
place if necessary (see GEARBOX below) .
Check if the countershaft O-ring no. 31 and the
output shaft O-ring no. 4 are brittle, hard or dam-
aged. Replace if necessary.
vrnr2006-022-006_a

1. Counters haft oil seal Installation

2. Distance sleeve
The installation is the reverse of removal proce-
Shift Shaft Oil Seal dure. Pay attention to the following details.
The shift shaft oil seal no. 38 can be removed with- Output Shaft and Countershaft Oil Seal
out removing the gearbox from the vehicle. Install output shaft oil seal and countershaft oil
Remove side panel and the shifting plate from seal with the oil seal installer (P/N 529036028) .
shift shaft to reach the oil seal.
Output Shaft Oil Seal
Removal of output shaft oil seal no . 46 requires
that the rear propeller shaft is separated from the
output shaft (refer to DRIVE TRAIN section) . The
removal of the gearbox or bearing cover is not nec-
essary.
NOTE: When 011 seal is removed also inspect 529036028

O-ring no. 4. OIL SEAL INSTALLER

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

420877650

CAUTION: Oil seal must be installed with seal-

ing lip toward gearbox.

ACTUATOR
European Community Models (CE)

Test
Using the Fluke 111 multimeter (P/N 529035868)'
1, Output shaft oil seal
2, Oil seal installer check if the 2WD/4WD selector works properly.

529035868

Remove the rear engine cover.

Unplug actuator connector.
- Turn ignition key ON and set engine run/stop
switch to RUN.
- Measure voltage as follows.

SWITCH
SWITCH WIRE VOLTAGE
POSITION
1. Counters haft oil seal
2, Oil seal installer
2WD WHITE/BLUE Battery
WHITE
Shift Shaft Oil Seal 4WD WHITE/BLACK voltage
Using a suitable tube with the proper diameter to
install the shift shaft oil seal. If the selector is out of specifications, check wires,
If gearbox housing is apart, the oil seal installer connectors and replace the selector if necessary.
(P/N 529 035 758) and installer handle (P/N 420 If the selector is good, check the vehicle harness.
877 650) can be used for shift shaft oil seal instal- If the vehicle harness is good, replace the actuator
lation, no. 39,

Removal
529035758 NOTE: Before beginning any servicing on the ac-
tuator, make sure the vehicle is in 4WD position.
No need to remove engine from vehicle.
Remove the RH footrest and the rear engine cov-
er. Refer to BODY.
Unplug actuator connector.
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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

Place a drain pan under actuator. Align the actuator fork with the pin on coupling
Unscrew actuator bolts . fork no. 10 then push the actuator in the housing.
See the following illustration to position the actu-
ator correctly.

When all actuator bolts are removed, pull the ac-

tuator out of housing.

Installation
Apply a small amount of Super Lube grease
(PIN 293 550 030) on actuator O-ring.

vmr2 006-022-1 33_a

Rotate the actuator counterclockwise until it ori-

ents itself to mounting position.
CAUTION: Do not cut or break the actuator
O-ring.
Install all actuator bolts then torque them to
25 N-m (18 Ibf-ft).
1. Actuator O-ring
Connect actuator.
Verify if coupling fork no. 10 is in 4WD position. Lift the front of vehicle.
The coupling fork should be positioned toward the Turn front wheels. The front propeller shaft
front of vehicle. should not turn (the PARK position must be se-
lected) .
If the front propeller shaft turns, the actuator is not
installed correctly. Remove actuator and reinstall
it.
Place ignition switch to ON position and select the
2WD position.
Turn front wheel again. The front propeller shaft.
The shaft should turn easily.
If the front propeller shaft does not turn, the ac-
tuator is not installed correctly. Remove actuator
and reinstall it.
CAUTION: Refill missing gearbox oil, refer to
GEARBOX OIL CHANGE above.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

Install all other removed parts.

OUTPUT SHAFT AND COUPLING

MECHANISM
Remove gearbox. Refer to GEARBOX further in
th is section.
Before removing the right housing and output
shaft no. 1 measure the backlash on output shaft.
This measure will indicate if output shaft adjust-
ment is necessary.

Output Shaft Backlash Procedure

Engage PARK position on the gear shaft to block
gearbox. vmr2006.Q22-0 11_a

Remove: 1. Distance sleeve

2. O-ring
- bearing cover with oil seal
Install the backlash measurement tool (PIN 529
036 030) at the end of output shaft.

2
IImr2006-022-010_a

529036030
1. Bearing cover
2. Oil seal
From center of tool bolt, measure 47 mm (1.85 in)
- distance sleeve and place a mark on the tab.
- O-ring.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

IIm(2006-022-021

POSITION FOR BIG FLAT SCREWDRIVER

vm r2006-022-O 12_8

1. Backlash measurement tool

2. Mark on tab
A. 47 mm (1.85 in)

Position the head of the dial indicator, aga inst the

tab at a 90° angle and on the line. Then, gently
rotate the output shaft.
This reading gives the backlash measurement.
Refer to the following table for backlash specifi-
cations.

OUTPUT SHAFT BACKLASH

0 .10 to 0.20 mm
NEW
(.0039 to .0079 in)
SERVICE LIMIT 0 .25 mm (.0098 in)

If backlash is not within the specification, remove POSITION FOR BIG FLAT SCREWDRIVER
the output shaft and select the next thicker or thin-
ner shim to meet the specifications . Remove output shaft.
NOTE: Use next thicker shim to increase backlash CAUTION: Use a soft hammer to remove out-
and next thinner shim to reduce backlash. put shaft from center housing.

Removal
Remove actuator no. 39 .
Remove the bearing cover with oil seal.
Unscrew all bolts retaining the right housing to the
center housing.
To remove right housing, use 2 big screwdrivers .

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

vmr2006 -022-025_a

1. Ball bearing
2. Thrust washer

- set screw, pin and coupling fork .

1. Output shaft
2. Coupling sleeve
3. Soft hammer

Continue removal procedure by removing :

coupling sleeve , O-ring, ball bearing and thrust
washer.

vmr2006-022·026_a

1. Set scre w
vmr20 06·022-o24 _S 2. Pin
3. Coupling fork
1. Coupling sleeve
2. a -ring
3. Ball bearing
4. Thrust w asher Inspection
- ball bearing and thrust washer Chec k output shaft no. 1 and its gear for cracks,
bend, pitting or other visible damages.
Check output shaft splines for wear or other dam-
ages.
CAUTION: Always replace output shaft and
bevel gear shaft at the same time. Adjust
these components upon replacement.
Check if the output shaft bearings no. 3 and no. 7
turn freely and smooth ly. Replace if necessary.
Replace oil seal no. 46 if brittle, hard or damaged.
Replace O-rings no. 4 and no. 8 if brittle, hard or
damaged .
Check splines of coupling sleeve no . 9 for wear or
other damages .
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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX A~ID 4X4 COUPLING UNIT)

Clean housing split surface and especially the

bearing areas from metal particles or other con-
tamination.

Installation
Install thrust washer no. 6, bearing no. 7, O-ring
no. 8 and coupling sleeve no. 9 onto the output
1 shaft.
Install thrust washer no. 2 and ball bearing no. 3.
O-ring no. 4 and distance sleeve no. 5 are not
1. Inspect splines installed at this time.
Measure the coupling sleeve groove width . Place the output shaft into the center housing.
Use soft hammer to put bearing exactly in place
against center housing.

vmr2006·022-03'_a

A. Groove w idth

COUPLING SLEEVE GROOVE WIDTH

5.25 to 5.35 mm
NEW
(.207to .211 in)
SERVICE LIMIT 5.50 mm (.217 in) 1. Soft hammer

Clean the bearing cover location then attach bear-

Check coupling fork claw thickness.
ing cover with oil seal to the hous ing.
Temporarily install the right housing with the four
(4) M8 TORX screws beside bearing seats .
NOTE: Prior to tightening the TORX screws, tap
on the gear end of output shaft with a soft hammer
to take up all gear free play.
Verify output shaft backlash. Refer to OUTPUT
SHAFT BACKLASH PROCEDURE in this section .
Adjust as required .
If backlash is within specifications, remove dial
indicator, backlash measuring tool, bearing cover
vm r200B-022-032_a
and right housing.
1. Coupling fork NOTE: Install coupling fork, pin and set screw in
2. Micrometer right housing before applying sealant to the mating
surface.
COUPLING FORK CLAW THICKNESS
4 .95 to 5.05 mm
NEW
(.195 to .199 in)
SERVICE LIMIT 4.80 mm (.189 in)

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

3
F12R17A

Do not apply in excess as it will spread out inside

vmr2006-02 2·035_3 housings.
1. Coupling fork NOTE: It is recommended to apply this specific
2. Pin
3. Set screw sealant as described here to get a uniform appli-
cation without lumps. If you do not use the roller
Clean all metal components in a solvent. method, you may use your finger to uniformly dis-
Housing mating surfaces are best cleaned using tribute the sealant (using a finger will not affect
a combination of Loctite chisel (gasket remover) the adhesion).
(PIN 413 708 500) and a brass brush. Brush a first Install all other screws on right housing then the
pass in one direction then make the final brushing O-ring no. 4 and the distance sleeve no. 5 on
perpendicularly (90°) to the first pass cross (hatch). end of output shaft. Chamfered bore of distance
CAUTION: Do not wipe with rags. Use a new sleeve has to face the engine.
clean hand towel only.
IMPORTANT: When beginning the application of
sealant, the assembly and the first torquing should
be done within 10 minutes. It is suggested to
have all you need on hand to save time .
Use Loctite 5910 (PIN 293 800 081) on mating
surfaces.
Use a plexiglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in)},
available in arts products suppliers for printing, and
roll the sealant to get a thin uniform coat on the
plate (spread as necessary). When ready, apply
the sealant on housing mating surfaces .

2 1
vmr2006~22·037 _a

1. O-ring
2. Dis tance sleeve

NOTE: To install the right housing align the cou-

pling fork no. 10 with the groove in the coupling
sleeve no. 9.
First, torque the four (4) M8 Torx screws in a criss-
cross sequence by hand then retighten to 25 N-m
(18 Ibf-ft).

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

M8

vmr2006· 022-036_a

vmr2006-022-040_i!
Tighten all M6 Torx screws to 10 N-m (89 Ibf-in)
1. Be vel gear
Before installing bearing cover, apply Loctite 5910
(PIN 293 800 081) on the housing and Super Lube
grease (PIN 293 550 030) on seal.
Install the actuator, refer to ACTUATOR.
Once this is done, complete final assembly.

GEARBOX
Removal
Remove engine from vehicle and place it on
footrest support. Refer to ENGINE REMOVAL
AND INSTALLATION for the procedure .
Drain gearbox. Refer to GEARBOX OIL CHANGE
in MAINTENANCE of this section for the proce-
dure.
Unscrew the three (3) nuts that attach the gearbox
to the engine .
Pull gearbox to separate it from engine .
MEASURE AXIAL CLEARANCE OF BEVEL GEAR
Disassembly
BEVEL GEAR AXIAL CLEARANCE
NOTE: During gearbox disassembly, inspect the
condition of each part closely. 0.02 to 0.15 mm
NEW
(.00079 to .0059 in)
Remove the output shaft. Refer to OUTPUT
SHAFT AND COUPLING MECHANISM in this SERVICE LIMIT 0.1 9 mm (.0075 in)
section .
Push bevel gear no. 11 with a pin slightly down Unscrew the left housing screws.
and measure the axial clearance of bevel gear with Place the left housing on a wood stand, center
a feeler gauge. housing pointing upwards .
NOTE: Bevel gear axial clearance must be mea- Using 2 big flat screwdrivers, lift the center hous-
sured before center and left housings separation. ing.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

vmr2006-{)22·055_3

1. Shift shaft assembly

Remove shift fork shaft.

POSITION FOR BIG FLAT SCREWDRIVER
Remove disengage shift fork from shift drum .

1 - -.....•

1. Shift fork shaft

2. Shift fork
3. Shift drum

vmr2006-02 2-046 Remove bevel gear shaft with low range gear as-
POSITION FOR BIG FLAT SCREWDRIVER sembly and shim.

Remove center housing completely.

Remove shift shaft assembly.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

1. Bevel gear 1. Thrust washer

2. Low range gear
2. Needle bearing
3. Shim
3. Reverse gear

Remove sliding gear with shift fork. Remove shim on CVT side.

1. Sliding gear 1. Shim on CVT side

2. Shift fork

Remove thrust washer, needle bearing and re-

verse gear.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UI\IIT)

Remove countershaft no. 18 with low range gear

and high range gear assembly.

1. Parking lock lever

- index lever with washer, step ring and spring

1. Countershaft
2. Low range gear
3 . High range gear

Insert a flat screwdriver in the slot of index lever.

Turn screwdriver clockwise and remove shift
drum.

1. Index lever
2. Washer
3 . Step ring
4 . Index spring

- support flange no. 37 .

To remove intermediate gear no. 23 and needle
bearing no. 22, use a press bench to push out the
intermediate gear shaft no. 21 .

1. Index leve r
2. Shift drum

Continue by removing the following;

- parking lock lever

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

To remove ball bearings of bevel gear no. 36 and

needle bearing of countershaft no. 33, use a blind
hole bearing puller.

R610ouli03A

For countershaft ball bearing, remove screw and

intermediate gear shaft, then push with a suitable
puller from outside in.

PRESS SHAFT IN THE DIRECTION AS SHOWN BY THE ARROW

1. Intermediate gear shaft
2. Left housing

Bearing Removal in Housing

e
If necessary heat housing up to 100 D (212 D F) be-
fore removing ball bearings or needle bearings .

& WARNING
Clean oil, outside and inside, from housing
before heating.

CAUTION: Always support gearbox housings

properly when ball bearings or needle bearings
are removed. Housing damages may occur if
this procedure is not performed correctly.
To remove bevel gear needle bearing use a punch. 1. Screw
2. Intermediate gear shaft
3. Ball bearing countershaft
4. Bevel gear ball bearing

Inspection
Always verify for the following when inspecting
gearbox components:
- gear teeth damage
- worn or scoured bearing surfaces
worn or scoured shift fork
- worn or scoured shift fork shaft
- rounded engagement dogs and slots
- bent shift forks
bent shift fork shaft
worn shift fork engagement pins
- worn tracks on shift drum
vmr2006-022-049_C!
- worn shift fork engagement groove
1. Bevel gear needle bearing - worn splines on shafts and gears.
2. Punch
3. Center housing

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

Bearings
Check if bearings no. 34 and no. 36 as well as
needle bearings no. 33 and no. 35 turn freely and
smoothly.
Check all bearings, bearing points, tooth flanks,
taper grooves and annular grooves. Annular
grooves must have sharp edges.
Shift Forks
Check both shift forks for visible damage, wear or
bent shift fork claws .
Measure the shift fork claw thickness .
vmr2006-022-076_8

1. Micrometer
A. Shift fork pin diameter

SHIFT FORK PIN DIAMETER

6.920 to 6.970 mm
NEW
(.272 to .274 in)
SERVICE LIMIT 6.850 mm (.270 in)

A Shift Drum
Check shift drum tracks for scouring or heavy
wear, like rounded engagement slots.
Replace isolating washer no. 27 if there are signs
vrnr2006-<l22-075_a
of wear or visible damages.
1. Micrometer
A. Shift fork claw thickness

- Shift fork no. 25 for high gear shifting. 1

SHIFT FORK CLAW THICKNESS

(high gear shifting) 3
4 .80 to 4.90 mm
NEW
(.189 to .193 in)
SERVICE LIMIT 4.70 mm (.185 in)

- Shift fork no. 26 for low/reverse gear shifting.

vmr2006-022-078_8

SHIFT FORK CLAW THICKNESS 1. Track for the low/reverse gear shift fork
2. Track for the high gear shift fork
(low/reverse gear shifting) 3. Isolating washer on the shift drum

5.10 to 5.20 mm
NEW Levers
(.200 to .205 in)
Check parking lever no. 29 for cracks or other
SERVICE LIMIT 5.00 mm (.197 in)
damages.

Measure shift fork pins . Index lever with roller no. 28 must move freely.
Gears
NOTE: Replace gears only together with the corre-
sponding meshing gears. Always replace circlips
and use special pliers to install them .
Measure the width of shift fork engagement
groove.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLlI\IG UNIT)

DIAMETER FREE PINION

29.000 to 29.013 mm
NEW
(1.1417 to 1,1422 in)
1 -.....
SERVICE LIMIT 29.015 mm (1.1423 in)

Shafts
Check shift shaft no. 30 for worn splines and
gears ,
Check intermediate shaft for wear,

vmr2006-022-077 _8

1, Main gear
2, Caliper
I'1•"'-' - . ~~.
~
1-~~
A. Width for engagement of shift fork

- Gear no. 20 for high gear shifting .

WIDTH OF SHIFT FORK ENGAGEMENT GROOVE

(high gear shifting) 1, Intermediate gear bearing
5,00 to 5,10 mm
NEW INTERMEDIATE GEAR SHAFT
(.197 to ,201 in)
SERVICE LIMIT 5.20 mm (.205 in) 24.979 to 25,000 mm
NEW
(.9834 to .9842 in)
- Gear no. 15 for low/reverse gear shifting.
SERVICE LIMIT 24.977 mm (.9833 in)
WIDTH OF SHIFT FORK ENGAGEMENT GROOVE
(low/reverse gear shifting) Check countershaft for wear.
5.30 to 5,40 mm
NEW
(.209 to ,213 in)
1 2 3
SERVICE LIMIT 5,50 mm (.217 in)

Check free pinions no. 14, no. 16, no. 19 and

no. 23 for wear.
vmr2006-022· 123_B

1, MAG side
4--1 2, Free pinion bearing
3, cvr side

COUNTERSHAFT
SERVICE LIMIT
2 MAG side 17,990 mm (.708 in)
Free pinion bearing 24.970 mm (.983 in)
CVT side 24.970 mm (.983 in)

Check bevel gear shaft.

vmr2006-022-080_8

TYPICAL
1. Micrometer
2, Free pinion

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

1 1 Clean mating surface of housing before taking

measurements using a combination of Loctite
chisel (gasket remover) (PIN 413 708 500) and a
brass brush . Brush a first pass in one direction
then make the final brushing perpendicularly (90°)
to the first pass cross (hatch) .
CAUTION: Do not wipe with rags. Use a new
clean hand towel only.
vm r2006-022-124 _a

1. Free pinion bearings

BEVEL GEAR SHAFT

SERVICE LIMIT
Free pinion bearing I 24.984 mm (.9836 in)

Shims
Always replace shim by a new one with the same
thickness, when reassembling the gearbox with
existing output shaft no. 1 and bevel gear shaft
no. 11 .

1-----
~. 2

130 --'"!=-----3
vmr2006-022-1 25_a

7. Shim fo r adjusting the bevel gear on center housing side

2. Area whe re wear signs appear
3. Thickness of the shim

Adjustment
Bevel Gear
NOTE: Only necessary if the backlash and axial
clearance of the bevel gear is out of specification
or if parts are changed (output shaft, bevel gear
shaft or housing) .
There are 2 adjustments to perform on the bevel
gear.
- bevel gear backlash on center housing
- bevel gear axial clearance on left housing.
The bevel gear backlash is adjusted by finding the
proper shim thickness E as per following illustra-
tion .
The bevel gear axial clearance is adjusted by find-
ing the proper shim thickness J as per following
illustration.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

vmr200B-022-079_a
-----..1..--- F - - - + - I
1. Mating surface - output shaft
2. Mating surface - left housing

Bevel Gear Backlash Procedure

Use the following course of calculation to deter-
mine the theoretical shim thickness D:
D=B-C-A
B = The distance between the thrust surface of
the bevel gear and the theoretical center of its
taper. This is defined by manufacturer and is
written on the bevel gear shaft.

This bevel gear reference number could be be-

tween - 10 and + 10.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

Take the obtained theoretical shim thickness D

and choose the corresponding shim number E ac-
cording to the following table .

THEORETICAL
SHIM NUMBER
SHIM THICKNESS
E
D
1.20 mm to 1.29 mm
120
(.0472 to .0508 in)
1.30 mm to 1.39 mm
130
CQ512 to .0547 in)
1.40 mm to 1.49 mm
140
(.0551 to .0587 in)
1. Be vel gear 1.50 mm to 1.59 mm
2. Bevel gear reference number 150
(.0591 to .0626 in)
Use following formula to find out value B. 1.60 mm to 1.69 mm
160
(.0630 to .0665 in)
1.70 mm to 1.79 mm
B= ( Bevel gear reference number ) + 37 .8 170
(.0669 to .0705 in)
100
1.80 mm to 1.89 mm
180
(.0709 to .0744 in)
For example : bevel gear reference number = - 3.
B = (- 3/100) + 37.8 = 37.77 NOTE: For example, if the theoretical shim thick-
ness D is 1.53 mm (.0602 in). choose the corre-
C = Distance between the shim thrust surface in sponding shim number 150 E. The shim number
the center housing and the mating surface to 150 represents a nominal value equal to 1.50 mm
left housing . (.0591 in) .
Bevel Gear Axial Clearance Procedure
Use the following course of calculation to deter-
mine the theoretical shim thickness I:
I=F+G-H-A-E
2 F = Distance between mating surface of left
housing to ball bearing inner race .

vm r2006-022-0S1_8

1. Deep gauge - measurem ent C

2. Shim surface in center ho using
3. M ating surface to le ft housing

A = 2 mm (.0787 in) nominal thickness of axial

needle bearing no. 12 .

When the measurements are taken, calculate the

theoretical shim thickness D using the formula (D
= B - C - A).

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r ,

Section 03 ENGINE AND GEARBOX (V490N660N810)

Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

A =2 mm (.0787 in) nominal thickness of axial

needle bearing no. 12.

E = The shim number nominal value as found in

the BEVEL GEAR BACKLASH PROCEDURE.
For example, shim number 150 represents a
value of 1,50 mm (.0591 in).

When the measurements are taken, calculate the

theoretical shim thickness I using the formula (I =
F + G - H - A - E).
Take the obtained theoretical shim thickness I and
choose the corresponding shim number J accord-
ing to the following table .

THEORETICAL
SHIM NUMBER
SHIIVI THICKNESS
J
I
1. Ball bearing inner race 1.22 mm to 1.31 mm
2. Mating surface of left housing 120
3. Depth gauge
(.0480 to .0516 in)
1.32 mm to 1.41 mm
G = Distance between mating surface of center 130
(.0519 to .0555 in)
housing and shim surface.
1.42 mm to 1.51 mm
140
(.0559 to .0594 in)
1.52 mm to 1.61 mm
150
(.0598 to ,0634 in)
1.62 mm to 1.71 mm
160
(.0638 to .0673 in)
1.72 mm to 1.81 mm
170
(0.677 to .0713 in)
1.82 mm to 1.91 mm
180
(0.717 to .0752 in)

For example, if the theoretical shim thickness I

is 1.53 mm (.0602 in), choose the corresponding
2 shim number 150 J .
Bevel gear axial clearance of 0.02 to 0.11 mm
1. Mating surface of ce nter gear housing (.00079 to .00433 in) is included in the above ta-
2. Shim surface ble.
H = Distance between thrust surfaces of bevel Assembly
gear shaft.
The assembly of gearbox is essentially the reverse
of disassembly procedure. However, pay atten-
tion to the following details.
Bearing Installation in Housing
Unless otherwise instructed, never use hammer
to install ball bearings or needle bearings . Use
press machine only.
If necessary heat housings up to 100°C (212°F)
before installing ball bearings or needle bearings .
>1m r20OS·022-084

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Section 03 ENGINE AND GEARBOX (V490N660N81 0)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

.& WARNING
Clean oil, outside and inside, from housing
before heating.

Place new bearing in freezer for 10 minutes before

installation.
Use a suitable installer for installing ball bearings 1. Needle bearing installer
of counters haft and bevel gear. 2. Installer handle

NOTE: Place gearbox housings on a wood stand

before installing bearings no. 34 and no. 36.
Install countershaft needle bearing no. 33 with the
main shaft needle bearing installer (PIN 529 035
762) and the installer handle (PIN 420 877 650) in
right housing.
3
1 2 1

vmr2006-D22-114_a

1. Needle bearing installer

2. Installer handle

1. Bevel gear needle bearing

2. Center housing
3. Needle bearing installer
4 4. Installer handle

Install new oil seals with the proper installer (refer

to OIL SEALS above).
3 Other Gearbox Components
Fit intermediate gear no. 23 with needle bearing
no. 22 on intermediate gear shaft no. 21.
NOTE: Fit gear with collar facing to housing side
on the intermediate shaft.

vmr20otl-022-050_a

1. Countershaft needle bearing

2. Right housing
3. Needle bearing installer
4. Installer handle

Install bevel gear needle bearing no. 35 using the

bevel gear needle bearing installer (PIN 529 035
763) and the installer handle (PIN 420 877 650).

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

2 1

i
1
1. Washer
2. Index lever
3. Step ring
4. Index spring

Install parking lock lever, teeth showing to coun-

\lmr20D6-022-089_"
tershaft.
1. Intermediate gear
2 Collar facing housing
3. Needle bearing
4. Intermediate gear shaft

Press intermediate gear shaft in the left housing.

vmI2006-022-066_a

1. Parking lock lever

Place shim of CVT side on bearing.

1. Intermediate gear shaft

Fit support flange no. 37 in the left housing and

install index lever.
NOTE: Fit step ring into index lever.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AI\ID 4X4 COUPLING UNIT)

vmr2006·022·092_a

vmr2006-022-094_a
1. Shim CVT side
1. Countershaft
Place reverse gear with needle bearing and thrust 2. Low gear
3. High gear
washer.
NOTE: Check if the screw to secure countershaft Install a new shim no. 17 onto bevel gear shaft,
bearing is installed. fork side.
Install bevel gear with sliding gear assembly to-
gether with shift fork .
NOTE: If a new bevel gear and output shaft are
used, it is necessary to verify the shim adjustment
prior to finalize assembly. Refer to ADJUSTMENT
above in this section. If the existing bevel gear is
used, it is mandatory to use a new shim no. 17
with the same thickness, a new needle bearing
no. 12 and shim no. 13.

1. Reverse gear
2. Needle bearing
3. Thrust washer
4. Countershaft bearing screw

Install countershaft with low gear and high gear

assembly.
vmr2006"'()22-095_a

1. Bevel gear
2. Sliding gear
3. Shift fork

Install a new needle bearing and shim.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

oil( ,

4
vmr2006-022- 101_a

1. Parking stop location

2. Reverse stop location
3. Neutral stop location
4. High gear stop location
1. Needle bearing 5. Low gear stop location
2. Shim
Install shift shaft assembly.
Insert a flat screwdriver in the slot of the index NOTE: Marks on shift drum/isolating washer and
lever, turn screwdriver clockwise and install shift shift shaft must align .
drum on neutral position as per following illustra-
tion.

1. Shift shaft assembly

2. Isolating washer
1. Index lever 3. Marks
2. Shift drum
3. Neutral position
Install shift fork no. 25 then engage both shift
fork pins in their corresponding groove on the shift
drum.
NOTE: Move sliding gears to facilitate engage-
ment of pins inside grooves.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

Do not apply in excess as it will spread out inside

gear housing.
1. Shift fork pins
2. Sliding gear NOTE: It is recommended to apply this specific
sealant as described here to get a uniform appli-
Install shift fork shaft no. 24. cation without lumps. If you do not use the roller
NOTE: Run all gears as a final function check be- method, you may use your finger to uniformly dis-
fore installing center housing. tribute the sealant (using a finger will not affect
the adhesion).
l\Jow, close the housings by doing the following:
Hand-torqued gear housing screws in a crisscross
Clean all metal components in a solvent. sequence. Repeat procedure, retightening all
Gearbox housing mating surfaces are best screws to 10 N-m (89 Ibf-in).
cleaned using a combination of Loctite chisel Install O-ring no. 31 including distance sleeve
(gasket remover) (PIN 413 708 500) and a brass no. 32 on countershaft CVT side.
brush. Brush a first pass in one direction then
make the final brushing perpendicularly (90°) to CAUTION: Place O-ring including distance
the first pass cross (hatch). sleeve right away. Chamfered bore of distance
sleeve has to face the gearbox.
CAUTION: Do not wipe with rags. Use a new
clean hand towel only.
IMPORTANT: When beginning the application of
the gear housing sealant, the assembly and the
first torquing should be done within 10 minutes.
It is suggested to have all you need on hand to
save time.
Use Loctite 5910 (PIN 293 800 081) on mating 2
surfaces.
Use a plexiglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in)),
available in arts products suppliers for printing, and
roll the sealant to get a thin uniform coat on the
plate (spread as necessary). When ready, apply
the sealant on gear housing mating surfaces.

vmr2006-022-100_a

COUNTERSHAFT END CVT SIDE

1. O-ring
2. Distance sleeve
3. Countershaft end CVT side

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

Refer to OUTPUT SHAFT AND COUPLING MECH-

ANISMto install these components. Measure the
output shaft backlash.

Installation
The installation is the reverse of the removal pro-
cedure.

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sa,les@.mldwe, ' manrUI,a s.c,o,m

www.lm idwestlm aln uas.com

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 10 (SHIFTER)

SHIFTER
SERVICE PRODUCTS
Description Part Number Page
Loctite 243 (blue).................................................................. 293 800 060 ......................................... 169

10 N·m
(89Ibf·in)

vrnr2006-046-007 _a

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 10 (SHIFTER)

GENERAL
Before performing any servicing on the transmis-
sion linkage system, be sure the transmission
lever is on NEUTRAL position and the parking
brake is applied.
During assembly/installation, use the torque val-
ues and services products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for 1. Tension spring
complete procedure. 2. Transmission lever
3. Link rod

&. WARNING - Detach tie-rod end from bracket.

Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins,
etc.) must be replaced with a new one.

PROCEDURES
TRANSMISSION LEVER
1. Tie-rod end
Shifter Lever Removal 2. Transmission lever
To remove the transmission lever, do the follow-
Ing: Unscrew link rod bolt.
- Place transmission lever in NEUTRAL position.
- Apply parking brake.
- Unscrew the transmission lever handle.

1. Link rod bolt

2. Link rod
3. Transmission lever

Pull link rod out of transmission lever bracket, pay

attention not to loose bushings located each side
1. Transmission lever handle of link rod anchor.

- Remove the RH side panel and the console.

Refer to BODY.
- Detach tension spring from bracket.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 10 (SHIFTER)

" --2

vmr2006-046-018_A

vmr2006-046-014y.
A. 82 mm ± 1 mm (3.228 in ± .039 in)
1. Link rod anchor
2. Bushings

LINK ROD
Shifter Lever Inspection
Link Rod Removal
Check the transmission lever for bending or
cracks. Remove RH side panel and rear engine cover.
Check the tie-rod at the end of lever. Remove link rod from shifting plate.
Replace the lever or the tie-rod if necessary.

Shifter Lever Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Place a washer on both sides of bracket when in-
stalling tie-rod end on bracket.

1. Shifting plate
2. Link rod

At the other end of link rod, unscrew link rod bolt.

1. Washers
2. Tie-rod end
3. Transmission lever

Apply Loctite 243 (blue) (PIN 293 800 060) on

transmission lever threads before installing the
handle.
If the tie-rod end replacement is necessary, use 1. Link rod bolt
2. Link rod
the following illustration to position the tie-rod 3. Transmission lever
properly.
Pull link rod out of transmission lever bracket, pay
attention not to loose bushings located each side
of link rod anchor.

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 10 (SHIFTER)

••·........-2

.....-1

vmr2006-046-014_a

1. Link rod anchor

2. Bushings
- Torque jam nuts, one on both ends of link rod.
- Verify if the transmission lever moves into the
Link Rod Inspection PARK and LOW slots. If not, the gearbox was
Check link rod for bending or cracks. not engaged on t\IEUTRAL. Place gearbox on
NEUTRAL position and redo the procedure.
Check ball bearing in link rod anchor. The bearing
should turn smoothly and freely. - Install removed parts and test drive to confirm
all is working well.
~.

SHIFTING PLATE
Shifting Plate Removal
NOTE: Do not remove shifting plate needlessly.
Remove link rod from shifting plate.

1. Link rod anchor

2. Ball bearing

Check tie-rod end for wear and excessive play.

Replace all defective parts.

Link Rod Installation

If no new parts are installed, reverse the removal
procedure. 1. Shifting plate
2. Link rod
If a new link rod, link rod anchor or a new tie-rod
end is installed, do the following:
NOTE: Mark the location of shifting plate before
- Screw the tie-rod end and the link rod anchor removing it from shift shaft.
completely on the link rod.
Install the tie-rod end on shifting plate and link
rod anchor on transmission lever.
Be sure gearbox is engaged on NEUTRAL posi-
tion.
Turn link rod until the transmission lever is locat-
ed in the middle of the NEUTRAL slot.

1. Mark both parts position

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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 10 (SHIFTER)

Remove shifting plate bolt.

1. Shifting plate bolt

Shifting Plate Inspection

Check shifting plate for cracks, bending or other
damages. Replace if necessary.

Shifting Plate Installation

The installation is the reverse of the removal pro-
cedure . However, pay attention to the following.
Be sure the gearbox is engaged on NEUTRAL be-
fore performing this procedure.
Align shifting plate mark with shift shaft mark. If
new parts are used, align shifting plate slot with
the shift shaft location without splines.
Install all removed parts and test drive to confirm
all is working well.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 01 (OVERVIEW)

OVERVIEW

FRONT

IDLE
BY BASS
VALVE

CAPS
ECM MAPTS

CPS Crankshaft Position Sensor

TPS Throttle Position Sensor
inputs CTS Coolant Temperature Sensor
~IECM OPS Oil Pressure Switch
CAPS Camshaft Position Sensor
outputs MAPTS Manifold Air Pressure and
----+ IECM ECM
Temperature Sensor
Engine Control Module

vmr2006-012-002_aen

ENGINE MANAGEMENT SYSTEM OVERVIEW

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 01 (OVERVIEW)

OPERATING PRINCIPLE
A highly advanced engine management system
(EMS) has been used to ensure a high power out-
put with cleaner combustion.
There are 3 main systems in interaction with the
engine management system (EMS):
1. Air induction.
2. Fuel system.
3. Electrical system.
NOTE: The cylinders are referenced as 1 (front)
and 2 (rear).

1. Intake manifold
2. Throttle body
3. Idle bypass valve

Intake Manifold
The intake manifold is mounted on the top of the
engine on both cylinder heads. It provides support
for the throttle body, fuel injectors, the fuel rails
and the MAPTS (manifold air pressure and tem-
perature sensor).
vm r2006-012-003_a
The air intake manifold is a resonator between
the throttle body and the air intake at the cylinder
1. Cylinder 1 (front)
2. Cylinder 2 (rear) heads.

FUEL SYSTEM
AIR INDUCTION
When the intake valve reaches the correct posi-
Air flows through air silencer, air filter, throttle tion, the ECM (engine control module) opens the
body, intake manifold and then goes into combus- fuel injector and fuel is discharged into the intake
tion chamber. port at the air intake manifold by the high fuel pres-
sure inside the fuel rail. The air/fuel mixture enters
Throttle Body then the combustion chamber through the open
The 46 mm throttle body is mounted on top of in- intake valve. This mixture is then ignited by the
take manifold. Fitted on the throttle body, there spark plug.
is the TPS and the idle bypass valve which allows
the ECM to control the idle speed while the throt-
tle plate is closed.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 01 (OVERVIEW)

Fuel Pressure Regulator

A fuel pressure regulator controls the pressure in
the system and allows excess fuel to return to the
fuel tank. Refer to FUEL SYSTEM.

1. Fuel rail (2)

2. Injector (2)
3. Throttle body
4. Ignition coil
5. Manifold air pressure and temperature sensor (MAPTS)
6. Intake manifold

Fuel Rail
Two fuel rails, one for each injector, are mounted
on the intake manifold. The fuel rails ensure all the vmr2 006 .Q 12-007_a

time, that enough fuel can be delivered to the fuel 1. Fuel pressure regulator
injectors. The fuel rails are fed by the fuel pump
with the properly regulated fuel pressure.
Fuel Filter
Fuel Injector The fuel filter is located between engine and fuel
Two fuel injectors (one per cylinder) are used to tank . Refer to FUEL SYSTEM.
inject fuel into the intake port of the cylinder head.

Fuel Pump Module

The fuel pump module is underneath fuel tank .
The module includes fuel pump, fuel pressure reg-
ulator and fuel level sensor. Refer to FUEL SyS-
TEM.

1. Fuel filter

1. Fuel pump module

2. In-line fuel filter

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 01 (OVERVIEW)

ELECTRICAL SYSTEM The ECM features a permanent memory that will

keep the programmed ignition key(s) active, fault
A communication link (CAN lines) is used to com- codes, customer information and other engine in-
municate between the ECM and the multifunction formation, even when the battery is removed from
speedometer. CAN lines consist of a pair of wires the vehicle .
(WHITE/BEIGE and BEIGE/GREEN).
The ECM features a self-diagnostic mode when
The communication link is also used to communi- ignition key is turned on . However, some com-
cate with the B.U.D.S. software . Refer to COM- ponents need the engine to be running so that
MUNICATION TOOLS AND B. U.D.S. SOFTWARE. they can be monitored. Some problems will turn
The speedometer multifunction display can show on a warning lamp or will set the engine in limp
fault codes . Refer to EMS DIAGNOSTIC. home mode . Refer to EMS DIAGNOSTIC section
for more information.
Engine Control Module (ECM)
The ECM controls the electrical system and the Power Distribution
engine management functions, by processing the Three relays are used to distribute power to dif-
information given by various sensors . ferent components. When ignition key is turned
ON and engine run/stop switch is in RUN posi-
tion, relay 2 is energized and in turn, it supplies the
windings of relay 1 and relay 3. The ECM provides
the trigger signal to activate each relay individual-
ly. Refer to the following diagram .
When starting engine, relay 1 and 3 are temporary
disabled to make all power available for the starter,
the fuel pump and the EMS .

R1503m otr215A

TYPICAL
1. ECM

The ECM is located in front of steering column .

R 1: Cooling fan
R2: Main
R3: Accessories

& WARNING
Some components are continuously pow-
ered by the VFB when ignition key is turned
on and engine run/stop switch is in RUN
position. The ECM switches the circuit to the
ground to complete the electrical circuits it
controls. Take this into account when trou-
bleshooting. Always disconnect the battery
prior to disconnecting any electric or elec-
tronic parts.

vmr2006-0 12-009_a

1. ECM location

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~
~I
EMS sensors
ECM fuse (F6) ECM and actuators

Fuel pump Fuel pump

fuse (F5)

Ignition coil (F1) Ignition coils (2)

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Fuel injectors
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signal fuse (F3) Fuel injectors (2)

Accessories Diagnostic
fuse (F4) connector
en
Y Taillbrake light ..O·
CD
n

I Multifunction =
L---;. speedometer
~
'-------:~.I VSS
m
Z
L-_ _~.~I
Starting system
solenoid -Zm
Q

3:
~ »
z
BAT ~ Accessories ~ RELAY 3 Accessories
Headlamps »
Q
fuse (F9) (accessories) fuse (F7)
m
Actuator 003:
2wd/4wd C m
gz
~I
Winch

-Power outlet
,
-g -
CD
C')

_. <
-t
.c:a.
OCD

-,. I RELAY 1
(cooling fan) I COf~~Og ~~
00)
<0)
t mO
:IJ<
ECM <CO
signal m.
...,...,
~

--
~O
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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 01 (OVERVIEW)

ECM and VFB Interaction with the Electrical System

COMMUNICATION I
LINK (CAN) Diagnostic
I
- TPS
I ECM - - WHfTAN-1
- MAPTS
TAN/GNl! - PI LOT LAM PS
- CTS
=I MUltifunctio~1 - DISPLAYS
- OPS speedometer
I
- CPS I VFB ~

- IDLE BYPASS
VALVE
- IGNITION KEY
- DESS
- START SWITCH
- OVERRIDE
SWITCH
- BRAKE SWITCH - LIGHTS
- GBPS - WINCH
(if so equipped)
- ACCESSORIES
- FUEL PUMP r--
- FUEL INJECTORS
- IGNITION COIL
- CAPS TPS = Throttle Position Sensor
- COOLING FAN MAPTS = Manifold Air Pressure and Temperature Sensor
CTS = Coolant Temperature Sensor
- VSS
OPS = Oil Pressure Switch
- RELAYS CPS = Crankshaft Position Sensor
CAPS = Camshaft Position Sensor
VSS = Vehicle Speed Sensor
GBPS = Gearbox Position Sensor
VFB = Vehicle Fuse Block
ECM = Engine Control Module
vm r2008-056-002_aen

ENGINE MANAGEMENT The CPS, the MAPTS and the TPS are the primary
SYSTEM sensors used to control the injection and ignition
timing. Other sensors (like temperature sensors,
The EMS calculates the proper air/fuel mixture and etc .) are used for secondary input.
ignition timing for each cylinder separately.
The ECM is the central point of the engine man- IGNITION
agement system . It reads the inputs, makes com-
putations, uses pre-determined parameters and The ignition system is fully managed by the ECM
sends the proper signals to the outputs for proper which controls the ignition system parameters,
engine management. such as spark timing , duration and firing order to
achieve the proper engine requirements.
ELECTRONIC FUEL INJECTION Ignition Coil
The ECM reads the signals from different sensors A double ignition coil induces voltage to a high
which indicate engine operating conditions at milli- level in the secondary winding to produce a spark
second intervals. at each spark plug independently.
Signals from sensors are used by the ECM to de- The ignition coil receives input from the ECM .
termine the injection parameters (fuel maps) re- Ignition coil is located in front of engine .
quired for optimum air-fuel ratio.
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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 01 (OVERVIEW)

Limp Home Mode

Besides the signals seen above, the ECM mayau-
tomatically set default parameters to the engine
management to ensure the adequate operation of
the engine if a component of the fuel injection sys-
tem is not operating properly. The engine will op-
erate with reduced performance to protect the en-
gine. In more severe cases, the engine RPM will
be limited, also to protect the engine .
These performance-reduced modes allow the rid-
er to go back home which would not be otherwise
possible without this advanced system. Refer
to the COMMUNICATION TOOLS AND B.U.D.S.
SOFTWARE for a complete chart.
When a sensor failure occurs,the ECM will send
out a signal to the multifunction speedometer to
vmr2006-01 2-009_b
warn the operator.
1. Ignition coil location
NOTE: LIMP MODE will be displayed in the multi-
function speedometer and check engine light w ill
Ignition Timing flash. Refer to LIGHTS, GAUGE AND ACCES-
SORIES.
The ECM is programmed with data (it contains ig-
nition mappings) for optimum ignition timing un- When minor fault occurs, the fault and message
der all operating conditions. Using engine operat- in the multifunction speedometer may disappear
ing conditions provided by the sensors, the ECM automatically when the ignition key is turned off
controls the ignition timing for optimum engine op- and kept off until lights turn off in multifunction
eration. There is no adjustment to perform. speedometer, then turned back on.
In the following situations, engine RPM will be
ENGINE MODES OF OPERATION limited.

Engine RPM Limiter CONDITION

MAX ALLOWED
RPM
The ECM will limit the maximum engine speed
when vehicle shifter is in: High engine temperature 4000
- forward position (Hi and La individually) Low battery voltage
- neutral position
Low oil pressure
- park position 5000
Safety fuel cut-off
reverse position.
(TPS or internal memory error)
The ECM uses the CPS and the GBPS (gearbox
position sensor) for this function . High battery voltage 7000
An override switch, on the handlebar, allows the
engine speed to run higher than the RPM limiter Drowned Mode (flooded engine)
when more power is needed in reverse operation . If engine is fuel-flooded and does not start this
Refer to LIGHTS, GAUGE AND ACCESSORIES. special mode can be activated to prevent fuel in-
jection and ignition while cranking . Proceed as fol-
Vehicle Speed Limiter lows to activate it.
The ECM will limit the maximum vehicle speed With ignition key in ignition switch while engine is
both in 2WD and in 4WD. For this purpose, the stopped, press and HOLD throttle lever at WOT
ECM uses the VSS (vehicle speed sensor) and the position.
GBPS (gearbox position sensor). Press the start button. The mode is now on.
Releasing throttle lever will bring back the normal
mode.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 01 (OVERVIEW)

If engine does not start, it may be necessary to re- Engine not running: When engine run/stop
move spark plugs and crank engine with rags over switch is in RUN position and ignition key is left
spark plug holes . Refer to ADJUSTMENT AND in the 01'1 position, the accessories are powered.
REPAIR PROCEDURES subsection . After 15 minutes, the ECM shuts down all func-
tions except multifunction speedometer. ECM
& WARNING and multifunction speedometer will draw power.
When disconnecting coil from spark plug, al- NOTE: If engine starting is desired at this point.
ways disconnect coil from main harness first. it is required to turn ignition key OFF, wait until
Never check for engine ignition spark from speedometer turns OFF then, turn key back ON.
an open coil and/or spark plug in the engine
compartment as spark may cause fuel vapor To prevent battery drain, always turn OFF either
to ignite. ignition key or engine run/stop switch.

DIAGNOSTIC MODE
MONITORING SYSTEM The fault codes are recorded in the memory of the
ECM. They can be checked by using the software
The ECM monitors the electronic components of B.U.D.S.
the fuel injection system and also parts of the
electrical system. When a fault occurs, the ECM Refer to the COMMUNICATION TOOLS AND
sends out signals to the multifunction speedome- B.U.D.S. SOFTWARE subsection .
ter to inform you of a particular condition. Refer
to the COMMUNICATION TOOLS AND B.U.D.S.
SOFTWARE for the fault codes chart.

Battery Voltage Warning Device

When the battery voltage is either too low or too
high, the ECM sends out a signal to the multifunc-
tion speedometer.
NOTE: Either LO BATT or HI BAIT will be dis-
played in the multifunction speedometer and
check engine light will flash. Limp home will be
set.

Low Oil Pressure Warning Device

When the engine oil pressure falls under a certain
level, the ECM sends out a signal to the multifunc-
tion speedometer.
NOTE: LOW OIL will be displayed in the multi-
function speedometer and check engine light will
flash. Limp home will be set.

Brake Monitoring
The ECM monitors the brakes through the brake
switch. If parking brake is activated or the driver
inadvertently keeps the brake depressed for more
than 15 seconds (either when vehicle moves or
notl. the ECI'v1 sends out a signal to the speedome-
ter. BRAKE will be displayed in the multifunction
speedometer.

Shutdown Mode
When engine run/stop switch is turned OFF or
ignition key is turned OFF position, speedometer
will turn off within 15 seconds. All the electrical
system is cut-off.
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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 01 (OVERVIEW)

ENGINE MANAGEMENT SYSTEM FLOW CHART

INPUTS OUTPUTS

Throttle position (TPS) I idle bypass valvel

Crankshaft position (CPS) Fuel pump

ENGINE CONTROL
MODULE (ECM)
Camshaft position (CAPS) Ignition coil

Coolant temperature (CTS) Fuel injectors

Manifold air pressure Communication

and temperature (MAPTS) port (diagnostic)

Oil pressure (OPS)

Battery voltage (BV)

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 02 (EMS DIAGNOSTIC)

EMS DIAGNOSTIC
GENERAL
Here is the basic order suggested to diagnose a
suspected engine management or fuel injection
related problem:
- Check the chart in the TROUBLESHOOTING
section to have an overview of problems and
suggested solutions.
- Check if the engine management system
(EMS) pilot lamp is ON or blinks. If so, use the
B.U.D.S. software and look for fault codes to
diagnose the trouble.
NOTE: When a fault code is present, the EMS
pilot lamp will turn on . When EMS is in limp home Use the mode button and scroll to Engine Hour
mode, the lamp will blink . (EH) on the gauge.
- Check all fuses .
- Check relay(s).
- Check fuel pressure.
- Check spark plugs condition.
- Check all connections of the wiring harness.
- Refer to ADJUSTMENT AND REPAIR PROCE-
DURES section for procedures .
When using the service action suggested in the
Fault section of B.UD .S., the system circuits are
referred to as 2-A-41, which means connector" A" Press and HOLD mode button while au ICKLY tog-
on the ECM and pin 41. The first digit (2) indicates gling HI - LO beam.
connector location in vehicle such as shown in the
NOTE: A minimum of 3 HI - LO toggles must be
WIRING DIAGRAMS.
completed within 2 seconds .
On-Board Diagnostic
Fault codes starting with the letter" P" followed
by 4 digits (P-1234) can be displayed in the
multifunction gauge for troubleshooting.
Proceed as follows :
NOTE: Renegade gauge is shown but procedures
apply to Outlander models as well.
Turn ignition key to lights ON position.
Step 7: Press and hold
Step 2. Quickly toggle HI- LO beam

Ifthere is no P-Code, the" No Active P Codes" will

be displayed .
If there is any P-Code, it will be displayed.
- If there is more than one P-Code, they will au-
tomatically scroll.
- Once the last P-Code is displayed, gauge dis-
plays END then defaults back to normal opera-
tion .

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 02 (EMS DIAGNOSTIC)

FAULT CODES TPS "ADAPTATION FAILURE" Fault

It is caused by the idle position moving out of an
General acceptable range.
The faults saved in the ECM (Engine Control Mod- Following problems can be caused by a TPS
ule) are kept even if the battery is disconnected. "Adaptation Failure" :
IMPORTANT: After a problem has been solved, - Idle speed is out of range.
ensure to clear the fault(s) in the ECM using the - Engine stops when throttle is released quickly.
S.U.D .S. software. This will properly reset the ap-
- Engine runs inconsistent in low partload or low
propriate counter(s) and will also record that the
RPM.
problem has been fixed in the ECM memory.
Many fault codes at the same time is likely to be POSSIBLE CAUSES ACTION
burnt fuse(s) or a faulty relay.
Sensor has been replaced Reset Closed Throttle
For more information pertaining to the fault codes and TPS closed position and Idle Actuator.
(state, count. first, etc.) and report, refer to not reset
S.U.D.S. online help .
Throttle body has been Reset Closed Throttle
replaced and TPS closed and Idle Actuator.
TPS (Throttle Position Sensor) Faults position not reset
Faults which are reported in S.UD.S. fall into two
groups : TPS faults and adaptation faults. These ECM has been replaced Reset Closed Throttle
and TPS closed position and Idle Actuator.
are displayed on the S.U.D.S. system as TPS OUT
not reset
OF RANGE and TPS ADAPTATION FAILURE.
Throttle cable too tight Tighten and reset
TPS "OUT OF RANGE" Fault Closed Throttle and
It is caused by the sensor reading going out of its Idle Actuator.
allowable range. This fault can occur during the Sensor is loose Tighten and reset
whole range of movement of the throttle. Closed Throttle and
To diagnose this fully, it is recommended to oper- Idle Actuator.
ate the throttle through its full range. It is also rec- Throttle bracket is loose Tighten and reset
ommended to release the throttle quickly as this Closed Throttle and
may also reveal a fault that is intermittent. Idle Actuator.
Idle speed screw (tamper Change throttle body.
POSSIBLE CAUSES ACTION proof) worn or loose
Check if connector is Fix. Idle bypass valve replaced Reset Closed Throttle
disconnected from TPS but not reset and Idle Actuator using
Check if sensor is loose Tighten and reset S.U.D.S.
Closed Throttle and
Idle Actuator. Fault Code P2119
Inspect sensor for Replace and reset Wrong ECM. Installed ECM is not appropriate for
damage or corrosion Closed Throttle and the vehicle. Engine will crank but will not start .
Idle Actuator. Refer to PARTS CATALOG for proper ECM accord-
Inspect wiring Repair. ing to vehicle.
(voltage test)
. Inspect wiring and sensor If bad wiring, repair.
(resistance test) If bad TPS, replace and
reset Closed Throttle
and Idle Actuator.
Test sensor operation Replace and reset
(wear test) Closed Throttle and
Idle Actuator.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 02 (EMS DIAGNOSTIC)

FAULT CODE TABLE

DESCRIPTION
ENGINE OF LIMP
P-CODE DESCRIPTION CAUSE ACTION GAUGE
REACTION HOME
EFFECT
P0106 Air pressure Sensing port dirty or Make sure sensor's Engine pilot Limp home No rev limit but
sensor voltage blocked. Sensor fa ilure connector is fully inserted. lamp/check air pressure is
out of range or unexpected reading at Check for approximately engine and set to a defau It
idle. Sensor fallen out of 5 volts between sensor limp home value
intake manifold. connector pins 1 and 3.
Check system circuits
2-A-12, 2-A-28 and 2-A-40.
P0107 Ai r pressure Damaged circuit wires. Make sure sensor' s Engine pilot Limp home No rev limit but
sensor voltage damaged or disconnected connector is fully inserted. lamp/check air pressure is
too low senso~ sensor shorted Check for approximately engine and set to a defau It
to ground. 5 volts between sensor limp home value
connector pins 1 and 3. after a few
Check system circuits seconds
2-A-12. 2-A-28 and 2-A-40.
palOS Air pressure Damaged circuit wires. Make sure sensor's Eng ine pilot Limp home No rev limit but
sensor voltage damaged or disconnected connector is fully inserted. lamp/check air pressure is
too high sensor. sensor shorted Check for approximately engine and set to a default
to a supply. 5 volts between sensor limp home value
connector pins 1 and 3.
Check system circuits
2-A-12, 2-A-28 and 2-A-40.
POlll Air temperature Intermittent air temperature Check system ci rcu its 2-A-7 Engine pilot Limp home No rev
sensor sensor reading or circuit and 2-A-2l . Replace the lamp/check limit but air
functional wires shorted to ground. sensor if necessary. engine and temperature is
problem limp home set to a default
value
POl12 Air temperature Air temperature sensor Disconnect the sensor Engine pilot Limp home No rev
sensor voltage or circuit wires shorted and check for a change lamp/check limit but air
too low to ground. in the fault code. If the engine and temperature is
fault code stays the same. limp home set to a default
look for a short circuit on value
the harness. If the fault
code is different. replace
the sensor. Check system
circuits 2-A-7 and 2-A-21.
POl13 Air temperature Disconnected sensor or Check for disconnected Engine pliot Limp home No rev
sensor voltage sensor's resistance too high. air temperature sensor lamp/check limit but air
too high on the intake. Check the engine and temperature is
air temperature sensor limp home set to a default
for approximately 2000 to value
4200 ohms at 10 to 25°C(50
to 7JOF). Replace the sensor
if necessary. Check system
circuits 2-A-7 and 2-A-2l .
POl16 Engine Intermittent engine Check system circuits Engine pilot No effect No rev limit
temperature temperature sensor reading 2-A-ll and 2-A-27. Replace lamp/check but engine
sensor or circuit wires shorted the sensor if necessary. engine and temperature is
functional to ground. limp home set to a default
problem value
/

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 02 (EMS DIAGNOSTIC)

DESCRIPTION
ENGINE OF LIMP
P-CODE DESCRIPTION CAUSE ACTION GAUGE
REACTION HOME
EFFECT
POl17 Engine Engine temperature sensor Disconnect the sensor and Engine pilot No effect No rev limit
temperature or circuit wires shorted check for a change in the lamp/check but engine
sensor voltage to ground. fault code. If the fault code engine and temperature is
too low stays the same. look for a limp home set to a defau It
short circuit on the harness. value
If the fault code is different,
replace the sensor. Check
for leakage between
sensor's connection and
ground. Check system
circuits 2-A-11 and 2-A-27.
POllS Engine Disconnected sensor or Check for disconnected Engine pilot No effect No rev limit
temperature sensor's resistance too high. engine temperature lamp/check but engine
sensor voltage sensor. Check the engine engine and temperature is
too high temperature sensor for limp home set to a default
approximately 2280 to value
2736 ohms at 19 to 21 °C(66
to 70°F). Replace the sensor
if necessary. Check system
circuits 2-A-11 and 2-A-27.
P0122 Throttle Damaged circuit wires. Check system circuits Engine pilot Engine will
position sensor damaged throttl e position 2-A-24. 2-A-25 and 2-A-39. lamp and not start
voltage too low sensor or damaged Refer to the SERVICE check engine
ECM pins. MANUAL for complete
throttle position sensor
testing procedure.
P0123 Throttle Damaged circuit wires. Check system circuits Engine pilot Engine will
position sensor damaged throttle position 2-A-24. 2-A-25 and 2-A-40. lamp and not start
voltage too high sensor or damaged Refer to the SERVICE check engine
ECM pins. MANUAL for complete
throttle position sensor
testing procedure.
P0231 Fuel pump Damaged or disconnected Check for damaged or Engine pilot Will not run
open circuit fuel pump, damaged disconnected connector lamp and
or shorted to circuit wires. damaged on fuel pump. Check for check engine
ground connectors or damaged approximately 1 ohm
ECM output pins. between pins 5-FP-3
and 5-FP-4 of the fuel
pump connector. Check
for approximately 1 ohm
between pins F5 and 2-8-29.
P0232 Fuel pump Damaged fuel pump, Check for approximately Engine pilot Will not run
shorted to damaged circuit wires, 1 ohm between pins 5-FP-3 lamp and long
battery damaged connectors or and 5-FP-4 of the fuel check engine
damaged ECM output pins. pump connector. Check
for approximately 1 ohm
between pins F5 and 2-8-29.
Check if system circuit
2-8-29 is shorted to 12 V.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 02 (EMS DIAGNOSTIC)

DESCRIPTION
ENGINE OF LIMP
P-CODE DESCRIPTION CAUSE ACTION GAUGE
REACTION HOME
EFFECT
P0261 Cylinder #1 Blown fuse, damaged Check fuse Fl . Check Engine pilot Engine pilot No rev but
injector open or disconnected injector, connections on injector. lamp/check lamp/check cylinder 1
circuit or damaged or disconnected Check for approximately engine and engine and will not work
shorted to circuit wires, damaged 14.5 ohms on injector. limp home limp home properly
ground ECM output pins. Check system circuit
2-A-15. Check connector
CJ connecting the two
harnesses together.
P0262 Cylinder #1 Damaged injector, damaged Check for approximately Engine pilot Engine pilot No rev but
injector shorted circuit wires, damaged 14.5 ohms on injector. lamp/check lamp/check cylinder 1
to battery connector or damaged Check if system circuit engine and engine and will not work
ECM output pins. 2-A-15 is shorted to 12 V. limp home limp home properly
P0264 Cylinder #2 Blown fuse, damaged Check fuse Fl. Check Engine pilot Engine pilot No rev but
injector open or disconnected injector, connections on injector. lamp/check lamp/check cylinder 2
circuit or damaged or disconnected Check for approximately engine and engine and will not work
shorted to circuit wires, damaged 14.5 ohms on injector. limp home limp home properly
ground ECM output pins. Check system circuit
2-A-33. Check connector
CJ connecting the two
harnesses together.
P0265 Cylinder #2 Damaged injector, damaged Check for approximately Engine pilot Engine pilot No rev but
injector sho rted circuit wires, damaged 14.5 ohms on injector. lamp/check lamp/check cylinder 2
to battery connector or damaged Check if system circuit engine and engine and will not work
ECM output pins. 2-A-33 is shorted to 12 V. limp home limp home properly
P0336 High engine CPS signal not plausible, Check for metal deposit Engine pilot Erratic
RPM detected damaged circuit wires, on sensor. Check circuit lamp and engine
damaged connector or between 2-A-5, 2-A-1 9 and check engine behavior
damaged tooth wheel . 4-CPS-1, 4-CPS-2. Replace
sensor if necessary.
P0337 No crankshaft Damaged circuit wires, Check for metal deposit Eng ine pilot No start
signal detected damaged CPS or damaged on sensor. Check circuit lamp and
tooth wheel. between 2-A-5, 2-A-19 and check engine
4-CPS-l,4-CPS-2 . Replace
sensor if necessary.
P0339 Crankshaft CPS signal not plausible, Check for meta I deposit Engine pilot Will not run
signal fault damaged circuit wires, on sensor. Check circuit lamp and
damaged connector or between 2-A-5, 2-A-1 9 and check engine
damaged tooth wheel. 4-CPS-1, 4-CPS-2. Replace
sensor if necessary.
P0344 Cam phase Blown fuse, damaged circuit Check fuse F4. Check for Engine pilot Limp home No rev but
sensor signal wires or damaged sensor. 12 volts between sensor's lamp and calculation of
missing connector pins 1 and 3. check engine RPM will be
Check system circuits less precise.
2-A-20, 2-A-34 and F4. Cold start will
take more
time.
P0351 No ignition Blown fuse, damaged circuit Check fuse F3. Check for Engine pilot Limp home No rev but
output stage wires, damaged connector 2.2 ± 0.3 ohm between lamp/check cylinder 1
cylinder #1 or damaged ignition coil. ignition coil pins. Check engine and will not work
connector HIC connecting limp home properly
the two harnesses together.
Check system ci rcuit 2-A-l .

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 02 (EMS DIAGNOSTIC)

DESCRIPTION
ENGINE OF LIMP
P-CODE DESCRIPTION CAUSE ACTION GAUGE
REACTION HOME
EFFECT
P0352 No ignition Blown fuse, damaged circuit Check fuse F3. Check for Engine pilot Limp home No rev but
output stage wires, damaged connector 2.2 ± 0.3 ohm between lamp/check cylinder 2
cylinder #2 or damaged ignition coil. ignition coil pins Check engine and will not work
connector HIC connecting limp home properly
the two harnesses together.
Check system circuit 2-A-1.
P0480 Engine fan Blown fuse, damaged fan Check fuse F4. Check for Engine pilot No effect
short-circuit relay, damaged circuit approximately 12 volts lamp and
to battery wires, damaged pins or between 3-PF-l D and check engine
damaged ECM output pin. engine ground. Check
system circuit 2-B-3.
P0480 Engine fan Blown fuse, damaged fan Check fuse F4. Check Engine pilot No effect
short-circuit to relay, damaged ci rcuit wires, for disconnected relay or lamp and
ground or open damaged or disconnected pi n 3-PF-l D and 3-PF-1 E. check engine
pins or damaged ECM Check for approximately
output pin. 12 volts between 3-PF-l D
and engine ground. Check
system circuit 2-B-3.
P0505 Idle air control Damaged actuator, Check for approximately Engine pilot Erratic
valve output damaged circuit wires, 50 ohms between pins A lamp and engine
stage cutoff damaged connector or and 0 and also between check engine behavior
memory damaged ECM output pins. pins Band C of the idle
difference air control valve. Check
for damaged circuit wires.
Check system circuits
2-A-35, 2-A-36, 2-A-37 and
2-A-38 . Check for damaged
connector or damaged
ECM output pins.
P0505 Idle air control Damaged actuator, Check for approximately Engine pilot Erratic
va Ive 0 utpu t damaged circuit wires, 50 ohms between pins A lamp and engine
stage fault damaged connector or and D and also between check engine behavior
damaged ECM output pins. pins Band C of the idle
air control valve. Check
for damaged circuit wires.
Check system circuits
2-A-35, 2-A-36, 2-A-37 and
2-A-38 . Check for damaged
connector or damaged
ECM output pins.
P0513 Incorrect DESS key not programmed. Clean DESS key. Program Check Will not
DESS® key Wrong DESS key used . Bad the DESS key. engine/ start
contact on the DESS key. incorrect
DESS key fai lure. DESS

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 02 (EMS DIAGNOSTIC)

DESCRIPTION
ENGINE OF LIMP
P-CODE DESCRIPTION CAUSE ACTION GAUGE
REACTION HOME
EFFECT
P0520 Oil pressure Low oil level. engine leak. Check oil level. Check oil Engine pilot No effect
switch oil pump failure. damaged pressure switch re sistance. lamp and
functional sensor. damaged or shorted With engine stopped. the check engine
problem circuit wires . resistance should be less
than 1 ohm. With engine
running. the resistance
of oil switch should be
infinitely high (OLI. Check
system circuit 2-A-1 0 to
engine ground.
P0562 Battery voltage Battery failure. damaged Check battery voltage for Engine pilot Limp home Rev at 5000
too low circuit wires. damaged 12 to 13 volts with engine lamp/check
or disconnected magneto stopped . Check battery engine/low
and regulator. voltage for 13.8 to 15.0 volts batt and limp
with engine idling . Check home
connections on magneto
and regulator.
P0563 Battery voltage Bad battery. damaged circuit Check battery voltage for Engine pilot Limp home Rev at 7000
too high wires or damaged regulator. 13.8 to 15.0 volts with lamp/check
An external battery charger engine idling . Check engine/hi
may have been used. connections on battery. batt and limp
Replace regulator if home
necessary.
P0600 CAN Bus Off Communication error Check for damaged circuit No ECU No effect
between cluster and ECM between l-CI-23. 4-B-29 communl-
and/or B.U.D.S. and 2-DB-l . Check for cation
damaged circuit between
l-CI-24. 4-B-27 and 2-DB-2.
Replace cluster if necessary.
P0600 CAN ID 514 Communication error Check system circuits No ECU No effect
missing between cluster and ECM 2-B-27 and 2-B-28 with communi-
and/or B.U.D.S. l-CI-23 and 1-CI-24. Refer cation
to the SERVICE MANUAL
for more details.
P0601 Throttle Wrong throttle body Check cable adjustment. Engine pilot
position sensor mechanical position during Check idle stop for wear. lamp/check
adaptation reset of closed TPS or no Make sure throttle plate engine
failure initialization after ECM is against throttle stop.
replacement. Reset closed TPS.
P0601 Module call Damaged ECM or faulty Try updating the ECM. Engine pilot
monitoring programming. If the problem persists. lamp/check
replace the ECM . engine
P0602 ECM not coded Damaged ECM or faulty Try updating the ECM . Engine pilot Will not
programming. If the problem persi sts. lamp/check start
replace the ECM. engine
P0604 RAM fault Damaged ECM or faulty Try updating the ECM. Engine pilot
programming. If the problem persists. lamp/check
replace the ECM. engine
P0605 EEPROM fault Damaged ECM or faulty Try updating the ECM. Engine pilot
programming. If the problem persists. lamp/check
replace the ECM. engine

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 02 (EMS DIAGNOSTIC)

DESCRIPTION
ENGINE OF LIMP
P-CODE DESCRIPTION CAUSE ACTION GAUGE
REACTION HOME
EFFECT
P0605 EEPROM Damaged ECM or faulty Try updating the ECM. Engine pilot
checksum fau It programming. If the problem persists, lamp/check
replace the ECM . engine
P0605 Coding 10 Damaged ECM or faulty Try updating the ECM. Eng ine pilot
checksum fault programming. If the problem persists, lamp/check
replace the ECM. engine
P0605 Coding Damaged ECM or faulty Try updating the ECM. Engine pilot
checksum fault programming. If the problem persists, lamp/check
replace the ECM . engine
P0605 Programming Damaged ECM or faulty Try updating the ECM. Engine pilot
checksum fault programming. If the problem persists, lamp/check
replace the ECM. engine
P0608 Sensor's power Inverted connectors Check system circuits Engine pilot Limp home No rev but
supply vo Itag e between air pressure sensor 2-A-12, 2-A-28, 2-A-40, lamp/check all associated
too low and TPS. Damaged circuit 2-A-24, 2-A-25 and 2-A-39. engine sensors will
wi res, shorted air pressure be set to a
sensor or shorted TPS. default value
P0608 Sensor's power Damaged circuit wires, Check system circuits Engine pilot Limp home No rev but
supply voltage TPS or air pressure sensor 2-A-12, 2-A-28, 2-A-40, lamp/check all associated
too high shorted to a su pp Iy. 2-A-24, 2-A-25 and 2-A-39 . engine sensors will
be set to a
default value
P0616 Starter relay 810wn fuse, damaged or Check fuse F4. Disconnect Engine pilot Will not
open circuit disconnected starter relay, the starter relay and check lamp/check start
or shorted to damaged circuit wires , for approximately 7.3 ohms engine
ground damaged connectors or between the small starter
damaged ECM output pins. relay terminals. Check
for approxi mate Iy 12 volts
between starter relay
OR/GN wire and ground.
Check system circuit 2-8-31.
P0617 Starter relay Damaged solenoid, Disconnect the starter relay Engine pilot Will not
shorted to damaged circuit wires, and check for approximately lamp/check start
battery damaged connector or 7.3 ohms between the small engine
damaged ECM output pins. starter relay terminals.
Check if system circuit
2-8-31 is shorted to 12 V.
P0705 Transmiss ion Improbable combination of Check for disconnected Check Limp home No rev but
range sensor transmission switches. or damaged transmission engine/"E" engine will
circuit contact. Check circuit is displayed react as if the
ma Ifuncti on 2-A-2, 2-A-6 and 2-A-31 . gear were in
(PRNHL) Refer to a.Uo.S. high
TRANSMISSION switch
diagnostic. Refer to
SERVICE MANUAL for
transmission service.
Pll02 Throttle Wrong throttle body Check cable adjustment. Engine pilot
position sensor mechanical position during Check idle stop for wear. lamp/check
adaptation reset of closed TPS or no Make sure throttle plate engine
failure initialization after ECM is against throttle stop.
replacement. Reset closed TPS.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 02 (EMS DIAGNOSTIC)

DESCRIPTION
ENGINE OF LIMP
P-CODE DESCRIPTION CAUSE ACTION GAUGE
REACTION HOME
EFFECT
Pll04 Throttle Wrong throttle body Check cable adjustment. Engine pilot
position sensor mechanical position during Check idle stop for wear. lamp/check
adaptation reset of closed TPS or no Make sure throttle plate engine
failure initialization after ECM is against throttle stop.
replacement Reset closed TPS.
P1116 High temp High temperature of the Refer to SERVICE MANUAL Check Limp home Rev at 4050
cooling liquid. for high engine temperature. engine/hi
temp
Pl148 Safety fuel cut TPS adaptation failure, Check cable adjustment. Engine pilot Limp home Rev at 5000
off detected TPS failure, damaged ECM Check idle stop for wear. lamp/check
memory or battery voltage Make sure throttle plate engine
out of range. is against throttle stop.
Reset closed TPS.
P1202 Oi I pressure low oil level, engine leak, Check oil leveL Check oil Engine pilot No effect
switch still oil pump failure, damaged pressure switch resistance. lamp/check
closed sensor, damaged or shorted With engine stopped, the engine
circuit wires. resistance should be less
than 1 ohm. With engine
running, the resistance
of oil switch should be
infinitely high (OL) Check
system circuit 2-A-l 0 to
engine ground.
P1203 Oil pressure Low oil level. engine leak, Check oil level. Check oil Engine pilot No effect
switch leakage oil pump failure, damaged pressure switch resistance. lamp/check
sensor, damaged or shorted With engine stopped, the engine
circuit wires. resistance should be less
than 1 ohm. With engine
running, the resistance
of oil switch shou Id be
infinitely high (Oll Check
system circuit 2-A-1O to
engine ground.
P1520 Low oil Low oil detected in engine. Refer to SERVICE MANUAL Check Limp home Rev at 4000
for low oil service . engine/low
oil
P1655 DESS® line Damaged circuit wires or Check system circuits Check Will not
shorted to mixed up connection pins. 2-8-38, and 2-8-39 with engine/ start
battery l-CC-C and 1-CC-D. incorrect
DESS
P1656 DESS® line Damaged circuit wires or Check system circuits Check Will not
shorted to mixed up connection pins. 2-8-38, and 2-8-39 with engine/ start
ground l-CC-C and l-CC-D. incorrect
DESS
P1675 Relay 2 shorted Damaged relay, damaged Check for approximately Engine pilot ECM will
to battery circuit wires, damaged 100 ohms between relay lamp/check not do
connector or damaged pins 85 and 86. Check if engine memory
ECM output pins. system circuit 2-8-14 is tracking
shorted to 12 V sequence

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 02 (EMS DIAGNOSTIC)

DESCRIPTION
ENGINE OF LIMP
P-CODE DESCRIPTION CAUSE ACTION GAUGE
REACTION HOME
EFFECT
P1676 Relay 2 open Blown fuse, damaged Check fuse F4 . Check for Engine pilot ECM will
circuit or or disconnected relay, approximately 100 ohm s lamp/check not do
shorted to damaged or disconnected between relay pins 85 eng ine memory
ground circuit wires, damaged and 86. Check system tracking
ECM output pins. circuit 2-B-14. sequence
P1683 CAN RAM Fault Communication error Check for damaged circuit Engine pilot No effect
between cluster and ECM between 1-CI-23, 4-B-29 lamp/check
and/or B.U .O.S. and 2-08-1. Check for engine
damaged circu it between
1-CI-24, 4-8-27 and 2-08-2.
Replace cluster if necessary.
P2119 ECU wrong Incorrect ECU or cluster Install proper recommended Engine pilot Will not
for eng ine. ECU or gauge for vehicle. lamp/check start
engine

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AI\ID REPAIR PROCEDURES)

ADJUSTMENT AND REPAIR

PROCEDURES
SERVICE TOOLS
Description Part Number Page
pliers ............ .. ..... .......... ...... ......... ..... ..... .. ..... ... ... ....... ......... .. 295 000 070 .. ........ .. ... ............. ...... ....... 206
ECM adapter .... ..... ........... ... ..... .... ............. ....... ..... ..... .......... . 420277 010 ... .... .. ..... .. ........ ............. .... 195
tachometer .. .. ......... ..... ...... ... .. .. .... ..... .......... ..... ...... .... .... .. .... 529014500 ...... ... ... .... ....... ... ... .. ... ....... 197
Fluke 111 multimeter .. ... ... ...... .... .... .. ........ .... ......... ..... .. ... .. .. 529 035 868 .. .... .. ..... ..... .... .... .. .. ... 195 , 199
Back probe test wires ......... ... .......... .. ..... .. ..... .. ........... .. .. ... ... 529 036 063 ... .. .. .. ... ...... ...... .. ... ........... . 195

SERVICE PRODUCTS
Description Part Number Page
Loctite 243 ......... ... ......... ............. ... ...... ... .. .. ............ ..... ... ... .. . 293 800 060 ... ...... .... .. .. ... ..... 212, 216, 218

GENERAL & WARNING

Engine problems are not necessarily related to the Always disconnect battery prior to working
electronic fuel injection system. on the fuel system. Always disconnect bat-
tery exactly in the specified order, BLACK (-)
It is important to ensure that the mechanical in- cable first. It is recommended to disconnect
tegrity of the engine/propulsion system is present: electrical connections prior to disconnecting
- good transmission system operation fuel lines.
- good engine compression and properly operat-
ing mechanical components, no leaks etc. & WARNING
fuel pump connection and fuel lines without The fuel system of a fuel injection system
leaks. holds much more pressure than on a carbu-
Check the chart in TROUBLESHOOTING section reted ATV. Prior to disconnecting a hose or to
to have an overview of problems and suggested removing a component from the fuel system,
solutions . follow the recommendation described here.
When replacing a component, always check its
operation after installation . - Use the B.U.D.S. software to release the fu-
el pressure in the system (refer to EMS OIAG-
NOSTlO, Look in the Activation section of the
FUEL SYSTEM software B.U.D .S.
& WARNING
Fuel is flammable and explosive under cer-
tain conditions. Ensure work area is well ven-
tilated. Do not smoke or allow open flames or
sparks in the vicinity.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

& WARNING It is possible that a component seems to operate

in static condition but in fact, it is defective. In
Fuel lines remain under pressure at all times.
this case, the best way to solve this problem is
Always proceed with care and use appropri-
to remove the original part and replace it with one
ate safety equipment when working on pres-
which is in good condition .
surized fuel system. Wear safety glasses.
Proceed with care when removing/installing Never use a battery charger to substitute tem-
pressure test equipment or disconnecting porarily the battery, as it may cause the ECM
fuel line connections. Use the software (engine control module) to work erratically or not
B.U.D.S. to release fuel pressure prior to to work at all. Check related-circuit fuse solidity
removing a hose. Cover the fuel line con- and condition with an ohmmeter. Visual inspec-
nection with an absorbent shop rag. Slowly tion could lead to false results.
disconnect the fuel hose to minimize spilling.
Wipe off any fuel spillage in the engine com-
& WARNING
partment. Do not allow fuel to spill on hot Some EMS components are continuously
engine parts and/or on electrical connectors. powered by the VFB (Vehicle Fuse Block)
Never use a hose pincher on injection system when ignition key is turned on and engine
high pressure hoses. Replace any damaged run/stop switch is set in RUN position. The
or deteriorated fuel lines. ECM switches the circuit to the ground to
complete the electrical circuits it controls.
When the repair is completed, ensure that all Take this into account when troubleshooting.
hoses are connected and secured . Perform the Always disconnect the battery prior to dis-
FUEL PRESSURE TEST and the FUEL TANK connecting any electric or electronic parts.
LEAK TEST as explained in FUEL TANK AND
FUEL PUMP section. Pay particular attention to ensure that pins are not
out of their connectors or out of shape .
& WARNING
When probing terminals, pay attention not to bend
Always perform the fuel pressure test if any the terminal as this could bring a loose connection
component has been removed. A pressure that would be difficult to troubleshoot.
test must be done before turning the ignition
key to ON and setting the engine run/stop & WARNING
switch to RUN. The fuel pump is activated Ensure all terminals are properly crimped on
each time in these conditions. After perform- wires and connector housings are properly
ing a fuel pressure test, use the valve on the fastened.
fuel pressure gauge to release the pressure (if
so equipped). Before replacing an ECM, always check electri-
cal connections . Make sure terminals are prop-
To locate a leak, pressurize the system . Check erly crimped on wires and fastened in housing,
for leaking fuel or fuel odor. Spray soapy water and that they are free of corrosion or moisture.
on all hose connections, fuel rail and injectors. Air Check if wiring harness shows any signs of scor-
bubbles will show the leaking area. ing . Ensure proper electrical connection. Partic-
ularly check ECM ground connections. A "defec-
ELECTRICAL SYSTEM tive module" could possibly be repaired simply by
unplugging and replugging the ECM. The voltage
It is important to check that the electrical system and current might be too weak to go through dirty
is functioning properly: wire pins .
- battery
For the electrical connectors, pay attention to the
- fuses following:
- relay(s) ECM connectors: Do not apply dielectric
- diodes grease or any other lubricant.
- DESS Other connectors: Apply a silicon-based dielec-
- ignition (spark) tric grease or other appropriate lubricant.
- ground connections Ensure that all electronic components are gen-
- wiring connectors uine. Any modification on the wiring harness may
- multifunction gauge. lead to generate fault codes or bad operation.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

NOTE: For diagnostics purposes, use B.U.D .S.

software. See COMMUNICATION TOOLS AND
B.U.D.S. SOFTWARE subsection.
After a problem has been solved, ensure to clear
the fault(s) in the ECM using the B.U.D.S. soft-
ware. Refer to EMS DIAGNOSTIC subsection .

Diagnostic Tools
To perform verifications, use the Fluke 111 multi-
meter (PIN 529 035 868) .

d20277010

Disconnect the desired connector from ECM and

reconnect on the tool connector. Probe required
. I terminals directly in the tool holes.
.; . . t 529035868
,
,I ..
. ~I'
,.~

To easily probe wire terminals through the back of

their connectors, Back probe test wires (PIN 529
036 063) can be used .

Resistance Measurement
When measuring the resistance with an ohmme-
ter, all values are given for a temperature of 20°C
(68°F). The resistance value of a resistance varies
with the temperature. The resistance value for
usual resistor or windings (such as injectors) in-
creases as the temperature increases . However,
.... bs20Q7-014·Q02
our temperature sensors are I\lTC types (Negative
Temperature Coefficient) and work the opposite
They can be inserted at the end of the standard which means that the resistance value decreases
probes of the Fluke 111 multimeter (PIN 529035 as the temperature increases. Take it into account
868). when measuring at temperatures different from
20°C (68°F). Use this table for resistance variation
relative to temperature for temperature sensors.

The most recommended and safest method to

probe ECM connector terminals is to use the
ECM adapter (PIN 420 277 010). This tool will
prevent deforming or enlarging terminals which
would lead to bad ECM terminal contact creating
intermittent or permanent problems.
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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

TEMPERATURE SENSOR TABLE Engine Connector

TEMPERATURE RESISTANCE (ohms) Remove center panel and dashboard. Refer to
BODY.
°C of MAPTS CTS
- 40 - 40 - 45000
- 30 - 22 28000 28000
- 20 -4 14500 15000
0 32 5500 5750
20 68 , 2.500 · 2600
40 104 1200 1200
60 140 600 600
80 176 320 320
100 212 180 180
130 266 90 90
CONVERSION CHART FOR TEMPERATURE SENSORS

The resistance value of a temperature sensor may

test good at a certain temperature but it might be
defective at other temperatures. If in doubt. try a
new sensor.
Also remember this validates the operation of the
sensor at room temperature. It does not validate
the over temperature functionality. To test it. the
sensor could be removed from the engine and
heated with a heat gun while it is stili connected to
the harness to see if the ECM will detect the high
temperature condition and generate a fault code.

ECM Connectors
The ECM connectors are identified by the letter
"A" and 118".

vrY'l12006-O 14·053 _a

TYPICAL - CONNECTOR REMOVAL

Use this illustration to locate the pin numbers on

the engine connector when performing tests.

ENGINE CONNECTOR PIN-OUT (ENGINE SIDE)

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AI\ID REPAIR PROCEDURES)

BASIC ADJUSTMENTS
IDLE SPEED
The idle speed is not adjustable. The ECM con-
trols the idle speed of the engine.
CAUTION: Never attempt to adjust the sealed
idle stop screw. It is calibrated at the factory.
Ifthe screw adjustment is changed, the throttle
body must be replaced.
If desired, the engine RPM can be verified with
the tachometer (P/N 529 014 500).
Install the tachometer wire on spark plug cable.

1. Contact here
2. Free-play here

CAUTION: If there is no free-play at idle posi-

tion, it may cause poor idling and startability
problems. Improper cable adjustment will
cause strain on cable and/or damage cable
bracket or throttle lever at handlebar.
& WARNING
Make sure idle speed stopper contacts throt-
tle cam when throttle lever is fully released at
handlebar.

If adjustment is needed, proceed with adjuster at

handlebar. Adjust to have 2 mm (.078 in) free-
play. When done, slide back cable protector over
THROTTLE CABLE adjuster.
Mechanically adjust the throttle cable as follows.
Handlebar and throttle cable must be at their nor-
mal position. Throttle cable routing must have
been performed before adjusting cable.
Activate throttle lever a few times. Make sure
throttle cam of throttle body rests against set
screw without any tension in the cable.

1. Ad/uster lock nut

2. Adjuster

Turn handlebar side to side and ensure there is still

free-play in each position .
To ensure there is no strain in the cable at wide
open position :

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

Remove throttle body cap and ensure the throttle

cam of throttle body rests against set screw with-
out any tension in the cable .

1. Adjuste r lock nut

2. Adjuster

- Fully depress throttle lever and hold.

- Slacken adjuster lock nut/adjuster until it just
releases lever. 1. Contact here
- Turn adjuster clockwise until it touches lever 2. Free·play here
again .
- From there, tighten adjuster 1/2 turn (to remove Open throttle approximately one quarter then
strain in cable). quickly release. Repeat 2 - 3 times to settle throt-
tle plate. If stopper does not rest against its stop
- Tighten lock nut. lever, perform throttle cable adjustment. Refer to
- Release throttle lever. THROTTLE BODY in this section.
Reinstall throttle body cover. To reset valve and TPS, click on the Reset button
Closed Throttle and Idle Actuator Reset in the Setting section of B.U.D.S.
Perform the Closed Throttle and Idle Actuator ...c-..". _ ~ ....
reset. Vehicle ,. K~ =:]
. ;;etting Mornlonng I..,
..
[<'Iosed ThrOllkl and !/lie AChlBtor-··- - - . - ----------,
CLOSED THROTTLE AND IDLE I . '. I
ACTUATOR RESET Throttle Opening: 0.00 Oeg
NOTE: This operation performs a reset of the val-
ues in the ECM. Beset
Il
This reset is very important. The setting of the
TPS will determine the basic parameters for all
ymr2 Q06.{) 14·084 aen
fue l mapping and several ECM calculations and
the setting of the idle bypass valve will determine NOTE: No message wil l be displayed if operation
the basic parameters for the idle speed control of is successful. If operation is wrong, an error mes-
the engine. sage will be displayed .
NOTE: Reset must be done each time the throttle NOTE: There is no idle speed adjustment to
position sensor (TPS) is loosened or removed or perform. The ECM takes care of that. If TPS is
throttle body is replaced or ECM is replaced. not within the allowed range while resetting the
CAUTION: An improperly set TPS or idle Closed Throttle and Idle Actuator, the ECM
bypass valve may lead to poor engine per- will generate a fault code and will not accept the
formance and emission compliance could setting.
possibly be affected. In addition, improper Start engine and make sure it operates normally
idle bypass valve reset may lead to poor en- through its full engine RPM range. If fault codes
gine starting, improper idle (too low or too
high) and engine stop on deceleration. appear, refer to EMS DIAGNOSTIC section for
more information .
Use the B.U.D.S. software to perform this adjust-
ment.
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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT Ar\ID REPAIR PROCEDURES)

IGNITION TIMING TERMINAL RESISTANCE

The ignition timing is not adjustable. 30 87
0.5 Q max.
I (continuity)
REPAIR PROCEDURES
MAIN RELAY (R2)
Relay (R2) Installation
NOTE: Relays may be inverted by 180 0 at installa-
tion and they will work correctly. Ensure to align
tabs of relay with terminals of fuse holder at instal-
lation.

If relay failed any test, replace it.

D1 DIODE (ECM)
A
The diode D1 is located in the fuse holder.
The fuse holder is located in the front service com-
partment.
vmr2006-020-003
Diode (D1) Installation
R2: Main relay
Validate D1 diode installation as shown.

Relay (R2) Continuity Test

Remove relay.
Use the Fluke 111 multimeter (P/I\J 529035868),
and select the Q position.
Probe relay as follows.

TERMINAL RESISTANCE A

Open circuit
30 87
I (OU

1. Position symbol on diode in same direction as symbol on fuse

holder

Problems Related to Diode D1

ECM does not turn on - Missing diode

- Inverted diode
installation
- Defective diode (open)
ECM does not turn off - Defective diode
smr2007-027-050_a
(engine will not shut off) (shorted)
Connect battery as shown and probe relay again
as follows.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

Diode (D1) Test If diode fail any test, replace it.

Remove diode and lay down on a non-metallic ta-
ble. ENGINE CONTROL MODULE
Set multimeter as shown. (ECM)
Quick Test to Validate ECM Operation
Turn ignition key to ON AND set engine run/stop
switch to RUN.
NOTE: When both switches are ON, it triggers the
ECM and it then turns on.

QUICK INDICATION THAT ECM IS NOT WORKING

(assuming the observed component is working)
Multifunction gauge does not turn on.
Fuel pump does not turn on for approx. 5 seconds
(when turning key on and setting engine run/stop
switch RUN).
Rear light does not turn on.
Headlamp do not turn on (with ignition key at light
position).
Probe diode paying attention to proper polarity. If Engine Stop Running for no Reason
It may be caused by the ECM that is improperly
reset (it restarts).
- If it occurs when using the winch, check diodes
D5 and D6. Refer to LIGHTS, GAUGE AND
ACCESSORIES section for diode testing proce-
dure.
- If it occurs at any time, check diode D2. Refer
to STARTING SYSTEM section for diode testing
procedure.

ECM Power Supply and Ground Pinout

FUNCTION COI\JI'JECTOR PIN
vmr2006-020-006_a
Power 12 Vdc B-11
MUST BE OPEN CIRCUIT
Grounds B 1, B2, B32 and B41

ECM Power Supply Verification

BAT

Ignition and
engine stop
switches ON

vmr2006-020-006_b

MUST BE AROUND 0.5 V

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

NOTE: If engine is not started within 15 minutes - If voltage is good, check ignition switch, engine
after ignition switch was turned on and engine run/stop switch and their wiring/connectors.
run/stop switch was set to RUN, ECM will go in Refer to IGNITION SYSTEM. If they test good,
sleep mode and will cut power to everything ex- check signal side of relay as described under
cept the multifunction gauge. To exit that mode, IF ECM WORKS WHEN BYPASSING RELAY
turn off ignition key and WAIT until multifunction below.
gauge turns off then, turn ignition key back on. - If voltage is not good, read voltage as follows.
Check fuses F8 and F6.
Check main relay R2.
To check relay operation, remove relay and bypass
it with a jumper between terminals as shown.

vmr2007-043-003_a

ECM CONNECTOR "8" MEASUREMENT

If ECM does NOT Work when Bypassing
Relay R2: PIN VOLTAGE
Problem is on the contact side of relay circuit,
check wiring/connectors from battery to ECM.
B-11 I Battery grou nd Battery voltage

- Disconnect connector "8" from ECM.

- Keep the jumper to bypass relay.

If voltage is now good, check ECM ground cir-

cuits and battery ground.
- If voltage is still not good, remove jumper in
vmr2006-014.()76_a
fuse box and read voltage as follows.

- Read voltage as follows.

ECM CONNECTOR "8" MEASUREMENT

PII\,J VOLTAGE
B-1 (ground) I B-11 12 Vdc

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

Remove center panel and dashboard. Refer to

BODY.
Disconnect both connectors from ECM.
Unscrew retaining screws and remove the ECM
from vehicle.

vmr2006-014-076_b

- If voltage is now good, check wiring/connectors

from fuse block to ECM.
- If voltage is I\JOT good, check wiring/connectors
from battery to fuse block.
If ECM WORKS when Bypassing Relay:
Relay is likely to be faulty. Test relay. Refer to
MAIN RELAY (R2) above in this section.
If relay tested good, problem is on the input sig-
nal of relay circuit. Do the following:
- Check diode D1. Refer to DIODE 01 (ECM)
above in this section.
- Check wiring/connectors from battery to fuse Install the new ECM to the vehicle.
block. Reconnect connectors to ECM, and then battery
- Check wiring/connectors from fuse block to cables.
ECM. Transfer the data from the previous ECM to the
- Try a new ECM. new one using B.U.D.S. then proceed with the
required resets and reprogram ignition key(s), if
ECM Replacement you were unable to transfer the data.
Prior to replacing a possibly faulty ECM, ensure NOTE: If data cannot be transferred, manually en-
that all the recommendations in the general intro- ter information in Vehicle tab and Engine serial
duction of this section have been carried out. Al- number in History, Part Replacement.
so, check ECM power supply and all grounds for
proper contact/cleanliness and tightness.
IMPORTANT: When the ECM is replaced, the igni-
tion key(s) and the Closed Throttle and Idle Actu-
ator must be reprogrammed/reset. Refer to their
specific section for adjustment.
To allow transferring the previous recorded infor-
mation from the old ECM to the new one, use the
B.U.D.S. software. Select ECM, Replace in the
Module menu. Follow instructions in its help sys-
tem.
NOTE: If the old ECM still works, its information
must be read by B.U.D.S. before being removed
from the vehicle in order to transfer vehicle infor- vmr2006-014-081_aen

mation and history to the new ECM.

Disconnect battery cables.

Battery BLACK negative cable must always be

disconnected first and connected last.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMEI\IT AND REPAIR PROCEDURES)

Activation
Rartr~~---------------------.

F Engloe,
r ECM
(' dlu5tet

$e11al Number.

vmr2006-014-082_en

After performing the required resets, ensure to

clear all faults from the newly replaced ECM. You should hear the injector working.
Security Exchange This will validate the injector mechanical and elec-
trical operation.
If you get the message shown in the following
illustration, the installed ECM is not appropriate If the injector does not work, check injector power
for the vehicle or its calibration has been changed. supply.
Engine will crank but will not start. Voltage Test
Disconnect the connector from the injector.
NOTE: If connector is hard to unlock, gently use a
screwdriver to release connector.

If it occured just after replacing the ECM, refer to

PARTS CATALOG to get the proper ECM accord-
ing to vehicle.
If you get this message after you have purposely
changed the ECM calibration, Click "Yes" to up-
date the system and to allow engine starting.
CAUTION: It is not recommended to start an
engine with the wrong calibration.

FUEL INJECTOR
NOTE: It is not necessary to activate the injector
Leakage Test since it is continuously powered.
The leakage test is validated when performing the
Use a multimeter and set it to Vdc. Read voltage.
"fuel delivery system diagnostic flow chart" in FU-
EL TANK AND FUEL PUMP.

Electrical Test
Turn ignition key ON and set engine run/stop
switch to RUN.
Using the B.U.D.S. software, energize the fuel in-
jector from the Activation section.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTIVIENT AND REPAIR PROCEDURES)

INJECTOR - If continuity is faulty, check fuse and if ok,

CYLINDER CONNECTOR MEASUREMENT repair/replace wiring going to injector.
WIRE Resistance Test
FRONT VIOLET/ Battery Reconnect the injector connector.
12 Vdc
REAR BLUE ground Disconnect the connector" A" from the ECM and
the engine connector.
Using a multimeter, check resistance value be-
tween terminals as follows.

ENGINE ECM
RESISTANCE @
INJECTOR CONNECTOR CONNECTOR
20°C (68°F)
PIN "A"
FRONT A-15
3 13.8 - 15.2 n
REAR A-33

If supply voltage is good, check ground circuit

between injector and ECM (see WIRING DIA-
GRAMS).
If ground circuit is faulty, repair/replace. vmr2007-043-001_a

- If ground circuit is good, refer to ECM RE- If resistance value is correct. refer to ECM RE-
PLACEMENT. PLACEMENT.
If supply voltage is not good, check continuity If resistance value is incorrect, remove injector
between fuse F3 and injector (see WIRING DIA- connector and check resistance value between in-
GRAMS) . jector pins as follows .
NOTE: Probe fuse exactly as shown. This vali-
dates fuse at the same time . RESISTANCE @
IN~IECTOR INJECTOR PIN
20°C (68°F)
Use a multi meter and set it to n. Read resistance.
FROI\IT
INJECTOR
1 2 13.8 - 15.2 n
REAR
CYLINDER CIRCUIT MEASUREMENT
WIRE
FRONT
VIOLET/
REAR BLUE
Fuse F3 Close to 0 n

- If continuity IS good, check relay and wIring

from battery.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

, 1

If readings are out of specifications, replace injec-

tor. vmr2 006-014-079_a

If readings are good, repair/replace wiring going to FUEL RAIL ASS'Y

injector. 1. Fuel rail
2. Fuel injector
3. Injector top a-ring
Fuel Injector Replacement 4. Injector bottom a-rin g
5. Manifold a-ring
Removal
Before removing the injector, the fuel rail has to be The fuel injector can be easily pulled out of the fuel
removed from the engine. Refer to FUEL RAIL for rail.
the procedure . Installation
For the installation, reverse the removal proce-
dure. Pay attention to the following details.
Apply a thin film of engine oil to O-rings to ease
insertion in rail.
Install new O-rings, if you reinstall a used injec-
tor then insert the fuel injector in place with your
hand. Do not use any tool.
Position the manifold O-ring as shown on injector.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTIVIENT AND REPAIR PROCEDURES)

Carefully insert injector in manifo ld paying atten- Release fuel pressure by running engine until it
tion to the manifold O-ring. Gently push in evenly runs out of gas.
all around while inserting injector. O-ring must be Turn ignition keyoff.
completely inserted and not visible, before finish-
ing pushing injector. Wrap a rag around the inlet hose and release the
quick fitting.

Unscrew rail retaining screws.

Gently pull rail up by hand.

Firmly push injector until it bottoms.

Reinstall fuel rail. See above.

FUEL RAIL
Pressure at fuel rails is supplied and controlled by
the fuel pump module. Refer to FUEL TANK AND
FUEL PUMP for pressure test.

Fuel Rail Replacement

To disconnect fuel rail, cut clamp on fuel hose us-
Removal
ing pliers (PIN 295 000 070). Refer to FUEL TANK
Disable fuel pump using B.U.D.S. Look in the Ac- AND FUEL PUMP for clamp removal/installation
tivation tab. procedures .

I Monlonno T A~~ F_ I ~~ T~~ ,'-7 -' NOTE: If fuel rail is removed purposely to access
fuel injector, it is not necessary to cut hose clamp .
Only to replace fuel rail.
,Ofntobliod 'etli'UlhlAcr

J
k/o)IPt.~ Rehel Installation
" ~, _.J For installation, reverse the removal process but
. '_
, _', _'~ , -.J pay attention to the following ,
_-::.:.:..
ReI=
"" ~ ' Install new clamps using pliers as per removal (if
~~s..:~~,,_.J
fuel rail was replaced) .
..
A thin film of injection oil should be applied to
'

' Irj«t'or Flow M0",",omont" -

,._~ __ J __ ~ O-rings of fuel injector to ease installation of fuel
rail.
I '
Install new O-rings.
mm r2007·106{)08_c
Install fuel rail and evenly tighten screws a little at
a time each side.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTIVIEI\IT AND REPAIR PROCEDURES)

Tightening torque of the rail retaining screws is IMPORTANT: Never attempt to adjust the sealed
6 /\jem (53 Ibfein). idle stop screw. It is calibrated at the factory. If
After securing inlet hose at quick fitting, re-enable the screw adjustment is changed, the throttle
fuel pump using B.U.D.S. body must be replaced.

I ' . .. \'"IIJI
MOniI [ AeMiiOll
L.....: __.-.:..:. J FlUb " I. '. Hoiby

. EHnllblod 0 Oi>l8blod

/~~I Pr.$S~~
~===-I .
I

_ _~:;..
"'I-,-,
~

---.~-~ -j
RoIov,2 I
___~~~:!~.._J

Inj<oct<VFIO>V~
. __~ ' _ _ J

.& WARNING Before replacing any part, check the following as

these could be causing the fault. Perform the test
Perform a fuel pressure test and ensure that
while the engine is off.
there is no leak. Refer to FUEL TANK AND
FUEL PUMP. Run engine and check for leaks. - Throttle cable adjustment too tight. Not return-
ing fully to idle stop.
- Throttle body idle set screw is loose or worn.
THROTTLE BODY - TPS is loose.
- Idle bypass valve is loose.
- Corroded or damaged wiring or connectors.
- Throttle body has been replaced and the Closed
Throttle and Idle Actuator reset has not been
performed.
- ECM has been replaced and the Closed Throt-
tle and Idle Actuator reset has not been per-
formed.

Electrical Inspection
Refer to THROTTLE POSITION SENSOR (TPS)
and IDLE BYPASS VALVE in this section.

Throttle Body Replacement

Removal
To remove the throttle body from engine, proceed
1. Throttle body as follows:
2. Throttle cable attachment - Remove side panels, center panel and dash-
3. Throttle plate
4. TPS board. Refer to BODY.
5. Idle bypass channel
6. Idle bypass valve - Remove air box retaining fasteners.

Mechanical Inspection
Check that the throttle plate moves freely and
smoothly when depressing throttle lever.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

- Disconnect vent hose.

- Detach throttle cable from shifter panel.

- Disconnect TPS and idle bypass valve connec-

tors .
- Remove dart.
- Detach throttle body from intake manifold.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

- Gently move throttle body away to detach throt-

tle cable.
- Remove throttle body cover.
- Detach throttle cable .

Do not reinstall cover yet.

Install throttle body on intake manifold. Ensure to
index throttle body tab with boot notch.

Installation
Installation of the new throttle body is the reverse
of the removal procedure . Pay attention for the
following details.
Properly install cable barrel to throttle cable end.

vmr2006.() 14-065_a

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMEr\IT AND REPAIR PROCEDURES)

For TPS and idle bypass valve replacement pro-

cedures, refer to the respective paragraph in this
section.
Adjustment
When the throttle body has been replaced, per-
form throttle cable adjustment and the Closed
Throttle and Idle Actuator reset. Refer to BASIC
ADJUSTMENTS in this section.

THROTTLE POSITION SENSOR

(TPS)
General
The throttle position sensor (TPS) is a potentiome-
ter that sends a signal to the ECM which is propor-
Clip throttle cable to shifter panel. tional to the throttle shaft angle .

Gently pull throttle cable toward rear to have a gap

between cable and shifter mechanism.

1. Throttle position sensor (TPS)

IMPORTANT: Prior to testing the TPS, ensure that

mechanical components/adjustments of throttle
body are adequate.
The EMS may generate several fault codes per-
taining to the TPS. Refer to EMS DIAGNOSTIC
section for more information.

GAP HERE TPS Wear Test

While engine is not running, activate throttle and
~ WARNING pay attention for smooth operation without physi-
Ensure shifter mechanism does not touch cal stops of the cable .
throttle cable. Depress throttle lever several Using the B.UD.S. software, use the Throttle
times to ensure it properly returns. Opening display under Monitoring.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

H NOTE: The resistance value should change

..
1 smoothly and proportionally to throttle move-
ment. Otherwise, replace TPS .
. .!; If resistance values are co rrect, perform the VOLT-
AGE TEST below.
If resistance values are incorrect, check wiring har-
ness. If wiring is faulty, repair/replace . If wiring is
good, replace TPS.
Reconnect ECM connector.

I/mr2006-0 14-083_aen TPS Input Voltage Test

Slowly and regularly depress the throttle . Ob- Disconnect connector from TPS .
serve the needle movement. It must change Turn ignition key ON and set engine run/stop
gradually and regularly as you move the throt- switch to RUN .
tle . If the needle "sticks" , bounces, suddenly
drops or if any discrepancy between the throttle Check the voltage readings from harness connec-
movement and the needle movement is noticed, tor as follows.
it indicates that the TPS needs to be replaced or
the computer used may be too slow to transfer CONNECTION VOLTAGE
data fast enough for real time display. Pin 1 with battery ground 5.0 V
Pin 2 with battery ground OV
TPS Resistance Test
Ensure TPS is connected to wiring harness . Pin 3 with battery ground 4.75 - 5 V

Disconnect the connector "A" from the ECM .

Using a multimeter, check resistance values on
ECM connector as per the following table .

THROTTLE WIDE OPEN

ECM CONNECTOR IDLE THROTTLE
POSITION POSITION
RESISTANCE Q
PI I\!
@ 20°C (68°F)
A-24 A-25 710- 1300 2600 - 2700
A-25 A-39 1600 - 2400 1600 - 2400
A-24 A-39 2600 - 2700 710 - 1300

If voltage test is not good, chec k/repair wiring

harness . If wiring tests good, refer to ECM RE-
PLACEMENT.
If voltage test is good, everything is in order (as-
suming resistance test was performed).

TPS Replacement
Remove center panel and dashboard. Refer to
BODY.
Loosen two screws retaining the TPS .
Remove TPS.
vmr2007-Q4J..004_a

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AI\ID REPAIR PROCEDURES)

8 10 · 12 ' 14 16 ·18 ·
I !I. ~ ! , I.

Battery VoRage

~
Engine

I8V POSiIion

[Q
.. ,',. '.' . .. '
I . ...... '.
4. 16 . .

I " . . '. .
, Intake Air Pressure .
mm r2 007-189-200_"en

This value implies no maintenance, it is NOT ad-

justable.
The IBV is controlled by a stepper motor (via the
ECM) and the value given is the position of the
THROTTLE BODY
1. Thro ttle position sensor (TPS) stepper motor.
2 . Screws
The value is given in steps. See chart.
Install the new TPS .
IBV STEPS IN B.U.D.S. VALVE POSITION
Apply Loctite 243 (PIN 293 800 060) on the TPS
retaining screws, then torque to 3 N-m (27 Ibf -in) . 0 Fully closed
Rein stall rema ini ng removed parts . Typical values: 25 - 50 (1) Partially open
Proceed w ith the Closed Throttle and Idle Ac- 150 Fully open
tuator Reset. See BASIC ADJUSTMENTS at the
beginning of this sect ion. (1) TypicallBV values at idle are given for a warm
engine and vary depending on altitude, air
temperature and production tolerances .
IDLE BYPASS VALVE (IBV)
An idle bypass valve with good res istance mea- The ECM constantly controls the IBV to maintain
surement can still be faulty. It is also possible its target idle speed when the throttle is closed .
that a mechanical failure occurs which is not de- NOTE : An eng ine giving an IBV position outside
tectable without measur ing the air flow. Replac- of this range is not necessarily faulty. It may on-
ing the idle bypass valve may be necessary as a ly give clues if poor idle or light throttle behavior
test. is experienced . Lower values may indicate a leak-
age in the air intake system; higher values can sug-
IBV Information in B.U .D.S. Software gest a dirty throttle body, obstructed idle by-pass
The I BV pos ition (Idle Bypass Valve) is displayed valve passage etc .
fo r information purposes only.
IBV Resistance Test
Disconnect idle bypass valve from the wiring har-
ness.
Using a multimeter, check the resistance in both
windings.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AI\JD REPAIR PROCEDURES)

If resistance test of valve windings is good, check

continuity of circuits A-35, A-36, A-37, A-38. If not
good, check/repair wiring/connectors.

IBV Visual Inspection

NOTE: Make sure the ignition key is turned off
during the following procedure.
Remove idle bypass valve from throttle body.
Check the piston and bypass channel for dirt/
deposits which can cause a sticking piston.
CAUTION: Always keep the ignition key turned
OFF, while the idle bypass valve is removed.
CAUTION: Do not try to operate the piston of
the idle bypass valve when it is dismounted.
Also do not move the piston by hand. The
drive screw is very sensitive and may be de-
stroyed.
Using a part cleaner, clean idle bypass in throttle
body from contamination then use an air gun to
dry it.
1. Idle bypass valve

Check the resistance between pins as shown.

& WARNING
Always wear eye protector. Chemicals can
IDLE BYPASS VALVE MEASUREMENT cause a rash break out and injure your eyes.

PIN
RESISTANCE n
@ 20°C (68°F)
1 4
50
2 3

1. Clean bore from contamination

Clean all remaining parts and install the idle bypass

valve on the throttle body.
Proceed with the Closed Throttle and Idle Actu-
ator Reset. See procedure in BASICS ADJUST-
MENTS at the beginning of this section.

If the resistance of one or both windings is not

good, replace the idle bypass valve.

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTIVIENT AND REPAIR PROCEDURES)

CRANKSHAFT POSITION Using a multimeter, recheck resistance as per ta-

SENSOR (CPS) ble .

ECM CONNECTOR MEASUREMENT

RESISTANCE Q
PIN
@ 20°C (68°F)
A-5 1 A-19 700 - 900 Q

vm r2006-014-002_8

1. CPS connector

NOTE: Take into account that a CPS fault can be

triggered by bent or missing encoder wheel teeth.
First check fault codes (refer to EMS OIAGNOS-
TIC) then check the teeth condition if necessary v m r2007 -Q43-004_a

(refer to MAGNETO SYSTEM).

If resistance value is correct, refer to ECM RE-
PLACEMENT.
CPS Resistance Test
If resistance value is incorrect, repair the connec-
Disconnect CPS wiring harness connector. Probe
tors or replace the wiring harness between ECM
terminals as shown.
connector and the CPS .
CPS CONNECTOR MEASUREMENT
CPS Replacement
RESISTANCE Q Unplug connector and remove CPS .
PIN
@ 20°C (68°F)
1
1 2 700 - 900 Q

LH SIDE OF VEHICLE
1. CPS connector

If resistance is not within specifications, replace

the CPS . 1. CPS
2. Retaining screw
If resistance tests good, reconnect the CPS con-
nector and disconnect the connector" A" on the Install new CPS and secure harness with a locking
ECM. tie .

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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

Tightening torque of the CPS retaining screws is If voltage is good, do the following test.
10 N-m (89 Ibf-in) . Remove CAPS sensor from engine.
Ensure connector is plugged.
CAMSHAFT POSITION SENSOR
Use a multimeter and set it to Vdc.
(CAPS)
Back-probe connector and read voltage as follows.

CAPS
CAPS CONNECTOR VOLTAGE
CONDITION

Free ORANGE/ I YELLOW/ Close to

GREEN GREEN o Vdc

1. CAPS

CAPS Voltage Test

Turn ignition key ON and set engine run/stop
switch to RUN.
Use a multimeter and set it to Vdc.
Back-probe connector and read voltage as follows.
CAPS
CAPS COI\lI\lECTOR VOLTAGE
CONDITION
CAPS CONNECTOR VOLTAGE
Metallic
ORANGE/GREEN I BLACK/GREEN Battery
voltage object on
ORANGE/
GREEN
YELLOW/
GREEN
Battery
voltage
sensor

If voltage is not good, check/repair wiring/

connectors.
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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTIVIENT AND REPAIR PROCEDURES)

If voltage is appropriate, check/repair wiring/ NOTE: This sensor is a multifunction device.

connector between sensor and ECM. If it is good,
refer to ECM REPLACEMENT. Sensor Pressure Function
If voltage is wrong, try a new CAPS. When engine is started and it runs at idle speed,
the sensor takes the atmospheric pressure and
CAPS Replacement stores it in the ECM. Thereafter, it takes the man-
Unscrew the retaining screw and replace the ifold air pressure at operating RPMs.
CAPS. Ensure to reinstall O-ring. Ensure sensor is correctly installed on intake
manifold. Otherwise, the MAPTS could generate
a fault code for an unexpected sensor range at
idle when it reads the atmospheric pressure .
Remove sensor and check for oil or dirt on its
end and if problem persists, check throttle plate
condition/position and the wiring harness. Per-
form the following tests.
Voltage Test
Check the voltage output from ECM to the pres-
sure sensor.
Turn ignition key ON and set engine run/stop
switch to RUN.
Disconnect plug connector from MAPTS and con-
nect a voltmeter as shown.
1. CAPS
2. Retaining screw MAPTS CONNECTOR MEASUREMENT

Apply Loctite 243 (P/N 293 800 060) on thread and PIN VOLTAGE
torque to 10 N-m (89 Ibf-in) . 1 I 3 5 Vdc

MANIFOLD AIR PRESSURE

AND TEMPERATURE SENSOR
(MAPTS)

If voltage test is good, replace the MAPTS.

If voltage test is not good, check the continuity of
the MAPTS circuit. See below.
Resistance Test
Disconnect the connector "AU from the ECM.
Using a multimeter, check continuity of circuits 12,
28 and 40.
If wiring harness is good, refer to ECM REPLACE-
MENT.
Otherwise, repair the connectors or replace the
1. Manifold air pressure and temperature sensor (MA PTS)
wiring harness between ECM connector and the
MAPTS.
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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

Quick Test Using a multimeter, recheck resistance value be-

Using B.UD.S . software, look the MAPTS from tween pins as shown.
the Monitoring section and read out the pressure
value while engine is stopped. ECM CONNECTOR MEASUREMENT

>-1IIn9
_"II I ....""',1IIIOn I F.....
I " PIN
RESISTANCE Q
@ 20°C (68°F)
..
f11, '1' "'.~ A-7
l A-2 8 2280 - 2740

"q F
oil'

I
. Int.ke Alt
• • ,. It
OIl.

;-,.11""""
vmr2006-014.083_ben

Perform the same test with a new MAPTS and

compare both readings.
Values have to be within ± 3.4 kPa (0.5 PSI).
If old MAPTS's value is out of this range, replace
it. vmr 2 007 ~.a3·004 _8

Sensor Temperature Function If resistance value is correct, refer to ECM RE-

The sensor also monitors the temperature at man-
PLACEMENT.
ifold . If resistance value is incorre ct , inspect/repair/
replace wiring harness between ECM connector
Resistance Test and the MAPTS.
Disconnect the connector from the MAPTS.
Using a multimeter, check the resistance of the
MAPTS Replacement
sensor itself as shown.

MAPTS MEASUREMENT
RESISTANCE Q
PIN
@ 20°C (68°F)
1 l 2 2280 - 2740

If resistance is not within specification, replace the 1. MA PTS

MAPTS. 2. Retaining screw

If resistance tests good, reconnect the MAPTS Disconnect MAPTS connector and remove the
and disconnect the connector "A" from the ECM. MAPTS.
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Section 04 ENGINE MANAGEMENT (V490N660N810)
Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

Apply Loctite 243 (PIN 293800060) on screw then If resistance tests good, reconnect the CTS and
torque to 6 N-m (53 Ibf-in). disconnect the ECM connector AU from the
U

ECM.
COOLANT TEMPERATURE Using a multimeter, recheck resistance on the
SENSOR (CTS) ECM connector as per table.

ECM CONNECTOR MEASUREMENT

RESISTANCE Q
PIN
@ 20°C (68°F)
A-11 I A-27 2280 - 2736

1. Coolant temperature sensor (CTS)

CTS Resistance Test vm r2007-043-004_a

Disconnect the plug connector from the CTS and If resistance value is correct, refer to ECM RE-
check the resistance of the sensor itself. PLACEMENT.
If resistance value is incorrect, repair the connec-
CTS SENSOR MEASUREMENT tors or replace the wiring harness between ECM
RESISTANCE Q connector and the CTS .
PIN
@ 20°C (68°F)
CTS Replacement
1 I 2 2280 - 2740
Disconnect CTS connector and remove CTS.
Install the new CTS and torque to 16 N-m
(142 Ibf-in) .
Reinstall remaining removed parts .
Refill and bleed the cooling system, refer to
COOLING SYSTEM subsection .

If resistance is out of specification, replace the

CTS.

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Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

FUEL TANK AND FUEL PUMP

SERVICE TOOLS
Description Part Number Page
pliers ................... .. .......... .. ......... ........ ........... ... ............... .... . . 295 000 070 .................... .. ........... ... ..... 225
small hose pincher ..... ... ........... .... ......... .. ...... ........ ...... ... ...... . 295 000 076 ........................... .. ............ 221
vacuum/pressu re pump ............................. .... ..... ........ .. ....... . 529 021 800 .. .. ..... ...... ...... ...... .......... .... 222
pressure gauge ... ............... .................... .. ..... ........... ... .. .. ... .. . 529 035709 .... .... .. ......... ...................... 224
T-fitting ......... .. .......... .... ........................................... .... ........ . 529 036 023 .......................... .. ............. 224

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Sectlo~
· (FUELSYST~~ND
0501FUEL TAN FUEL PUMP)

10

~
-~--
3

" rl-2

vmr2008-059-00 1_3

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Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AI\ID FUEL PUMP)

GENERAL .&. WARNING

.&. WARNING Fuel lines remain under pressure at all times.
Always proceed with care and use appropri-
Fuel is flammable and explosive under cer- ate safety equipment when working on pres-
tain conditions. Ensure work area is well ven- surized fuel system. Wear safety glasses.
tilated. Do not smoke or allow open flames or Proceed with care when removing/installing
sparks in the vicinity. pressure test equipment or disconnecting
fuel line connections. Use the B.U.D.S .
.&. WARNING software to release fuel pressure prior to
Always disconnect battery prior to working removing a hose. Cover the fuel line con-
on the fuel system. Always disconnect bat- nection with an absorbent shop rag. Slowly
tery exactly in the specified order, BLACK (-) disconnect the fuel hose to minimize spilling.
cable first. It is recommended to disconnect Wipe off any fuel spillage in the engine com-
electrical connections prior to disconnecting partment. Do not allow fuel to spill on hot
fuel lines. engine parts and/or on electrical connectors.
Never use a hose pincher on injection system
Whenever working on fuel system, always verify high pressure hoses. Replace any damaged
for water or dust infiltration in reservoir. or deteriorated fuel lines.
During assembly/installation, use the torque val-
When the repair is completed, ensure that all
ues and service products as in the exploded
hoses are connected and secured. Perform the
views.
FUEL PRESSURE TEST and the FUEL TANK LEAK
Clean threads before applying a threadlocker. Re- TEST as explained in this section.
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for .&. WARNING
complete procedure. Always perform the fuel pressure test if any
component has been removed. A pressure
.&. WARNING test must be done before turning the ignition
Torque wrench tightening specifications key to ON and setting the engine run/stop
must strictly be adhered to. switch to RUN. The fuel pump is activated
Locking devices (e.g.: locking tabs, elastic each time in these conditions. After perform-
stop nuts, self-locking fasteners, cotter pin, ing a fuel pressure test, use the valve on the
etc.) must be replaced with new ones. fuel pressure gauge to release the pressure (if
so equipped) .
.&. WARNING
The fuel system of a fuel injection system To locate a leak, pressurize the system . Check for
holds much more pressure than on a carbu- leaking fuel or fuel odor. Spray soapy water on all
reted ATV. Prior to disconnecting a hose or to hose connections and injectors . Air bubbles will
removing a component from the fuel system, show the leaking area.
follow the recommendation described here.
INSPECTION
- Use the B.U.D.S . software to release the fuel
pressure in the system. Look in the Activation FUEL TANK LEAK TEST
section.

Ensure to also perform the fuel pressure test.

Fill up fuel tank.

Remove the RH side panel. Refer to BODY.
Install a small hose pincher (P/N 295 000 076) on
vent line (OUTLET side) no. 1.

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Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUI\/IP)

Check Valve and Pressure Relief Valve

Operation
Air can enter fuel tank at all times through INLET
side (check valve).

PINCHER ON OUTLET SIDE

Using the vacuum/pressure pump (P/N 529 021

800), pressurize fuel tank through vent line (INLET
side).

The check valve prevents fuel to flow out.

Air cannot go out through pressure relief valve.

PUMP ON INLET SIDE

Pressurize fuel tank as follows. If pressure in fuel tank builds up and exceeds 2.5-
7.6 kPa (.36-1.1 PSI), pressure reliefvalve opens
TIME WITHOUT and let excess pressure evacuate through OUT-
PRESSURE
PRESSURE DROP LET side.
21 kPa (3 PSI) 3 minutes

If pressure drops, locate fuel leak(s) and repair/

replace leaking component(s) .
To ease locating leak(sl. spray soapy water on
components; bubbles will indicate leak loca-
tion(s).

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Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUIVIP)

Installation
Always reinstall check valve with the black side as
Test
shown.
While tank is still pressurized from the above test,
do the following:
When removing hose pincher, alternately touch
and release end of pressure relief valve no. 7 . You
should feel pressurized air flowing out indicating
relief valve is working.

Always reinstall pressure relief valve according to

arrow on valve as shown.

Ensure grommet no. 9 is not plugged.

Remove fuel tank cap.
Blow air from outlet nipple. Air must freely flows
towards fuel tank neck.

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Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

FUEL PRESSURE TEST Install fuel pressure gauge (P/N 529 035 709) and
T-fitting (P/N 529 036 023) between disconnected
The pressure test will show the available pressure hoses (in-line installation) .
at the fuel pump outlet. It validates the pressure
regulator. the fuel pump and leaks in the system.
NOTE: Refer also to the FUEL SYSTEM DIAG-
NOSTIC FLOW CHART at the end of this section
to help diagnose a fuel system related problem.
Ensure there is no leak from hoses and fittings.
Repair any leak.
Before proceeding to the pressure test ensure the
battery is fully charged. Battery voltage must be
over 12 volts.
Disable fuel pump using B.U.D.S. Look in the Ac-
tivation tab and select Disabled.

krcl Pro Roll()' I· 1. Hitting - In-lin e installation

2. Fuel pressure gauge connection
' . .~_ ~ F._uel.~ _ J
.~ r ~ . Using B.U.D.S., reactivate fuel pump by selecting
~.!_
2 _~ Enabled.
• St,j!! SOf.T".":. __ J

I~"'t'" Flow M&""""rfItr(

-.-J -.-:..:. .::._-1

mmr2007-106-D08_c

Release fuel pressure by running engine until it

runs out of gas.

& WARNING vmr200S-o t 5-109_ben

The fuel hose may be under pressure. Cov- Turn ignition key ON and set engine run/stop
er the fuel line connection with an absorbent switch to RUN and observe fuel pressure . Turn
shop rag. Slowly disconnect the fuel hose ignition key off then back on. Repeat the test.
to release the pressure . Wipe off any fuel
spillage inside engine compartment. FUEL PRESSURE 350 kPa (51 PSI)

Ensure there is enough gas in fuel tank . A rapid pressure drop indicates leakage either
Disconnect outlet hose. from the fuel rail or from the fuel pump check
valve. Check fuel rail for leaks. If it is not leaking
then replace fuel pump.
A slow pressure drop indicates leakage either
from the fuel injector or from the fuel pressure
regulator. Check fuel injector for leaks. If it is not
leaking then replace fuel pump.
If there is no leakage, start engine and observe
fuel pressure . The fuel pressure should be the
same as above.
If pressure is within limits, fuel pump and pressure
regulator are working adequately.
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Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUIVIP)

Release fuel pressure in the system using

B.U.D.S. Look in the Activation tab.
Remove pressure gauge from inlet hose. Recon-
nect inlet hose.

& WARNING
Wipe off any fuel spillage. Fuel is flammable
and explosive under certain conditions. Al-
ways work in a well ventilated area. F01e04A

1. Securing clamp
Reinstall removed parts .

PROCEDURES
FUEL HOSE AND OETIKER
CLAMPS
Fuel Hose Replacement
When replacing fuel hoses, be sure to use hoses
and clamps as available from BRP parts depart-
ment. This will ensure continued proper and safe
operation .

& WARNING
F01B05A

1. Securing clamp in limited access

Use of improper fuel lines could compromise
fuel system integrity.
IN-LINE FUEL FILTER
& WARNING
Replace fuel filter as per maintenance chart sched-
Whenever removing a hose in the fuel sys-
ule . Refer to MAINTENANCE.
tem, always use new Oetiker clamps at as-
sembly. Then, validate fuel tightness by per- Filter Removal
forming a fuel pressure test .
Detach filter from body.

Oetiker Clamp Replacement

To secure or cut Oetiker clamps no. 3 on fuel lines,
use pliers (PIN 295000 070).

Remove Oetiker clamps and pull hoses off.

1. Cutting clamp
Filter Inspection
If fuel filter is suspected to be clogged, it may be
checked as follows.
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Section 05 FUEL SYS"rEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

Using low compressed air, check if fuel filter is

clogged. Air should flow easily through filter. In
doubt, install a new filter.

Filter Installation
Use arrow on filter to position it according to fuel
flow.

FENDER REMOVED FOR CLARITY

Disconnect fue l line no. 5 at quick connect. See

FUEL PUMP below.
Detach in-line fuel filter from body.

TYPICAL

FUEL TANK
Fuel Tank Draining
& WARNING
Never perform this operation when the en-
gine and/or the exhaust system is/are hot.
Never use a hose pincher on injection system
high pressure hoses.

Remove fuel tank cap and siphon gas in an ap- Remove reta ining screws no. 4.
proved fuel container.

Fuel Tank Removal

Remove side panels (refer to BODY! .
Disconnect vent line (OUTLET side) from body.

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Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

- Lay down front of fuel tank on table .

Firmly push on top of fuel tank and hold.
- Pullout protector from tank tab.

Lift frame just enough to extend RH rear shock

absorber. Remove upper screw and move shock
absorber away.

v m r20Q6-O 15-002 _a

1. Tank protector
2. Tank tab

FENDER REMOVED FOR CLARITY Completely remove protector.

Bend fender then pullout the fuel tank through Fuel Tank Inspection
the RH side of vehicle. Pull enough to reach fuel
Inspect fuel tank for any damage or cracks which
pump connector and unplug it.
may result in fuel leaks. If so, replace tank with a
new one. Inspect tank and protector attachment
points for damage. Inspect protector for damage.

Fuel Tank Installation

NOTE: Removing top plate from frame to ease
routing hoses and wiring.
Secure tank into protector. Reverse removal pro-
cedure .
Reconnect fuel pump connector.
Insert the fuel tank into the frame.
Reconnect hoses .
Tighten retaining screws as per following se-
Fuel Tank Protector quence.
To release protector no. 2 from tank:
NOTE: This procedure should be done with parts
at room temperature. Ensure wiring is on the top of fuel tank.
- Work on a stable table.
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Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

OBSERVATION SIGNIFICATION
Battery voltage is - It validates relay R2 supplies
read for approx power to fuel pump .
2 seconds then, - It validates the ground circuit
it will drop to through ECM.
approx. 11 Vdc
- When voltage drops to
approx 11 Vdc, it validates
the ECM works to switch
fuel pump on and off.
Battery voltage is - Fuel pump power supply
not read circuit from relay R2 is
defective.
- Fuel pump ground circuit to
ECM is defective.
- ECM is faulty.

If battery voltage is not read, check the fuel pump

Install gearbox vent tube in its hook on fuel tank
power supply and ground circuits as follows.
protector.
Refuel tank and ensure there are no leaks by per- Fuel Pump Power Supply
forming the FUEL TANK LEAK TEST and the FUEL Recheck voltage as follows.
PRESSURE TEST as described in this section.

FUEL PUIVIP
Fuel Pump Circuit Test
Turn ignition key ON and set engine run/stop
switch to RUN.
Read voltage as follows .

If battery voltage is not read, remove relay R2 and

read voltage as follows.

If voltage is now good, check fuse block wiring

and wiring/connectors between fuse block and fu-
el pump.

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Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

If battery voltage is read, check fuel pump ground CAUTION: While pulling out the fuel pump, pay
circuit to ECM. attention to fuel sensor float arm. Float arm
can get stuck and bend which can reduce the
Fuel Pump Ground Circuit fuel sensor capabilities.
Check continuity of fuel pump circuit going to
ECM. Fuel Pump Installation
For installation, reverse the removal process but
ECM I
FUEL PUMP
CONNECTOR CONNECTOR MEASUREMENT pay attention to the followi ng.
Install a new gasket.
PIN RESISTANCE Q Pay attention to pump orientation as shown.
@ 20°C (68°F)
8-29 I 4 Close to on

If it is good, check ECM. Refer to ENGINE MAN-

AGEMENT
GASKET AND FLANGE NOT SHOWN FOR CLARITY PURPOSES
ONLY
Fuel Pump Removal 1. Fuel lin e on this side
Use B.U.D.S . to release fuel pressure. Look in
Activation tab . Tighten retaining screws as per illustrated se-
quence. For the first sequence from 1 to 10, turn
Remove fuel tank .
screws only to make a contact between parts, do
Remove fuel pump retaining screws no. 6. not tighten yet. For sequence 11 to 19, properly
Gently push pump up as shown. torque to 2 Nem (18 Ibfein).
Install hoses properly on IN and OUT nipples .

GASKET AND FLANGE NOT SHOWN FOR CLARITY PURPOSES

ONLY

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Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

FUEL SYSTEM DIAGNOSTIC FLOW CHART

Fuel pump does not run Fuel pump runs
Turn ignition key ON and set engine for 5 sec. then stops
stop switch to RUN
f
• Check that fuel pump is enabled
in B.U.D.S.
• Check fuses and relays.
· Check ignition switch and
engine stop switch. Install fuel pressure gauge
• Check fuel pump operation.
• Repair or replace if necessary.
I on fuel pressure line
f
~ Turn ignition key ON and set engine Replace fuel
~
,
stop switch to RUN pump module
J

Repair or
f
Fuel pressure less
I
,
Fuel pump runs

Fuel pressure is
f
Fuel pressure more
replace
I than 350 kPa (51 PSI)
I 350 kPa (51 PSI)
I I than 350 kPa 51 PSI)

~
Fails Check fuellinel
rail for leaks I ,
~ OK ~ Crank or Start engine I
Fails
Perform fuel pump test I
OK-
t t
Fast
pressure drop
r Fuel pressure less
than 350 kPa (51 PSI)
I
Fuel pressure more
than 350 kPa (51 PSI)
I
Fuel pressure is
350 kPa (51 PSI)
I
~ Yes ~
Verify fuel
pump check
valve
OK Check
fuellinel
rail for leaks
I
rFails~ Repair or
replace
r-- I FUEL SYSTEM OK' I
FLs
OK
i
t OK
Fa('s

~ Check fuel '--- Perform fuel Replace fuel

injectors pump test pump module
~Fails ~ ~ Retest I
10K

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Section 06 ELECTRICAL SYSTEM
Subsection 01 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE)

COMMUNICATION TOOLS AND

B.U.D.S. SOFTWARE
SERVICE TOOLS
Description Part Number Page
Optional extension cable ........ .. .. .... ..................................... . 529 035 697 ................ .. ................... .. .. 232
Optional extension cable .... ....... ....... ........... ....... ... .. .. ..... .... .. 529035703 .... ...... .. .... ......................... 231
Communication kit. ............................ .. .......... ......... ............. . 529035981 .... .. .. .... .. .. ......................... 231
MPI-2 .......... .... .. ..... ....... ..... ....... ......... .. .... .... ... ..... ................ . 529036018 ............ .. ............... .. .......... 232
Diagnostic cable .................................................................. . 710 000 851 .... ... .................... ... ........... 232

COMMUNICATION TOOLS Connections with Vehicle

Two different MPI (Multi-Purpose Interface) can &. WARNING
be used with B.U.D .S. software: MPI and MPI-2 .
If the computer you are using is connected to
the power outlet, there is a potential risk of
MULTI-PURPOSE INTERFACE electrocution when working in contact with
(MPI) water. Be careful not to touch water while
working with the computer.
PART REQUIRED
PC computer Remove service compartment cover and locate
communication connector.
B.U.D.S. software
Use latest version available on Unplug communication connector.
BOSSWeb
Communication kit (PIN 529 035 981)

Optional extension cable (PIN 529 035 703)

Connect the 6-pin adapter to the vehicle connec-

tor.

MPI Supply
The MPI can use the vehicle power for its supply.
Four AA batteries or an AC/DC power supply can
also be used. Make sure to respect MPI specifi-
cation if a power supply is used .

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Section 06 ELECTRICAL SYSTEM
Subsection 01 (COMMUI\IICATION TOOLS AND B.U.D.S. SOFTWARE)

vdd2 006-001-103

Use S.U.D.S. software as described further in

B.U.O.S. SOFTWARE.

Connect the diagnostic cable to the 6-pin adapter. MULTI-PURPOSE INTERFACE-2

(M PI-2)
PART REQUIRED
PC computer
S.U .D.S. software
Use latest version available on
BOSSWeb
MPI-2 (PIN 529036018)
vdd200S'()O ' ·105

Connect the other diagnostic cable connector to

MPI connector.
Connect serial cable to MPI connector.

Optional extension cable

(PIN 529 035 697)

Diagnostic cable (PIN 710000851)

Connect remaining serial cable connector to the

serial port of a PC (personal computer).

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Section 06 ELECTRICAL SYSTEM
Subsection 01 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE)

MPI-2 Supply
The MPI-2 uses the USB power of the PC com-
puter for its supply.

Connections with Vehicle

& WARNING
If the computer you are using is connected to
the power outlet, there is a potential risk of
electrocution when working in contact with vdd200G-OO l -151
water. Be careful not to touch water while
working with the computer. Connect remaining IVlPI-2 connector to the USB
port of a PC (personnal computer).
Remove service compartment cover and locate
communication connector.
Unplug communication connector.

m m r20C6-079-200

Use B.U.D.S. software as described further In

B.U.O.S. SOFTWARE.

S.U.D.S. SOFTWARE
Connect diagnostic cable to vehicle connector. B.U.D.S. (Bombardier Utility and Diagnostic Soft-
ware) is designed to program key(sl. to allow
electrical component inspection, diagnostic op-
tions and adjustments such as the closed throttle.
For more information pertaining to the use of the
B.U.D .S. software, use its help which contains de-
tailed information on its functions.
Ensure to use the latest B.U.D .S. version available
on BOSSWeb.
When using the B.U.D.S. software:
Turn ignition switch ON and set engine run/stop
switch to RU N to activate the communication.
- Ensure that 115200 speed is properly selected
in "MPI" under "Choose speed".

Connect remaining connector to MPI-2 connector.

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Section 06 ELECTRICAL SYSTEM
Subsection 01 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE)

A33C5KA

NOTE: If you are using an old PC computer, it may

be necessary to use a slower speed so that the
communication works.
- Ensure that the protocol" Kw2000" is properly
selected in "MPI" under "Choose protocol.

A33C5LA

- Ensure the status bar shows KW2000 with the

number 2 to its right.
NOTE: Number 2 means that 2 "ECU" are con-
nected (ECM and multifunction gauge).

F18HOXA

CONNECTION SUCCESSFUL - ECM AND MULTIFUNCTION

GAUGE ARE CONNECTED

If an "X" is shown, this means that no commu-

nication between MPI and ECM/multifunction
gauge takes place. Possible causes are:
- ECM is not powered-up
- multifunction gauge is not powered-up
- wrong protocol is used
- bad connection between MPI and module.

Changes in ECM
Anytime a change is brought in ECM through
B.U.D.S., there will be an "EMS Tracking" mes-
sage that will say" Remove key from vehicle".
When this occurs, remove the key from ignition
switch and wait until the message disappears
(it lasts approximately 15 seconds after key re-
moval).

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Section 06 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)

IGNITION SYSTEM
SERVICE TOOLS
Description Part Number Page
ECM adapter .. .... ..... .... ..... ... ........ .. ..... .... ....... .... ... .... .... .... ... .. 420277 010 .. .......... ......... ....... ............. 235
Fluke 111 multimeter .... ... ....... .. .. ............ .. .. .... ..... ... ... .......... 529035868 ... .. ........... .... .. ........ ........... 235

GENERAL
NOTE: It is a good practice to check for fault codes
using B.U.D.S. software as a first troubleshooting
step. Refer to EMS DIAGNOSTIC sub section.
The EMS controls the ignition system . For more
information, refer to ENGINE MANAGEMENT
section .
The battery supplies the primary side of ignition
coil through a relay while the ECM completes
the circuit for each cylinder by switching it to the
ground at the right moment. The ECM can detect 420277010

open and short circuit in the primary w inding but

it does not check the secondary winding. PROCEDURES
.& WARNING
IGNITION SWITCH
Never check for engine ignition spark from
an open coil and/or spark plug as spark may Quick Test
cause potential fuel vapor to ignite.
Set engine run/stop switch (located on multifunc-
tion switch housing) in the RUN position .
Ignition Timing Turn ignition switch to ON position .
Ignition timing is not adjustable . If multifunction speedometer turns on (assuming
it works) , the ignition switch and engine run/stop
Tools switch are good .
For best electrical measurement results, use the If multif unction speedometer does not turn on,
Fluke 111 multimeter (P/N 529035 868). check the follow ing in this order:
- ECM is properly powered (refer to ENGINE
MANAGEMENT)
ignition switch
- engine run/stop switch.

529035868 Switch Resistance Test

Remove center panel and dashboard . Refe r to
BODY.
Unplug ignition switch conne ctor.

NOTE: To probe the ECM connector terminals,

use the ECM adapter (P/N 420277 010) to prevent
damaging terminals. Refer to ENGINE MANAGE-
MENTfor more information .

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Section 06 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)

Using a multimeter, test switch as follows.

If out of specification, repair wiring/connector.
If as per specification, continue testing .
Wiring Test Between Ignition Switch
and Multifunction Switch

MULTIFUNCTION
IGNITION RESISTANCE
SWITCH
SWITCH @ 20°C
CONNECTOR
CONNECTOR (68°F)
(MG1)
Pin E Pin 2 Close to 0 it

vmr2005-018-002_a

PINOUT

IGNITION RESISTANCE
PIN
SWITCH @ 20°C (68°F)
OFF Infinite (OU
ON with lights B E
1 n max .
ON without lights

If switch is out of specification, replace with a new

one.
tL-----------{@I--~t
If switch tests good, continue testing.
If out of specification, repair wiring/connector.
Switch Wiring Test (Ignition Function)
Switch Wiring Test (DESS Function)
Wiring Test between Ignition Switch
and Battery Ground Wiring Test Between Ignition Switch and ECM
Unplug ignition switch connector and disconnect
IGNITION SWITCH RESISTANCE connector B from ECM.
CONNECTOR @ 20°C (68°F)
Check continuity of wiring between ignition
Battery switch and ECM as follows .
Pin "B"
I ground
Close to 0 it

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Section 06 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)

IGNITION
ECM RESISTANCE
SWITCH
CONNECTOR @ 20°C (68°F)
CONNECTOR
C 8-39
Close to 0 Q
D 8-38

If any test fails, repair wiring/connector. If switch is out of specification, replace with a new
one.
ENGINE RUN/STOP SWITCH Switch Wiring Test (Ignition Function)
NOTE: The engine run/stop switch is located on Wiring Test Between Multifunction
multifunction switch housing . Switch and ECM
Quick Test MULTIFUNCTION
ECM RESISTANCE
Refer to IGNITION SWITCH above. SWITCH
CONNECTOR @ 20°C (68°F)
CONNECTOR
Switch Resistance Test 8-26 Pin 1 Close to 0 Q
(Ignition Function)
Using a multimeter, test switch as follows.

MULTIFUNCTION
SWITCH RESISTANCE
POSITION
CONNECTOR (MG1) @ 20°C (68°F)
(run/stop)
RUN 1 Q MAX.
1 2
STOP Infinite (Ol)

Switch Resistance Test (DESS Function)

Check multifunction switch as follows .

MULTIFUNCTION ECM RESISTANCE

SWITCH CONNECTOR @ 20°C (68°F)
STOP Close to 0 Q
8-38 8-39
RUN Infinite (Ol)

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Section 06 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)

Activation

vm r2007-046-002_a

If any test fails, check continuity of wiring/

connectors . If they test good, replace switch .

IGNITION COIL

You should hear the spark occurring. In doubt use

an inductive spark tester. If there is no spark, per-
form the following checks.
NOTE: Keep in mind that even if there is a spark
during this static test, voltage requirement is high-
er to produce a spark in the combustion chamber
when engine is running. Ignition coil could be not
working in real operation. Replacing ignition coil
may be necessary as a test.
NOTE: Ensure spark plug cable is on the appropri-
ate cylinder.

Ignition Coil Input Voltage

vmr2000-018- 100
Ensure ignition coil is properly powered as follows .
Quick Test with B.U.D.S. Remove RH inner fender. Refer to BODY.
Using the vehicle communication kit (VCK) with
the B.U.D.S. software, energize the ignition coil
for each spark plug .

Disconnect the 3-pin connector from the ignition

coil and check the voltage supplied by the main
relay.

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Section 06 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)

" mr2007-046-Q0A_a

If wiring harness is defective, repair the connector

or replace the wiring harness between ECM con-
nector and the ignition coil.
Turn ignition switch to ON and set engine run/stop
switch to RUN. If wiring harness is good, refer to ECM in ENGINE
MANAGEMENT.
Using a multimeter, read voltage.
Ignition Coil Resistance Test
IGNITION COIL
VOLTAGE An ignition coil with good resistance measure-
CONNECTOR
ment can still be faulty. Voltage leak can occur
Pin 2 with battery ground 12 V at high voltage level which is not detectable with
an ohmmeter. Replacing the ignition coil may be
necessary as a test.
Disconnect ignition cable from spark plug.
Primary Windings
Reconnect connector to ignition coil.
Remove center panel and dashboard . Refer to
BODY.
Disconnect engine connector.

+
smr 2005-05 7-0 16_a

TYPICAL

The voltage should be 12 V.

If 12 V is NOT read, check continuity of ignition
coil supply circuit.
If 12 V is read, disconnect the ECM connector" A"
and check the continuity of appropriate circuit.

CIRCUIT CIRCUIT
NUMBER NUMBER
COMPONEI\JT
(ignition coil (ECM
connector) connector)
Cylinder 1 (front) 1 A-1 Disconnect" A" connector from ECIVl.

Cylinder 2 (rear) 3 A-41

Using a multimeter, check resistance in primary
windings as follows.

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Section 06 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)

ECM Troubleshooting Fouled Spark Plug

PRIMARY ENGINE RESISTANCE
CONNECTOR @ 20°C (68°F) Fouling of the spark plug is indicated by irregular
CIRCUIT CONNECTOR "Au
running of the engine, decreased engine speed
Front A-1 due to misfiring, reduced performance, and in-
Pin 2 .3 - .6 Q creased fuel consumption. This is due to a loss
Rear A-41
of compression. Other possible causes are: pro-
longed idling or low-speed riding, a clogged air fil-
ter, incorrect fuel, defective ignition system, in-
correct spark plug gap, lubricating oil entering the
combustion chamber, or too cold spark plug. The
plug face of a fouled spark plug has either a wet
black deposit or a black carbon fouling . Such coat-
ings form a conductive connection between the
center electrode and ground.

Spark Plug Analysis

vrTl r2007-046-005_5

If any resistance is not good, replace ignition coil.

If the windings test good, check wiring/connec-
tors and if adequate, try a new ECM.
Secondary Windings
Due to the integrated diode, it is not possible
to take any resistance measurement of the sec-
ondary winding. AOOEOAA 2 3
TYPICAL
SPARK PLUG 1. Overheated (light grey, white)
2 . Normal {/ight brown, brown)
3. Fouled (black, wet or dry, dark deposits, grey, melted coating)
Spark Plug Removal
Unplug the spark plug cable . The plug face reveals the condition of the engine,
operating condition, method of driving and fuel
Clean the spark plug area with pressurized air. mixture . For this reason it is advisable to inspect
Unscrew spark plug. the spark plug at regular intervals, examining the
plug face (i.e. the part of the plug projecting into
the combustion chamber).

Spark Plug Installation

Prior to installation make sure that contact sur-
faces of the cylinder head and spark plug are free
of grime.
- Using a wire feeler gauge, set electrode gap as
specified in TECHNICAL SPECIFICATIONS.
- Apply antiseize lubricant over the spark plug
threads to prevent possible seizure.
- Hand screw spark plug into cylinder head and
tighten with a torque wrench and a proper sock-
TYPICAL
1. Spark plug cable et.
2. Spark plug

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Section 06 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)

1. Proper socket
2. Improper socket

- Torque spark plug to 20 N-m (15 Ibf-ft).

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Section 06 ELEC"rRICAL SYSTEM
Subsection 03 (CHARGING SYSTEM)

CHARGING SYSTEM
SERVICE TOOLS
Description Part Number Page
Fluke 111 multimeter .... ... ........ .... ........ ..... .. .. ... .. .. .... ............ 529035 868 .... .. .... .. ..................... ...... .. 244
4-pin magneto harness adapter .. ...... .. .... .. .... .... ... ...... ...... .. ... 529036021 .. .. .. .... .. ....... .. .... .. ...... 246-247

SERVICE TOOLS - OTHER SUPPLIER

Description Part Number Page
Snap-on inductive ammeter.. .. .. ..... ... .... .. .. .. .. .... .. .. .... ... .. ....... MT110 .. .... .. .. ........... .. .. ...... .... .. .... 244

SERVICE PRODUCTS
Description Part Number Page
dielectric grease...... ..... .. ..... ....... ...... .. ... .. .. .. .. ... .. .. ...... ... .. ..... 293 550 004 .. .... .. .... .... ....... .. .. ... .. .. .... ... 250

GENERAL Voltage Regulator/Rectifier

The purpose of the charging system is to keep the The rectifier receives AC curren t from the magne-
battery at a full state of charge. to and transforms it into direct current (DC) .
NOTE: For an overview of the vehicle electrical The voltage regulator, included in the same unit,
system, refer to ENGINE MANAGEMENT. limits voltage as follows to prevent any damage
to electrical compone nts.
Magneto
MODEL VOLTAGE Vdc
The magneto is the primary source of electrical
energy. It transforms magnetic field into electric All 14.8
current (AC).
The magneto has a 3 phase series stator.

vmr20Q6...0l7-002

vmr2006-0 17-001

TYPICAL

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Section 06 ELECTRICAL SYSTEM
Subsection 03 (CHARGING SYSTEM)

NOTE: If the battery will not stay charged, the

problem can be any of the charging system com-
ponents. If these all check good, try a new voltage
regu lator/rectifier.

Battery
The battery is the DC source for the electric
starter, the ECM and all accessories .

PROCEDURES
NOTE: First, ensure that battery is in good condi-
tion prior to performing the following test.
For best results, use the Fluke 111 multimeter
(P/N 529035 868).
Use a Snap-on inductive ammeter (P/N MT110) or
equivalent and place it over the RED wire going
out of voltage regulator/rectifier.
- Start engine .
- Read current.
529035868
TEST ENGINE SPEED CURRENT

4000 RPM Appro x. 3 - 7 A

- If current is below specification, check magneto

(stator) output prior to concluding that rectifier
If the battery is regularly discharged, check battery
and solenoid terminals. is fau lty.

DC Current Test with a Multimeter

VOLTAGE
REG U LATOR/RECTIFIE R & WARNING
Pay attention not to touch chassis with any
Static Test: Continuity tool when disconnecting/connecting wires.
Due to internal circuitry, there is no static test avail- Pay attention so that battery positive post
able. does not touch chassis when moving battery.

DC Current Test with an Inductive - Disconnect battery cable and voltage regulator/
Ammeter rectifie r wire from solenoid post.
Pullout cover.

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Section 06 ELECTRICAL SYSTEM
Subsection 03 (CHARGING SYSTEM)

1. Move battery cable away to remove wire underneath

2. Remove this wire

Reconnect battery cable. - If current is below specification, check magneto

(stator) output prior to concluding that rectifier
is faulty.
- Properly reconnect voltage reg ulator/rectifier
wire.

Voltage Test
Proceed as follows:
- Release battery strap. Pull back battery to
reach battery posts.
- Start engine.
- Connect a multimeter to battery posts. Set
multimeter to Vdc scale.
- Start engine.
- Read voltage.

TEST ENGINE SPEED VOLTAGE

4000 RPM 14.4 - 15.2 Vdc

1. Battery cable installed

2. Voltage regulator/rectifier wire disconnected

- Set multimeter to Adc.

- Start engine.
- Connect multimeter probes between voltage
regulator/rectifier wire and solenoid post.
- Read current.

TEST ENGINE SPEED CURRENT

4000 RPM Approx. 3 - 7 A

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Section 06 ELECTRICAL SYSTEM
Subsection 03 (CHARGING SYSTEM)

If voltage is above specification, replace voltage

regu lator/rectifier
NOTE: If voltage exceeds 19 Vdc, gauge will dis-
play OVER VOLTAGE. In this case, replace voltage
1. Magneto connector
regulator/rectifier by a new one. 2. Leave this tool connector unplugged
If voltage is below specification, check stator,
wiring and connections . - Set multimeter to n.
Properly secure battery. - Connect multimeter between YELLOW wires.
- Read resistance.
Reinstall cover.
RESISTANCE @
STATOR TERMINAL
20°C (69°F)
Remove seat and RH side panel. 1 and 2
Remove protective plate as necessary. 1 and 3 0.1 - 1 n
2 and 3
Static Test: Continuity
- Disconnect the magneto wiring harness con-
nector.

V07G05A

TYPICAL

- Install the 4-pin magneto harness adapter

(P/N 529 036 021) on magneto connector.
Leave the other connector unplugged.
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Section 06 ELECTRICAL SYSTEM
Subsection 03 (CHARGING SYSTEM)

- If any reading is out of specification, replace - If there is a resistance or continuity, the stator
stator. coils and/or the wiring is grounded and needs
Replug connectors properly. to be repaired or replaced.
Replug connectors properly.
Static Test: Insulation
Keep connector as for the previous continuity test. Dynamic Test: AC Voltage
- Set multimeter to Q. 1. Disconnect the voltage regulator/rectifier con-
nectors.
- Connect multimeter between any YELLOW
wire and engine ground.
- Read resistance .

RESISTANCE @
PROBE
20°C (69°F)
Any YELLOW wire and Infinity (open circuit)
engine ground

2. Unplug magneto wiring harness connector.

V07G07A

TYPICAL

vmr2006-O 17·006

3. Install the 4-pin magneto harness adapter

(P/N 529 036 021) between unplugged con-
nectors.

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Section 06 ELECTRICAL SYSTEM ·
Subsection 03 (CHARGING SYSTEM)

BATTERY
Battery Information
These vehicles are equipped with a VRLA battery
(Valve Regulated Lead Acid). It is a maintenance-
free type battery.
Refer to battery manufacturer's instructions for
proper filling, activation and routine charging pro-
NOTE: Both connectors must be plugged. cedures .

Troubleshooting
Discharged or Weak Battery
- battery posts and/or cable terminal oxidized
- loose or bad connections
- faulty battery (does not keep a full charge)
- main system fuse burnt, faulty wiring/
connections, voltage regulator/rectifier or sta-
tor.

Battery Unloaded Test

NOTE: An unloaded test is made on a battery
without discharging current. It is the simplest and
most commonly used . However, be aware that
4. Set multimeter to Vac scale . the voltage test can be good, while the battery
5. Start engine . does not have enough power to crank the engine.
A load test gives a more accurate condition of the
6. Connect multi meter between YELLOW wires. battery.
7. Read voltage .
Check the charge condition using a multimeter.
TEST ENGINE With a multi meter, voltage readings appear in-
TERMINAL VOLTAGE
SPEED stantly to show the state of charge. Always
respect polarity.
1 and 2
4000 RPM 1 and 3 10- 25 Vac FULLY CHARGED BATTERY VOLTAGE
2 and 3 12.6 Vdc minimum

Battery Load Test

This is the best test of the batteries condition.
Use a load testing device that has an adjustable
load.
Apply a load of 3 times the ampere-hour rating of
the battery. At 14 seconds into the test, check
battery voltage.

TIME TO MEASURE
VOLTAGE
INTO TEST
14 seconds Min. 10.5 Vdc

8. If voltage is lower than specification, replace

stator.
9. Replug connectors properly.

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Section 06 ELECTRICAL SYSTEM
Subsection 03 (CHARGING SYSTEM)

Battery Removal
~ WARNING
Always respect this order for removal; dis-
connect BLACK (-) cable first. Electrolyte
or fuel vapors can be present and a spark
may ignite them and possibly cause personal
injuries.

Outlander 500/650/800 Series

Release battery strap.

Disconnect BLACK (-) cable first, then the RED (+)

cable.
Remove battery.
Renegade Models
Remove storage box.
Unfasten retaining rod.

1. Strap

Pull back battery to reach battery posts.

Pullout top bracket.

Disconnect BLACK (-) cable first. then the RED (+)
cable.
Remove battery.

Battery Cleaning
Clean the battery rack, cables and battery posts
using a solution of baking soda and water.

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Section 06 ELECTRICAL SYSTEM
Subsection 03 (CHARGING SYSTEM)

Remove corrosion (if so) from battery cable ter-

minals and battery posts using a firm wire brush .
Rinse with clear water and dry well.

Battery Inspection
Visually inspect battery casing for cracks or oth-
er damage. If casing is damaged, replace battery
and thoroughly clean battery rack with water and
baking soda .
Inspect battery posts condition, battery rack
mounting, straps and strap attachment points.

Battery Storage
If the battery is in storage or used infrequently,
disconnect the battery cables to eliminate drain
from electrical equipment.
For extended storage, remove the battery from
1. Hook at bottom
vehicle. 2. Temporary squeeze strap here
Clean battery terminals and cable connections us-
ing a wire brush. Apply a light coat of dielectric Temporary put battery in rack.
grease (PIN 293 550 004) on terminals. Connect battery cables.
Clean battery casing using a solution of baking so- Properly position battery with positive post to-
da and water. Rinse battery with clear water and wards front and negative post at rear. Route
dry well using a clean cloth. cables as shown.
Regularly charge battery as per manufacturer's
recommendations.
For other recommendations during storage, refer
to battery manufacturer's instructions.

& WARNING
Ensure to store battery in a safe place, out of
reach for children.

Battery Installation
& WARNING
Always connect RED (+) cable first then
BLACK (-) cable.

Outlander 500/650/800 Series Secure with strap.

Temporary hook battery strap as shown.

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Section 06 ELECTRICAL SYSTEM
Subsection 03 (CHARGING SYSTEM)

voa2001·00 1-0863

1. Secured strap

Renegade Models
Reinstall battery in vehicle . Secure retaining rod.
Reinstall storage box.

MAIN GROUND
Pull out cover.

Ensure main ground connection is clean and tight.

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Section 06 ELECTRICAL SYSTEM
Subsection 04 (STARTING SYSTEM)

STARTING SYSTEM
SERVICE TOOLS
Description Part Number Page
ECM adapter ............... ... ........................... ....... ......... .. ... .. ..... 420277 010 ..... ............. .. ....... .. ....... .. ... 254
Fluke 111 multimeter ..... ...... ........ .... .. .. ............. .. ............... .. 529035868 .......... ...... ... ..... ... ...... ... ..... 253

SERVICE PRODUCTS
Description Part Number Page
dielectric grease ................. .... ....... .. ...... ............................... 293550004 ......................................... 259

GENERAL Ignition switch turned ON

First ensure the problem is not related to engine Engine run/stop switch in RUN position
mechanical components . If not, test the starting Transmission in Park or Neutral position
system.
NOTE: Engine can be cranked in other positions if
Causes of problems are not necessarily related to
any brake lever is held when pressing start button.
starter but may be due to the following:
- burnt fuse Start button is pressed and held
(within 15 minutes since ignition key was turned on.
- faulty battery
Otherwise, it will be required to turn ignition switch
- D2 diode OFF. wait until multifunction gauge turns off then
relay turn ignition back ON).
- start button
- ignition Switch Battery
- engine run/stop switch To check battery condition, refer to CHARGING
starting solenoid SYSTEM section .
electrical cables
Ignition Switch and Engine
- connections .
Run/Stop Switch
Check these components before removing starter.
To validate ignition switch and engine run/stop
Consult the TROUBLESHOOTING section for a switch operations, refer to IGNITION SYSTEM.
general view of possible problems.
Electrical Cables and Connections
Engine Cranking Conditions
Check all connections, cables and wires. Tight-
The following conditions must be met to allow en- en any loose connections. Replace any chafed
gine cranking. wires/cables.

Tools
For best electrical measurement results, use the
Fluke 111 multimeter (P/N 529035 868).

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Section 06 ELECTRICAL SYSTEM
Subsection 04 (STARTING SYSTEM)

529035868

To probe the ECM connector terminals, use the

ECM adapter (PIN 420 277 010) to prevent damag-
ing terminals. Refer to ENGINE MANAGEMENT
for more information.

Probe diode paying attention to proper polarity.

420277010

PROCEDURES
FUSES "mr2006{)2G-006_a

MUST BE OPEN CIRCUIT

Make sure the main fuse (F8) and the accessories
fuse (F4) is (are) in good condition.
NOTE: If fuse F4 continuously burns, diode 02 is
likely defective.
NOTE: The solenoid may be the cause of a burnt
fuse. If the solenoid test good, one of the acces-
sory may be defective.

D2 DIODE (starter solenoid)

Diode Test
Remove diode and lay down on a non-metallic ta-
ble.
Set multimeter as shown . vmr2006-020-006_b

MUST BE AROUND 0.5 V

If diode fail any test, replace it.

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Section 06 ELECTRICAL SYSTEM
Subsection 04 (STARTING SYSTEM)

Diode, Installation If it turns on, you are knowing now the problem
Pay attention to the installation direction to allow is on the output side of the starting system (ECM
proper operation. output signal to starting solenoid, wiring harness
going to the solenoid and starter motor).
If it does not turn on, check the start button as
follows.

Start Button Resistance Test

•c Remove center panel and dashboard. Refer to
BODY.
•
A Using a multimeter, measure the resistance be-
A
tween the following wires .

MULTIFUNCTION
vmr2006-020-003_c
SWITCH
POSITION RESISTANCE
1. Position symbol on diode in same direction as symbol on fuse CONNECTOR (MG2)
holder PIN (start)
Switch
START BUTTON released
Infinite (OU

Quick Test Switch 1 6

depressed 0.6 [2 max .
When engine does not crank, here is a quick tip to
and held
see if start button works :
- Set engine run/stop switch in RUN position.
- Turn ignition switch on. Wait approx. 5 sec-
onds so that fuel pump stops .
Press start button. You should hear fuel pump
run for approximately 5 seconds. If so, the start
button is working.
If start button does not work, proceed with the
tests below.
- If start button is working, depress brake pedal
and try start button again.
- If engine starts, check the gearbox position sen-
sor (GBPS). Refer to GEARBOX.
If engine does not start, check the other com-
ponents of the starting system .

Test with B.U.D.S.

Use the vehicle communication kit (VCK) with
the B.U.D.S. software. Use the Monitoring tab. Replace multifunction switch if defective.
Press the vehicle's start button and look at the
Start button LED . If switch tests good, check wiring as follows .

Start Button Wiring Test

Disconnect ECM connector" B" .
Test continuity of wiring between start button con-
Imr200S-056-005_en
nector and ECM connector as follows.

It should turn on, indicating the starting system is

working on the input side of the starting system
(start button, ECM and wiring).

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Section 06 ELECTRICAL SYSTEM
Subsection 04 (STARTING SYSTEM)

CONNECTOR
MULTIFUNCTION
SWITCH (MG2) RESISTANCE
ECM
PIN (harness side) @ 20°C (68°F)
(start)
PIN
B-21 1 1 Q ma x.

If wiring is faulty, repair/replace harness and/or

connectors. If it tests good, check D2 diode . Re-
fer to 02 DIODE (STARTER SOLENOID) above.

STARTING SOLENOID
NOTE: Solenoid is located on the frame , besides
battery rack.
Pullout cover.
Reconnect ECM connector" B".
If switch tests good, test continuity of wiring be-
tween start button connector and battery ground
as follows .

CONNECTOR
MULTIFUNCTION
RESISTANCE
SWITCH (MG2) BATTERY
@ 20°C (68°F)
(start)
PIN
Battery
6 1 Q max .
ground

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Section 06 ELECTRICAL SYSTEM
Subsection 04 (STARTING SYSTEM)

Connect a jumper wire between solenoid terminal

and battery ground.

Inspect connections and clean as necessary.

Solenoid Signal Test

Disconnect connector with ORANGE/GREEN wire
from solenoid and check voltage as follows. 1. Disconnect ORANGE/BROWN terminal
2. Jumper to battery ground
Turn ignition key ON and set engine run/stop
switch to RUN. If solenoid works, check wiring/connectors for
Read voltage (do not press start button). continuity as follows .

SOLENOID COI\lNECTOR ECM SOLENOID

VOLTAGE RESISTANCE
(harness side) CONNECTOR TERIVIINAL
@ 20°C (68°F)
PIN (harness side)
ORANGE/GREEN with
12 Vdc
battery ground B-31 ORANGE/BROWN Close to 0 n

If voltage is not adequate, check accessories fuse

(F4). If fuse is good, test continuity of wiring be-
If solenoid does not work, test solenoid.
tween solenoid and fuse F4.
If voltage is adequate, do the following test. Static Test: Continuity
Reconnect ORANGE/GREEN terminal to solenoid . Disconnect terminals from solenoid.
Disconnect ORANGE/BROWN terminal from sole- With a multimeter, check primary winding resis-
noid. tance as follows.

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Section 06 ELECTRICAL SYS"rEM
Subsection 04 (STARTING SYSTEM)

MEASUREMENT For the following test, we do not want the engine

SOLENOID TERMINAL to run . Set ECM in engine drowned mode as fol-
RESISTANCE lows:
@ 20°C (68°F)
- Depress and hold throttle lever at full throttle
A I B Approximately 5 Q position .
- Install a rubber band or some tape to maintain
throttle lever in this position while testing .
Depress start button and while engine is cranking,
measure the voltage drop as follows with a multi-
meter.

SOLENOID CONNECTOR MEASUREMENT

Post coming
from battery
I Poststarter
going to
0.2 Vdc max.

Check for stuck solenoid plunger.

SOLENOID CONNECTOR MEASUREMENT

Battery post I Starter post Open circuit

.& WARNING
Remove any rubber band or tape from throt-
tle lever to release it.

If voltage is out of specification, replace solenoid .

If solenoid tests good, check the electric starter.
Reinstall cover.

ELECTRIC STARTER
Starter Test
Using booster cables, carefully supply current
If any measurement is out of specification, replace
from the battery directly to the starter. Connect
solenoid .
the BLACK (-) cable first. Then connect the re-
Dynamic Test maining jumper cable from the battery then to the
starter.
Turn ignition key ON and set engine run/stop
switch to RUN . If starter turns ensure the cables/connections
from solenoid to starter are in good condition.
If starter does not turn, replace starter.

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Section 06 ELECTRICAL SYSTEM
Subsection 04 (STARTING SYSTEM)

Starter Removal
Turn OFF ignition switch.
Disconnect BLACK (-) cable from battery.

& WARNING
Always disconnect BLACK (-) cable first and
reconnect last.

Remove the RH side cover and the engine cover

(refer to BODY!.
Disconnect RED (+) cable from starter.
Clean starter area.
Remove starter mount screw.

Starter Installation
Installation is the reverse of removal procedure.
However, pay particular attention to the following.
Make sure that starter and engine mating surfaces
are free of debris. Serious problem may arise if
the starter is not properly aligned .
Bring starter close to its location . Rotate it so that
its mounting ear allows installation in engine hous-
ing . Push in place and align mounting ear to install
screw.
Torque starter screw to 25 N-m (18 Ibf-ft).
Connect the RED (+) cable to the starter and
SOME PARTS REMOVED FOR CLARITY PURPOSE ONLY torque nut to 6 N-m (53 Ibf-in) . Apply dielectric
grease (PIN 293 550 004) on terminal and nut.
Carefully pry starter out of its housing .
First connect RED (+) cable to battery then con-
nect the BLACK (-) cable .

& WARNING
Always connect RED (+) cable first then
BLACK (-) cable last. Whenever connecting
the RED (+) cable to the starter motor, make
sure the battery cables are disconnected to
prevent electric shock.

Test starter operation .

Pull starter out.

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Section 06 ELECTRICAL SYSTEM
Subsection 05 (DIGITALLY ENCODED SECURITY SYSTEM (DESS))

DIGITALLY ENCODED SECURITY

SYSTEM (DESS)
GENERAL & WARNING
NOTE: It is a good practice to check for fault codes If the computer you are using is connected
using B.U.D.S. software as a first troubleshooting to the 110 Vac power outlet, there is a poten-
step. Refer to EMS DIAGNOSTIC. tial risk of electrocution when working in con-
tact with water. Be careful not to touch water
The ignition key contains a ROM chip with a while working with the VCK.
unique digital code that is the equivalent of a
unique teeth pattern on a conventional key.
Connect the MPI or the MPI-2 interface as
When the ignition key is turned OI\J, the ECM described in COMMUNICATION TOOLS AND
is powered up as well as the multifunction B.U.D.S. SOFTWARE.
speedometer and the accessories. Then, the
Install key in ignition switch and turn it to ON .
ECM reads the ignition key and, if it is not recog-
nized, no engine starting will be possible.
NOTE: When a key is not recognized by the ECM,
INVALID KEY will be displayed in the multifunction
speedometer.
To work on a particular DESS-equipped vehicle,
the ignition key must have been programmed first.
NOTE: All ignition keys have the same teeth pat-
tern . Therefore, they can be used and turned in
the switch of any DESS-equipped vehicle. How-
ever, unless the DESS system recognizes (in the
ECM) a valid programmed key, the engine starting
will not be allowed.
NOTE: Actually, it is the memory of the ECM that Ensure engine run/stop switch is in RUN position.
is programmed to recognize the digital code of the
ignition key.
The system is quite flexible . Up to 8 ignition keys
may be programmed in the memory of the ECM .
They can also be erased individually or all at once .
Note that the DESS circuitry is already activated
on all new ECM.

DESS KEY PROGRAMMING

Use the latest B.U .D.S. software available from
BOSSWeb. Refer to COMMUNICATION TOOLS
AND B. u.o.S. SOFTWARE for proper connection
instructions.
The B.U.D.S. software is designed to allow,
among other things, the programming of ignition 1. Run
key(s) and entering customer information.
For more information pertaining to the use of the Read ECM using Read Data button .
software B.U.D.S., use its help which contains de-
tailed information on its functions .

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Section 06 ELECTRICAL SYSTEM
Subsection 05 (DIGITALLY ENCODED SECURITY SYSTEM)

[§J
J
vmr2006·0 12·1003en
Read Data Write Data
Turn ignition key OFF and remove key.
Install the new key to be programmed.
TROUBLESHOOTING
Turn ignition key ON.
Click on Keys tab . If DESS key is not recognized by the ECM, key
is defective or there is a wiring problem, CHECK
ENGINE light will turn on and a message will be
displayed in the multifunction speedometer.
Ensure DESS wiring is not reverted (BLACK/
GREEN and ORANGE/RED).
To test wiring and ignition switch, refer to IGNI-
TION SYSTEM section.

1<8'/1 Used
sm JZ005·0n-OOl_en

Click on ADD KEY button on bottom of screen.

j
"_ F'"
F",.
~ r f oot'

'-'"
smr2005-072-003_Aen

1. Click on this tab

A new key is now saved in the computer.

NOTE: To program other key(sl. install a new key
in ignition switch, turn it ON and click again on Add
Key tab.
Ensure to save new data in ECM using Write Data
button.

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

LIGHTS, GAUGE AND ACCESSORIES

SERVICE TOOLS
Description Part Number Page
Fluke 111 multimeter ........ ... .. .. .... .. .... .... .. ........... ... ... .. .... .. .. . 529035868 ....... ..... ...... .. ... ..... ..... 263-265
Back probe test wires .... ...... ....... .. ... ..... ..... .. .... .... ..... .... .... ... . 529036063 .. .. .... .. .. .. ....... .. ... .. .... ......... 264

GENERAL IMPORTANT: In an usuai electric circuit, the bat-

tery supplies a switch which then supplies the
NOTE: For a complete overview of the vehicle electric component. Therefore the switch opens
electrical system, refer to ENGINE MANAGE- and closes the positive side of the circuit. In cir-
MENT. cuits controlled by the ECM , the battery supplies
& WARNING the electric component and the ECM works as a
switch to complete the circuit to the ground. Take
It is recommended to always disconnect the this into account when troubleshooting the electri-
battery when replacing any electric or elec- cal system.
tronic parts. Always disconnect battery ex-
actly in the specified order, BLACK (-) cable Pay attention to ground wires .
first. Do not place tools on battery. Checking for Shorts Between 2 Wires
Clean threads before applying a threadlock-
er. Refer to SELF-LOCKING FASTENERS and When checking continuity of a wire in a circuit,
LOCTITE APPLICATION at the beginning of wires should be che cked for short circuit as fol-
this manual for complete procedure. lows.
During assembly/installation, use the torque Make sure to isolate circuit by unplugging conne c-
values and service products as in the explod- tors.
ed views. Torque wrench tightening specifi- Let's suppose that the circuit to be checked has
cations must strictly be adhered to. Locking a RED and a BLACK wire . Using an ohmmeter,
devices (e.g.: locking tabs, elastic stop nuts, measure the resistance between the RED and the
self-locking fasteners, etc.) must be replaced BLACK wire . The resistance should be infin ite
with new ones. (Ol) . Otherwise, there is a short circuit between
both wires . We must therefore identify and cor-
rect the fa ult.
Diagnostic
The following gives general electrical-related prob- Recommended Tools
lems. For specific system-related problems, refer For best results, use the Fluke 111 multimeter
to proper system section. (P/N 529 035 868).
It is possible that a component seems to operate
in static condition but in fact, it is defective. In
this case, the best way to solve this problem is
to remove the original part and replace it with a
known good component.
IMPORTANT: When solving an electrical problem, 529035868
the first thing to do is to check battery condition
as well as its cables and connections . Also en-
sure the ignition switch is turned on and engine
run/stop switch is set to RUN. Check solidity
(close to battery) and related-circuit fuse condition
with an ohmmeter (visual inspection could lead to
false results) . Also visually examine harness and
connections.

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

To easily probe wire terminals through the back of CAUTION: Do not use a higher rated fuse as
their connectors, Back probe test wires (PIN 529 this can cause severe damage.
036 063) can be used. Fuses are located in the front service compart-
ment and at the back near battery (under cover).

Fuses in Front Service Compartment

vbs2007-014-002

They can be inserted at the end of the standard

probes of the Fluke 111 multimeter (PIN 529035
868).
vmo2006-007 -C' 2_tI

FRONT - FUSES LOCATION

7. IF7) Ignition coils
2. IF2) Cooling fan
3. IF3) Fuel injectors
4. IF4) Accessories
5. IF5) Fuel pump
vmr2008·058-001 6. IF6) Engine Control Module IECM)
7. IF7) Accessories

Electrica I Con nectors NOTE: A short circuited D5 or D6 diode will cause

Pay particular attention to ensure that pins are fuse F7 to burn. Refer to 05 AND 06 DIODES
not out of their connectors or damaged. The (WINCH RELAY) further in this section.
troubleshooting procedures cover problems not
resulting from one of these causes. Fuses located at the Rear
CAUTION: Ensure all terminals are properly Remove cover.
crimped on wires and connector housings
are properly fastened. replacing any electric
or electronic part(s), always check electrical
connections. Make sure that they are tight
and they make good contact and are corro-
sion-free. The voltage and current might be
too weak to go through dirty wire pins. Check
the posts for signs of moisture, corrosion or if
they look dull. Clean pins properly and then
coat them with silicon-based dielectric grease
or other appropriate lubricant (except if oth-
erwise specified) when reassembling them.
See connectors information in ELECTRICAL
CONNECTORS.

PROCEDURES
FUSES
If a fuse is damaged, replace it with one of the
same rating.

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Section 06 ELECTRICAL SVS"rEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

vmr2006-020-051_a

RELAY R3 (ACCESSORIES)

Relay Continuity Test

REAR - FUSES LOCATION
1. (F9) Accessories Remove relay.
2. (FB) Main
Use the Fluke 111 multimeter (PIN 529 035 868),
and select the r2 position.
ACCESSORY RELAY (R3) Probe relay as follows.
NOTE: Relay may be inverted by 180 0 at installa- TERMINAL RESISTANCE
tion and it will work correctly. Ensure to align tabs
of relay with terminals of fuse holder at installa- Open circuit
30 87
tion. I (OU

• t "a~ 11 12

vmr2006-020-003
smr2007-027-050_3

R3. Accessory relay

Connect battery as shown and probe relay again
The easiest way to check a relay is to remove it as follows.
and bypass it with a jumper. If the components
then work, test relay. If it tested good, check TERMINAL RESISTANCE
wiring/connectors. See illustration to find where 0.5 Q max.
to bypass the relay. 30 87 (continuity)
I

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

Gauge Operation
Outlander 500/650/800 Series

4 1

If relay failed any test. replace it. 6 7

MULTIFUNCTION GAUGE
Unit Selection (MPH vs km/h)
The multifunction gauges are factory preset in Im-
perial units but it is possible to change them to
Metric units
Use B.U.D.S. software. Go in Setting tab and use vmo200S-001-020_8
Cluster Scale . 1. Display 1 (speedometer)
2. Display 2 (mode)
3. Display 3 (mode/message)
4. Display selector button
5. Tachometer
6. Transmission position display
7. Fuel level display
8. Indicator lamps

Display 1 (Speedometer)
This display will show vehicle speed.
Outlander 500/650/800 Series

vmo200S-001-020_g

1. Vehicle speed
1. Unit selection 2. Unit selection

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

Display 2 (mode) This display will show either an abbreviation of the

mode selected in display 2 or will communicate
important messages to the operator if an anomaly
occurs .
Abbreviation Mode :
- 000 (odometer)
- TRIP (trip meter)
- TRIP TIME (hour meter)
- ENGINE HOURS (vehicle hour meter)
- RPM (engine revolutions per minute) .

vmo2008-00 1·020_e

1. Display 2 (mode)
2. Displa y 3 (mode/message)
3. Selector button

By pressing the selector button, the following

modes can be displayed:
- odometer (000)
- trip meter (TRIP)
- hour meter (TRIP TIME)
vehicle hour meter (ENGINE HOURS)
- engine revolutions per minute (RPM) .
Display 3 (mode/message)

vmo2008-00 1-020_h

1. Displa y 3 (mode/message)
2. Display 2 (mode)

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AI\JD ACCESSORIES)

Message Mode:

MESSAGE PILOT LAMP(S) ON DESCRIPTION

Indicates that you have used the wrong ignition key,
use the proper key for this vehicle.
INVALID KEY Check engine
It is also possible that the ignition key has a bad
contact, remove and clean key.
Is displayed when parking brake is applied for more
PARK BRAKE Parking brake
than 15 seconds (while riding).
Low battery voltage, check battery voltage and
LO BATT Check engine
charging system.
High battery voltage, check battery voltage and
HI BAn Check engine
charging system.
Engine low oil pressure, stop engine immediately
LOW OIL (1) Check engine
and check oil level.
HI TEMP (2) Check engine Engine is overheating, refer to COOLING SYSTEM.
Serious fault detected by the engine management
that can change the normal operation of the engine.
LIMP HOME Check engine
Check engine indicator lamp will also blink, refer to
ENGINE MANAGEMENTfor more details.
Engine management fault. Check engine
CHECK ENGINE Check engine indicator lamp will also be ON, refer to ENGINE
MANAGEMENTfor more details.
Periodic maintenance required.
MAINTENANCE
Check engine NOTE: To reset message, use B.U.D.S. software and
SOON
click Reset Service button in Vehicle tab.
Communication error between multifunction gauge
NO ECM
Check engine and engine control module (ECM). Refer to ENGINE
COMMUNICATION
MANAGEMENT.

CAUTION: (1) If the light does not turn off right

after engine starting, stop engine. Check en-
gine oil level. Refill if necessary. If the oil level
is good, see LUBRICATION.
CAUTION: (2) If the light does not turn off right
after engine starting, stop engine. See COOL-
ING SYSTEM.
Display Selector Button
Button used to navigate between modes or to re-
set data depending on the feature selected.

vmo2008-001-020_1

1. Selector button

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

Tachometer DISPLAY FUNCTION

Measures engine revolutions per minute (RPM). P Park
Multiply by 1000 to obtain the actual revolutions.
R Reverse
N Neutral
H High gear
L Low gear

NOTE: If the letter" E" is displayed in the trans-

mission position display, it means that there is a
electrical communication error. Refer to ENGINE
MANAGEMENT.
Fuel Level Display
Bar gauge that continuously indicates the amount
of fuel left in the fuel tank .
Also, an indicator lamp will indicate a low-fuel con-
dition as only one bar is displayed.

1. Tachometer
2. Operating range
3. Tachometer via display 2 (mode)

Transmission Position Display

This display will show transmission position.
1

vmo200B-001·020_f

1. Fuel level display

2. Low fuel indicator lamp

vmo2008-001-020 _d

1. Transmission position

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AI\ID ACCESSORIES)

Indicator Lamps
3
1

v m(2Q07-050-002_b

1. Multifunction display selector button

2. Transmission position display
3. Multifunction display
4. Fuel level display
2 5. 4WD indicator lamp
6. Low fuel level indicator lamp
7. Check engine indicator lamp
8. High beam indicator lamp
9. Flasher/hazard signal indicator lamp (Europe only)
10. MPH, Km/h indicator lamp

Multifunction Display
(Normal Display Mode)
After vehicle startup, the normal display mode
1. Parking brake indicator lamp shows either:
2. 4WD indicator lamp - vehicle speed
3. Low fuel level indicator lamp
4. Check engine indicator lamp - engine revolution per minute (RPM)
5. High beam indicator lamp
- both parameters simultaneously (combined
mode).
Parking brake is activated.
Speed Mode: in this mode, the display shows the
speed of the vehicle either in km/h or in MPH.
@ 4WD system is activated.

Low fuel level . There is only 30% of

@ fuel left in fuel tank, approximately 6 L
(1.6 U.S. gal).

© Check engine/DESS system operation.

@ High headlamp beam position selected .

Renegade Models RPM Mode: in this mode, the display shows the
This vehicle is equipped with an electronic multi- engine RPM.
function gauge.

Combined Mode: in this mode, the display shows

vmr2007 ·050-002_a
the speed of the vehicle and the engine RPM.
It is backlit every time the ignition switch is turned
ON and engine run/stop switch is set to RUN.
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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

1. Selector button

The gauge will display the selected mode for 10

seconds then will return to the normal display
mode.
While in a resettable mode, push and HOLD se-
lector button for 2 seconds to reset it.

1. Vehicle speed Multifunction Display Codes/Messages

2. Engine RPM
Fault Codes:
Mode Selection: to change from one mode to the Fault codes (if so) can be displayed in the gauge .
other, proceed as follows: Refer to ENGINE MANAGEMENT.
1. Turn ignition key to ON. Wait until 'greeting' is Messages:
finished.
The following messages can also be viewed in the
2. Press and release selector button once to dis- multifunction display:
play OD (odometer) .

3. Press selector button and HOLD for 2 sec-

onds . This will change the displayed mode to
either Speed, RPM or Combined .
4. To select another mode, repeat steps 2 and 3
until you get the mode desired.
Multifunction Display
(temporary display mode)
Press and release selector button to change the
normal display mode to the following temporary
mode:
- odometer
- trip meter (resettable)
- hour meter (resettable)
- vehicle hour meter.

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

DISPLAY CHECK ENGINE

MESSAGE DESCRIPTION
FREQUENCY LAMP
Indicates that you have used the wrong
ignition key, use the proper key for this vehicle .
INVALID KEY - -
It is also possible that the ign ition key has a bad
contact, remove and clean key.
Displayed whenever brake is used more than 15
BRAKE - - seconds.
Low battery voltage . Check battery voltage and
LO BATT Every 5 seconds ON
charging system.
High battery voltage . Check battery voltage and
HI BATT Every 5 seconds ON
charging system.
LOW OIL Engine low oil pressure. Stop engine immediately
(1) Every 5 seconds ON
and check oil level.
- Low fuel indicator lamp also turns on . Refer to
LOW FUEL Every 5 seconds
INDICATOR LAMPS.
HI TEMP Engine is overheating . Refer to COOLING
(2) Every 5 seconds ON
SYSTEM.
Serious fault on the engine that can change the
LIMP HOME Every 5 seconds Blinking normal operation of the engine . Refe r to ENGINE
MANAGEMENTfor more details.
EMS fault. Refer to ENGINE MANAGEMENTfor
CHECK ENGINE Every 5 seconds ON
more details.
Periodic maintenance required .
MAINTENANCE NOTE: To reset message, use B.U.D.S.
Every 30 minutes ON
SOON software and click Reset Service button in Vehicle
tab .
Communication error between gauge and
NO ECM
- - engine control module (ECM) . Refer to ENGINE
COMMUNICATION
MANAGEMENT.

CAUTION: (1) If the light does not turn off right DISPLAY FUNCTION
after engine starting, stop engine. Check en- P Park
gine oil level. Refill if necessary. Do not use
the vehicle until repaired. N Neutral

CAUTION: (2) If the light does not turn off right R Reverse
after engine starting, stop engine. Do not use H High gear
the vehicle until repaired. L Low gear
Transmission Position Display
NOTE: If the letter "E" is displayed in the trans-
This display will show transmission position .

, mission position display, it means that there is a

electrical communication error.
Fuel Level Display
Bar gauge continuously indicates the amount of
fuel in the fuel tank while riding.

vm r2007·050-002_d

1. Transmission position

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

Function Display Problems

When the functions do not display, check for fault
code(s). Refer to ENGINE MANAGEMENT sec-
tion. When a specific function does not work, pro-
ceed as follows.
Fuel Level
As a quick test with B.U.D .S., go in Activation tab
and activate fuel level display area.
vmr2007-050-002_8
If it does not work, check wiring/connectors and if
1. Fuel level display they are good, try a new multifunction gauge.
2. Low fuel indicator lamp
If it works, check fuel level sender. Refer to pro-
Indicator Lamps cedure further in this section.
Transmission Position Display
If the letter" E" is displayed in transmission posi-
tion display, there is an electrical communication
error. Refer to GEARBOX AND 4X4 COUPLING
UNIT.
As a quick test with B.U.D .S., go in Activation tab
and activate transmission position display area.
If it does not work, try a new multifunction gauge .
4 2 3 If it works, check gearbox switches . Refer to
vmr2007-Q5D-002_'
GEARBOX AND 4X4 COUPLING UNIT.
1. 4WD indicator lamp
2. Low fuel level indicator lamp
3. Check engine indicator lamp 2/4WD Pilot Lamp
4. High beam indicator lam p
5. Flasher/Hazard signal indicator lamp (Europe only) As a quick test with B.U.D .S., go in Activation tab
6. MPH or km/h in dicator lamp and activate 2/4WD lamp area.
If it does not work, try a new multifunction gauge .
When this indicator is ON, it indicates the
4WD system is activated. If it works, check gearbox switch. Refer to GEAR-
BOX AND 4X4 COUPLING UNIT.
When this indicator is ON, it indicates that
there is only 30% of fuel left in fuel tank, HI Beam Pilot Lamp
approximately 6 L (1.6 U.S. gal). As a quick test with B.U.D .S., go in Activation tab
When this indicator is ON, it indicates an and activate HI beam lamp area.
engine fault code, look for message in If it does not work, try a new multifunction gauge .
multifunction display.
When this indicator blinks, it indicates that If it works, check if headlamp work. If headlamp
the LIMP HOME mode is activated, refer do not work, refer to HEADLAMP. If headlamp
to TROUBLESHOOTING for more details. work, check wire/connectors between multifunc-
tion gauge and low/hi beam switch.
When this indicator is ON, it indicates high

..
mph
intensity is selected on the headlamps and
ignition key is in LIGHTS position.
When this indicator is blinking, it indicates
the flasher/hazard is activated (Europe
only).
GAUGE
CONNECTOR

Pin 5
MULTIFUNCTION
SWITCH
CONNECTOR
(MG2)
Pin 5
RESISTANCE

Close to 0 n
The proper lamp turns on to indicate the
Kmlh unit the speedometer uses.

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

Disconnect gauge connector. Turn Ignition key

ON and set engine run/stop switch to RUN. Read
voltage from vehicle harness as follows .

GAUGE COI\lI\lECTOR
VOLTAGE
(harness side)
Pin 17 I Pin 20 Battery voltage

If wire is faulty, replace/repair.

Multifunction Gauge Pinout

FUNCTION PIN
Power 12 Vdc 17
Ground 20
CAN line 18
CAN line 19
Fuel level gauge supply 4
If there is no voltage, recheck voltage as follows.
Fuel level gauge ground 21
2/4WD switch signal 7 GAUGE CONNECTOR
VOLTAGE
(harness side)
HI beam signal 5
Pin 17 I Battery ground Battery voltage

Voltage Test

QUICK CHECK
OBSERVATION POSSIBLE CAUSE
Burnt fuse (F8)
Faulty relay (main)
Burnt fuse (F4)
ECM not - burnt fuse (F6)
powered: - defective diode
Multifunction gauge (D1)
does not turn on
- defective ECM
Defective multifunction gauge
Faulty multifunction switch or
key

Wiring/connectors

If voltage is not appropriate, check/repair wiring

and/or connectors from battery.

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Section 06 ELEC"rRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

If battery voltage is good, check ground circuit

(pin 20) wiring/connector. If they test good, tem-
porarily connect pin 20 to battery ground. If mul-
tifunction gauge turns on, try a new ECM .
When everything else has been tested and multi-
function still does not turn on, try a new one.

Multifunction Gauge Removal

Outlander 500/650/800 Series
Remove center panel and dashboard. Refer to
BODY.
Unplug gauge connector.
Locate locking tab then push edge of dashboard
to release tab .
Multifunction Gauge Installation
For the installation, reverse the removal proce-
dure.

New Multifunction Gauge Registration

(coding)
Whenever multifunction gauge is replaced, it is re-
quired to use S.U.D.S. to register it in ECM. Simply
click Yes when the following message appears.

While holding tab, rotate gauge to unlock.

IMPORTANT: If a multifunction gauge from anoth-

er vehicle model is installed and is not registered in
ECM through S.U.D .S., engine starting will not
be allowed until gauge is registered with prop-
er coding.

Country Selection
Renegade Models
To enable flasher pilot lamp in gauge of European
Community (CE) models, use S.U.D.S. software
and set cluster country to Renegade CE under
Renegade Models Settings.
Remove dashboard. Refer to BODY
Push gauge tabs while pulling it out.

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

·~ I
RoedO"",

VeIlIdo I Koyt
I·
I s ",""" I
l~.~~_
i -I I ..,
MoriIanng F_

O.OOOeg

,. VeII!ctoSPoo<!
C i;llgIneRPM
' RPM~
If voltage is not good, check/repair wiring/
vdd200B-OO J-079_a
connectors ,
Outside Europe, select Renegade. If voltage is good, do the following test.
Lift rear of vehicle so that rear wheels are off the
VEHICLE SPEED SENSOR (VSS) ground.
Locate VSS connector in gearbox area, Set transmission to 2WD and to Neutral.
Back-probe connector and read voltage while
slowly rotating rear wheels with your hands ,

SPEED SENSOR
CONNECTOR VOLTAGE
(harness side)
Alternate reading of:
ORANGE/ battery voltage, approx,
PINK
GREEN o Vdc, battery voltage
and so on

TYPICAL - V810 ENGINE SHOWN

Turn ignition key ON,

Set engine run/stop switch to RUN ,
Use a multimeter and set it to Vdc,
Back-probe connector and read voltage as follows,

SPEED SENSOR CONNECTOR

VOLTAGE
(harness side)
ORANGE/ BROWN/ Battery
NOTE: Since we measure pulsating voltage, the
GREEN I ORANGE voltage
numeric display will continuously change. The
analog display may be easier to follow.

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Section 06 ELEC"rRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

FUEL LEVEL RESISTANCE

FLOAT
AT GAUGE MEASUREMENT
POSITION
CONNECTOR 20°C (68°F)
Float down
100 ± 7 S1
(empty)
Pin 12 Pin 15
Float up
5±2S1
(full)

1. Analog display

If voltage is appropriate, check/repair wiring/

connector between sensor and ECM. If it is good,
try a new ECM .
If voltage is wrong, try a new sensor.
NOTE: Whenever the VSS is found defective,
check diode D2. It could be the cause of the VSS
failure.
Test diode D2 as explained in STARTING SYSTEM
section .

FUEL LEVEL SENDER

The fuel level sender is part of the fuel pump mod-
ule mounted inside the fuel reservoir.
If resistance is not within empty and full values
(depending on fuel quantity), check and repair
wiring and/or connectors between mult ifunction
gauge and fuel level sender. If they test good,
replace fuel pump module. Refer to FUEL TANK
AND FUEL PUMP.
If fuel level sender and wiring/connectors are
good, try a new multifunction gauge.

MULTIFUNCTION SWITCH
Apply parking brake, place transmission lever in
NEUTRAL position and start engine.

vmr2006-0t 2-007_b

FUEL PUMP MODULE

1. Float and arm

Disconnect multifunction gauge connector.

Measure resistance as per table.

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

1. Low/Hi beam switch

2. Start sw itch
vmr 2006-020-066_a
3. Engine ru n/s top sw itch
4. Override sw itch
Replace multifunction switch if defective.

Sta rt Switch Override Switch

Refer to STARTING SYSTEM. Using a multimeter, measure the resistance be-
tween the following wires .
Engine Run/Stop Switch
MULTIFUNCTION
Refer to IGNITION SYSTEM.
SWITCH SWITCH RESISTANCE
POSITION CONNECTOR @ 20°C (68°F)
Low/Hi Beam Switch (MG1)
Using a multimeter, measure the resistance as fol-
lows . Released 0.2 Q ma x.
Pin 5 Pin 6
Pushed Open (Ol)
MULTIFUNCTION
SWITCH RESISTANCE
POSITION
CONNECTOR @ 20°C (68°F)
(MG2)
Switch to
Pin 2 Pin 4
LO
0.2 Q ma x.
Switch to
Pin 5 Pin 4
HI

Replace multifunction switch if defective.

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

12-VOLT AUXILIARY POWER 12-VOLT POWER OUTLET

OUTLET
12-Volt Power Outlet Removal
The 12-volt auxiliary power outlet allows the instal- Remove console . Refer to BODY.
lation of additional accessories .
Unplug the connectors of the power outlet.
12-Volt Auxiliary Power Outlet Test Unscrew the retaining nut.
Remove center panel and dashboard. Refer to
BODY. 12-Volt Power Outlet Installation
Turn ignition key on and set engine run/stop switch Reverse the removal procedure .
to RUN.
12-Volt Power Outlet Test
Unplug power outlet connector.
Remove center panel and dashboard . Refer to
BODY.
Turn ignition key on and set engine run/stop switch
to RUN .
Unplug the power outlet connectors .
Using a multimeter, measure the voltage as fol-
lows .

WIRE COLOR VOLTAGE

RED/BLACK 1 BLACK 12-14.5Vdc

Using a multimeter, measure the voltage as fol-

lows.

WIRE COLOR VOLTAGE

RED/BLACK I BLACK 12 - 14.5 Vdc

! .

vmr2006.()2o-061_a
No voltage :
• Check fuses F4, F7, relay R3 (accessories) Ensure to reconnect RED/BLACK wire to positive
and wiring condition. terminal.
- Voltage is good :
• Check accessories.

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AI\ID ACCESSORIES)

TYPICAL

- No voltage:
- Voltage is good :
• Check fuses F4, F7, relay R3 (accessories)
and wiring condition. • Change headlamp bulb(s).
- Voltage is good: - No voltage :
• Check fuses F4, F7, relay R3 (accessories)
• Change power outlet.
and wiring condition .
• Check ignition switch as follows.
HEADLAMP
SWITCH RESISTANCE
Headlamp Test POSITION
PIN
@ 20°C (68°F)
Disconnect headlamp connector. Refer to BULB
OFF Infinite (OU
REPLACEMENT.
ON with
Using a multimeter, measure the voltage on head-
lights
1 n max.
lamp connector as follows. A F
ON
SWITCH without Infinite (OU
WIRE COLOR VOLTAGE
POSITION lights
LO beam GREEN BLACK
12 - 14.5 Vdc • Check low/hi beam switch . refer to MULTI-
HI beam BLUE BLACK FUNCTION SWITCH elsewhere in this sec-
tion .

Bulb Replacement
CAUTION: Never touch glass portion of an
halogen bulb with bare fingers, it shortens its
operating life. If glass is touched, clean it with
isopropyl alcohol which will not leave a film
on the bulb.
All Models except Renegade
Remove cover screws.

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

1. Screws
2. Cover

Remove rubber protector over headlamp housing . TYPICAL

Lift and hold the spindle then remove the bulb.

7. Rubber protector
2. Headlamp housing

Unplug connector from headlamp.

NOTE: Use small locking tab to unlock connector
then pull on connector. V06GOSA
~------------------------------------~
TYPICAL

Properly reinstall removed parts in the reverse or-

der of their removal.
Validate head lamp operation.
Renegade Models
NOTE: The same headlamp is used on both sides
of vehicle and for LO and HI beams.
Unplug connector from bulb .

PUSH ON LOCKING TAB TO UNLOCK CONNECTOR

Press the spindle then push it on the side to unlock

headlamp bulb.
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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

Headlamp Beam Aiming

Select high intensity.
Beam aiming is correct when center of high beam
is 131 mm (5 in) below the headlamp horizontal
center line, scribed on a test surface, 5 m (17 ft)
away.
NOTE: Sit down the driver or place the same
weight on the vehicle.
Measure headlamp center distance from ground.
Scribe a line at this height on test surface (wall
or screen) . Light beam center should be 131 mm
(5 in) below scribed line.

Rotate bulb.

vmr2006 ..Q2~01_a

1. Head/amp center lines

2. Light beam center

Pullout bulb.

1. Light beam center

A. 5 m (17 ft)
B. 131 mm (5 in)

Adjustment
Turn adjustment screws to adjust beam height and
side orientation as described below. Adjust both
headlamps evenly.

Properly reinstall removed parts in the reverse or-

der of their removal.
Validate headlamp operation.

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

TYPICAL
1. Head/amp cover
2. Adjustment screws

TAILLIGHT
Bulb Replacement
Unscrew lens screws to expose bulb .

If motor does not turn in any test, replace motor.

If it works, continue testing.
Voltage Supply to Switch
Remove center panel and dashboard. Refer to
BODY.
Disconnect the winch control switch connector.

V07G1AA 2
TYPICAL
1. Lens
2. Screws

Push bulb in and hold while turning courterclock-

wise to release.
Install the new bulb by 'first pushing in while turn-
ing clockwise.
Using a multimeter, measure the resistance as fol-
WINCH lows.
XT Models Only

Winch Test
Winch Motor
Using boosting cables, connect battery power to
IN post of winch then to OUT post.
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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

WINCH SWITCH
CONNECTOR VOLTAGE
(harness side)
Pin A JBattery ground 12 Vdc

If there is no voltage in either test, check

wiring/connectors. If they are good, replace
winch switch.
If there is voltage, test winch relay as follows.
Winch Relay
Reconnect terminals at winch relay.
Measure voltage drop between relay and motor as
If there is no voltage, check fuses F9, F7, relay R3 follows.
(accessories) and wiring condition.
RELAY VOLTAGE
If there is voltage, test switch as follows. POSITION
TERMINAL DROP
Winch Control Switch Switch pressed to Battery post
0.2 Vdc max.
Disconnect terminals at winch relay. IN and held and IN cable

POSITION TERMINAL VOLTAGE

Switch pressed LIGHT/BLUE and
12 Vdc
to IN and held battery ground

RELAY VOLTAGE
POSITION
TERMINAL DROP
Battery post
Switch pressed to
and OUT 0.2 Vdc max .
POSITION TERMINAL VOLTAGE OUT and held
cable
Switch pressed GREEN/BLUE and
12 Vdc
to OUT and held battery ground

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AI\ID ACCESSORIES)

Remove:
- locking pin

If voltage drop read is higher than specification in

either test, check wiring/connectors . If they are
good, replace winch relay.
V07A2GA

If voltage read is battery voltage, the relay does

1. Locking pin
not close. Replace with a new one.

Winch Removal - hook

- bolts retaining the winch from both LH and RH
Disconnect, the battery BLACK (-) cable first, then
sides .
the RED (+) cable .

.& WARNING
Always respect this order for disassembly;
disconnect BLACK (-) cable first. Electrolyte
or fuel vapors can be present in engine com-
partment and a spark may ignite them and
possibly cause personal injuries.

Disconnect the winch power cables .

V07A2HA 1
1. Bolts to be removed

Remove winch.

Winch Installation
For the installation, reverse the removal proce-
dure .

WINCH CONTROL SWITCH

1. Po wer connections Winch Control Switch Test
NOTE: Note the position of the power cables for Refer to WINCH above.
reinstallation.

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

Winch Control Switch Removal

Remove screws retaining winch control switch to
handlebar.
Remove steering cover, refer to BODY.
Disconnect the w inch control switch connector.

Winch Control Switch Installation

For the installation, reverse the removal proce-
dure .

D5 AND D6 DIODES
(Winch Relay)
Diode Test
NOTE: Refer to WIRING DIAGRAM for diode lo-
cation.
Remove center panel and dashboard. Refer to WIRES TO PROBE
BODY. WIRE TO (harness side)
DISCONNECT
Disconnect winch switch connector. DIODE WINCH WINCH
AT WINCH
RELAY SWITCH RELAY
CONNECTOR POST
GREEN/BLUE
D5 GREEN/BLUE
(green on relay)
Ground
LIGHT BLUE
D6 LIGHT BLUE
(black on relay)

Probe diode wires paying attention to proper po-

larity. See illustrations.

Disconnect appropriate wire going to winch relay

(behind RH front wheel) . Refer to table.

MUST BE OPEN CIRCUIT

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Section 06 ELECTRICAL SYSTEM
Subsection 06 (LIGHTS, GAUGE AND ACCESSORIES)

MUST BE AROUND 0.5 V

If any diode test fail, replace diode.

NOTE: Diodes are located in wiring harness ap-
proximately where shown.

Properly reinstall removed parts.

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sa,les@.mldwe, ' manrUI,a s.c,o,m

www.lm idwestlm aln uas.com

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)
SERVICE TOOLS
Description Part Number Page
pulley holding tool. ......... .. ....... ... .... .. ....... .. .. ...... .. .. .............. .. 529 006 400 ........... ............... ... ........ .. . 293
drive pulley puller .... .. .... ..... ...... ...... ... ..... ... ...... .... ........ .. ...... .. 529 035 746 ............................. ...... ...... 293
driven pulley expander .. .... ....... .. .... ..................................... .. 529035747 .. ... .. .. ...... ...... .. ...... .. .. .... .... 291
pulley holding tool. ........................... .. ...... ....... .... ......... ... ..... . 529035771 ......................................... 300

SERVICE PRODUCTS
Description Part Number Page
Isoflex grease Topas NB 52 ........................... ............. .. ........ 293550021 ..................... ...... .. .... 298-299
pulley flange cleaner ...................................... .. ..................... 413 711 809 .. .. ........ .. .... ............... 295, 301

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Isoflex grease
~opas~NB52

Pulley
flange
~j25

r·
26
t

cleaner

T3

T4

1'1'
100 Nom (74 Ibfoft)
T2 60 Nom (44 Ibfoft)
T3 10 Nom (89 Ibfoin)
T4 7 Nom (62 Ibfoin)
T5 5 Nom (44 Ibfoin)
vmr2Q07 -051-Q02_B

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

GENERAL PROCEDURES
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle. DRIVE BELT
To perform the following instructions, it is not nec-
essary to remove engine . Removal
This CVT is lubrication free . Never lubricate any Remove CVT cover screws.
components except drive pulley one-way clutch NOTE: Remove the center top screw last. This
and friction washer. screw allows to support the cover during removal .
During assembly/installation, use the torque val- Remove the CVT cover and its gasket.
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

& WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pin, etc.) must be replaced
with new ones.

& WARNING 'Jmr200e-02'·002_a

Never touch CVT while engine is running. 1. CVT cover screw

2. CVT cover
Never drive vehicle when CVT cover is re- 3. Gasket
moved.
Open driven pulley with the driven pulley expander
& WARNING (P/N 529035 747) .
Any drive pulley repairs must be performed
by an authorized Can-Am dealer. Subcompo-
nent installation and assembly tolerances re-
quire strict adherence to procedures detailed.
I~( -- 5290357471

CAUTION: Never use any type of impact Screw tool in the threaded hole of driven pulley
wrench at drive pulley removal and installa- and tighten to open the pulley.
tion.
& WARNING
The clutch assembly is a precisely balanced
unit. Never replace parts with used parts
from another clutch assembly.

CAUTION: These pulleys have metric threads.

Do not use SAE threads puller. Always tighten
puller by hand to ensure that the drive pulley
has the same type of threads (metric vs SAE)
prior to fully tightening.

1. Driven pulley expander

2. Fixed sheave of driven pulley

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

To remove belt, slip the belt over the top edge of

fixed sheave, as shown.

1. Arrow printed on belt

2. Drive pulley (front)
3. Driven pulley (rear)
4. Rotation direction
Inspection
Install the center top screw of cover in first.
Inspect belt for cracks, fraying or abnormal wear.
Replace if necessary. Tighten the CVT cover screws as per following se-
quence.
Check drive belt width at cord level. Replace if it
is out of specification (see table below).

DRIVE BELT WIDTH

SERVICE LIMIT I 30.00 mm (1.181 in)

vmr2006-021-007 _a

DRIVE PU LLEY
1. Drive belt
2. Cord in drive belt

Installation
For installation, reverse the removal procedure.
Pay attention to following details.
The maximum drive belt life span is obtained
when the drive belt has the proper rotation direc-
tion. Install it so that the arrow printed on belt
is pointing towards front of the vehicle, viewed
from top.
1. Belt
2. Drive pulley
3. Driven pulley

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSIVIISSION (CVT))

Removal
Remove belt no. 1.
Block the drive pulley. To do this, two procedures
can be followed .
First Possible Procedure:
- Remove spark plugs.
- Lock crankshaft at TOC position. Refer to BOT-
TOM END section .

1. Mark on drive pullev sliding sheave

2. Mark on governor cup

Unscrew the drive pulley screw (right hand

thread), then remove it as well as the conical
spring washer and thrust washer.

1. Crankshaft locking bolt

2. Engine drive shaft (front side)

Second Possible Procedure:

Block drive pulley with the pulley holding tool
(PIN 529 006400).

529006400

I
~===---=--=--=--=--~______-~ra- ":J vmI2006-021-051_b

1. Drive pullev screw

2. Conical spring washer
3. Thrust washer

& WARNING
Sliding sheave of drive pulley is spring load-
ed.

Push with your hand the sliding sheave no. 2 of

the drive pulley then remove the screw complete-
ly.
Slowly release sliding sheave.
Screw drive pulley puller (PIN 529035746) in fixed
vmr2006-021 -Ql0_11
sheave and remove fixed pulley.
1. Pullev holding tool
2. Drive pullev sliding sheave 529035746
3. Area to place holding tool hook

When the drive pulley is blocked, mark sliding

sheave and governor cup to ensure correct rein-
stallation.
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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

NOTE: Use protection plates to avoid marks

and/or damages to the governor cup.
CAUTION: Always replace all rollers at the
same time. Partly worn rollers may cause
damage to the CVT system.

vmr2006-021-013_a

1. Drive pullev puller

2. Fixed sheave

Disassembly
Governor Cup 1. Punch
Carefully lift governor cup no. 3 until slider shoes 2. Vice

no. 4 come at their highest position into guides.

!'JOTE: The following procedure is not necessary
except if roller must be removed. Refer to IN-
SPECTION before proceeding.
Remove slider shoes out of each bearing sleeve.
Use a flat screwdriver if necessary.

1....

vmr2006-021-016_a

1. Removal direction
2. Assemblv direction

NOTE: Whenever removing a governor cup with

already two marked boxes replace it by a new one.

A400motr171A

1. Slider shoe

Put governor cup on a vice to push out bearing

sleeve of roller in the foreseen direction (against
arrow). Use an appropriate punch (diameter of
punch must be smaller than the bearing sleeve di-
ameter).
CAUTION: Do not clamp the governor cup in vmr2006-021-018
the vice to push out bearing sleeve. Governor
cup will be damaged.

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Sliding Sheave
Unscrew lock nut and remove centrifugal lever piv-
ot bolt. This drive pulley is equipped with 6 levers.
Remove centrifugal lever no. 7 and both thrust
washers no. 8.

vmr2006-021-021_8

1. Springs
"mr2006-021-019_8
2. Spring sleeves

1. Lock nut
2. Centrifugal lever pivot bolt
3. Centrifugal lever Cleaning
4. Thrust washers
Clean pulley faces and shaft with fine steel wool
Fixed Sheave and dry cloth.
Remove friction washer no. 12. Using a paper towel with pulley flange cleaner
(P/N 413 711 809) cleaning solvent, clean crank-
& WARNING shaft tapered end and the taper inside the fixed
Always wear safety glasses to remove spring sheave of the drive pulley, crankshaft threads and
sleeves. threads of drive pulley screw no. 15.
CAUTION: Avoid contact between cleaner and
Pull and rotate one-way clutch slowly until the crankshaft seal because damage may occur.
sheave of spring sleeves are visible .
Remove all hardened oil deposits that have baked
on crankshaft and pulley tapered surfaces with
coarse or medium steel wool and/or sand paper
no. 600.
CAUTION: Do not use any other type of abra-
sive.
Reclean mounting surfaces with paper towel and
pulley flange cleaner (P/N 413 711 809).
Wipe off the mounting surfaces with a clean, dry
paper towel.
CAUTION: Mounting surfaces must be free of
any oil, cleaner or towel residue.

vmr2006-021-020_a

1. One-way clutch
2. Fixed sheave
3. Spring sleeve area

Hold both spring sleeves with fingers and release

when one-way clutch is disengaged.
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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

1. Roller
2. Slider sho e
A. Roller outer diameter

ROLLER OUTER DIAMETER

1. Taper of fixed sheave
13.70 to 13.80 mm
NEW
Only use petrol base cleaner when cleaning bush- (.539 to .543 in)
ings no. 10 and no . 11 . SERVICE LIMIT 13.20 mm (.519 in)
CAUTION: Do not use acetone to clean bush- ROLLER INNER DIAMETER
ing.
8.05 to 8.15 mm
NEW
Inspection (.317 to .321 in)

Drive Pulley SERVICE LIMIT 9.00 mm (.354 in)

Drive pulley should be inspected annually. Centrifugal Lever Pivot Bolt

Governor Cup Measure diameter of centrifugal lever pivot bolt
Check governor cup for cracks or other visible no. 9, replace if it is out of specification .
damages . Replace if necessary.
Roller and Slider Shoe
Check each roller for roundness of external diam-
eter.
Check if rollers move freely. R6 10tran1 2A A
CAUTION: Whenever replacing rollers and slid- 1. Centrifugal lever pivot bolt
er shoes, always replace all rollers and slider A. M easure diam eter here
shoes at the same time.
Check slider shoes for visible wear and replace if CENTRIFUGAL LEVER PIVOT BOLT DIAMETER
damaged . 6.078 to 6.100 mm
I\JOIVIINAL
NOTE: If necessary, use a screwdriver to remove (,239 to .240 in)
slider shoes . SERVICE LIMIT 6.00 mm (.236 in)

Centrifugal Lever
Check bushing diameter in the centrifugal lever
no. 7 for wear. Replace centrifugal lever if nec-
essary.

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

CENTRIFUGAL LEVER BORE DIAMETER

6.035 to 6.078 mm
NOMINAL
(.238 to .239 in)
SERVICE LIMIT 6.200 mm (.244 in)

Replace centrifugal lever, thrust washers, centrifu-

gal lever pivot bolts and lock nuts if the contact
surfaces show heavy visible wear.

vmr20 06-Q2 1-024 _8

A. Centrifugal lever pivot bolt bore diameter

CENTRIFUGAL LEVER PIVOT BOLT

BORE DIAMETER
3 4 2 6.11 3 to 6.171 mm
NOMINAL
vmr2006-02 1-0 19 _b ( 24 1 to .243 in )
1. Lock nut 6.300 m m ( 248 in)
2. Centrifuga l lever pivot bolt
SERVICE LIMIT
3 . Centrifugal lever
4. Thrust washers
5. Contact surface to the roller Measure bushing diameters of sliding sheave.
Use a dial bore gauge to measure bushing diame-
& WARNING ter. Measuring point must be at least 5 mm (1/4 in)
Whenever replacing centrifugal levers, al- from bushing edge.
ways replace all lever at the same time.
Otherwise, unbalanced drive pulley will oc-
cur because of levers difference.

Sliding Sheave
Check sliding sheave for cracks and sliding con-
tact surface for excessive wear. Replace sliding
sheave if necessary.
Measure centrifugal lever pivot bolt bores . Re-
place sliding sheave if bores are out of specifica-
tion or otherwise damaged .

R610t ran 14A

1. Bushing on fixed sheave side

A. Bore diam eter of bushing

SLIDING SHEAVE LARGE BUSHING

55 .000 to 55 .040 mm
NOMINAL
(2.165 to 2.167 in)
SERVICE LIMIT 55.200 mm (2.173 in)

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Spring
Measure spring free length and squareness. If
spring is out of specification, replace by a new
one .

SPRING FREE LENGTH

SERVICE LIMIT I 85 mm (3.347 in)
CLUTCH SPRING SOU ARE NESS
SERVICE LIMIT I 4mm (.157 in)

One-Way Clutch
Check bearings for excessive play and smooth op-
eration. Replace one-way clutch if necessary.
CAUTION: Be careful not to damage the inside
of one-way clutch during bearing removal.
R610tran11A

1. Bushing on governor cup side

A. Bore diameter of bushing

SLIDING SHEAVE SMALL BUSHING

32 .000 to 32.040 mm
NOMINAL
(1.260 to 1.261 in)
SERVICE LIMIT 32.200 mm (1.268 in)

Replace sliding sheave if bushings no. 10 and/or 2

no. 11 is (are) out of specification. Visually inspect
coatings. 1
Fixed Sheave
Check fixed sheave contact surface to the gover- vmr2006-02 1-028_8

nor cup for scratches or other damages. If so, re- 1. One-way clutch
2. Bearings
place fixed sheave.
Measure length of spring sleeve no. 14 and check
if edges on top of the spring sleeve are excessive-
ly worn. If they out of specifications, replace both
spring sleeve at the same time .

SPRING SLEEVE LENGTH

9.2 to 9.4 mm
NOMINAL
(.362 to .370 in)
SERVICE LIMIT 9 mm (.276 in)

Assembly
For assembly, reverse the disassembly procedure.
Pay attention to following details .
vmr2006-02 1-021 _a
One-Way Clutch
1. Visually check here
NOTE: Using Isoflex grease Topas NB 52 (P/N 293
Check for any marks on fixed sheave plate . Re- 550021) , lubricate spring and spring sleeve no. 14
place if necessary. and between one way clutch bearings no. 13.

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Friction Washer Each time when replacing the bearing sleeves sign
NOTE: Apply Isoflex grease Topas NB 52 (PIN 293 the foreseen box with a punch.
550021) on both sides of friction washer no. 12. CAUTION: Do not tap too hard. Violent dam-
NOTE: Friction washer has to be assembled with age of the governor cup may appear.
collar towards to the one way clutch.

vmr2006-021-017

CAUTION: Rollers must move easily after in-

1. Friction washer stallation.
2. Collar
3. One way clutch Insert slider shoes into governor cup to properly
slide in guides.
Sliding Sheave
Install centrifugal levers no. 7 with their thrust
Installation
washers no. 8. For installation, reverse the removal procedu re.
Pay attention to the following details.
CAUTION: Centrifugal levers must move easily
after installation.
& WARNING
Governor Cup Do not apply antiseize or any lubricant on
Rebuild governor cup with new bearing sleeves, crankshaft and drive pulley tapers.
thrust washers no. 6, rollers and slider shoes.
CAUTION: Never use any type of impact
CAUTION: Final position has to be aligned with
wrench at drive pulley removal and installa-
the contact surface of the slider shoes (no pro-
tion.
trusion).
Clean mounting surfaces as described in CLEAN-
ING above.
Install drive pulley on crankshaft extension.
CAUTION: Do not forget to place thrust washer
prior to install conical spring washer.
Install conical spring washer with its concave
side towards drive pulley then install drive pulley
screw.

I. Top edge of bearing sleeve

2. Mating surface of slider shoes
3. Vice

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Section '07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Using the pulley holding tool (P/N 529 035 771),

hold the driven pulley during the removal of the
driven pulley screw. Do not remove screw com-
pletely.

529035771

vmr 2006-021-051 _a

1. Drive pulley screw

2. Conical spring washer
3. Thrust washer

& WARNING
Never substitute conical spring washer
and/or screw with jobber ones. Always use
BRP genuine parts for this particular case.
1. Driven pulley screw
2. Pulley holding tool
To torque the drive pulley screw, block the drive
pulley. Refer at the beginning of this section for Push the driven pulley and maintain it in this posi-
the two possible procedures. tion during the removal of screw. Remove driven
When the drive pulley is blocked, torque screw to pulley screw and washer.
100 N-m (74 Ibf-ft) .

vm r2006-02 '·03o_3

1. Pulley holding tool (PI N 529 006 400)

2. Drive pulley removal/ins talla tion area

1. Driven pulley screw

2. Thrust washer
DRIVEN PULLEY 3. Driven pulley fixed sheave

Removal & WARNING

Remove drive belt (see DRIVE BELTabove). Driven pulley is spring loaded. Hold driven
clutch pulley tight and slowly remove the
driven pulley screw to release spring tension.

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSIOI\I (CVT))

Remove the driven pulley with the spring, cam and

the plate.

vmr200S'()2 1·034 _s
1. Soft hammer
2 . Shaft
1. Fixed sheave of driven pulley
2. Sliding sheave of driven pulley
3. Spring Remove shaft from ball bearing .
4 . Cam
5. Plate
Remove distance sleeve and O-ring no. 26 from
countershaft.
Replace O-ring if brittle, hard or damaged.
Disassembly
Fixed Sheave
Remove retaining ring and lift torque gear.

1. O-ring
2. Distance sleeve

Cleaning
When a dust deposit has to be removed from the
1. Retaining ring cam or the shaft. use dry cloth.
2. Torque gear
3. Fixed sheave of driven pulley Clean pulley faces and shaft with fine steel wool
and dry cloth.
NOTE: The following procedure is not necessary Use pulley flange cleaner (PIN 413 711 809) to
except if ball bearing or shaft must be removed. clean driven pulley.
Refer to INSPECTION before proceeding.
Clean the CVT air guide area from contamination.
Heat ball bearing area up to 100°C (212°F) before
removing ball bearing. Using a paper towel with pulley flange cleaner
(PIN 413 711 809) to clean countershaft end and
Use a soft hammer to push shaft with bearing the inside of the shaft no. 23.
no. 17 out of fixed sheave.
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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

CAUTION: To avoid damage, make sure cleaner BUSHINGS BORE DIAMETER

does not contact the countershaft oil seal. .
30.060 to 30.100 mm
NOMINAL
(1 .183 to 1.185 in)
SERVICE LIMIT 30.200 mm (1 .189 in)

Fixed Sheave
Check fixed sheave for cracks and excessive wear.
Replace fixed sheave if necessary.
Check ball bearing for free play and smooth oper-
ation . Replace if necessary.
Check shaft for heavy wear or visible damage. Re-
place if necessary.
If the shaft is removed, using a dial bore gauge,
measure bushing diameter. Measuring point
must be at least 5 mm (1/4 in) from bushing edge.
This bushing can not be replaced. Replace fixed
1. Countershaft support sheave if bushing no. 18 is out of specification.
2. Countershaft oil seal
Visually inspect coatings.

Inspection BUSHING BORE DIAMETER

30.060 to 30.100 mm
Sliding Sheave NOMINAL
(1.183 to 1.185 in)
Check sliding sheave for cracks and sliding con-
SERVICE LIMIT 30.200 mm (1.189 in)
tact surface for excessive wear. Replace sliding
sheave if necessary.
Check torque gear for visible damage and cracks .
Check bushings no. 22 for cracks, scratch and
for free movement when assembled to sliding Measure wear limit with a caliper.
sheave.
Using a dial bore gauge measure bushing diame- B
ter. Measuring point must be at least 5 mm (1/4 in)
'from bushing edge .
This bushing can not be replaced. Replace sliding
sheave if bushings no. 22 are out of specification.
Visually inspect coatings.

vmr2006.Q21-039_a

A. Measurement inside
8. Measurement outside

WEAR ON TEETH BOTH SIDES

SERVICE LIMIT I 7.500 mm (.295 in)
1. Bushings
2. Backside of sliding shea ve of driven pulley

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Cam SPRING FREE LENGTH

Check cam for visible damage and wear limit with
a caliper.
SERVICE LIMIT I 125 mm (4.921 in)
CLUTCH SPRING SQUARENESS
2
SERVICE LIMIT I 3.8 mm (.150 in)

Assembly
For installation, reverse the removal procedure .
Pay attention to following details.
Heat ball bearing area up to 100°C (212°F) before
ball bearing installation.
NOTE: Place new ball bearing in a freezer for 10
minutes before installation .
Install ball bearing with the writing on top and push
only on the outer ring .

1. Contact surface
2. Caliper
A. Width to be measured due to wear on contact surface

WIDTH ON TOP SURFACE

SERVICE LIMIT I 9.00 mm (.354 in)

7. Ball bearing
2. Fixed sheave of driven pulley

CAUTION: Do not use hammer, use press ma-

chine only.

1. Caliper 2
2. Sliding sheave
3. Contact surface
A. Wear to be measured

WEAR ON CONTACT SURFACE

SERVICE LIMIT I 1.00 mm (.039 in) 7. Shaft
2. Fixed sheave
3. Press machine
Spring
Measure spring free length and squareness. If Install torque gear then secure it with retaining
spring is out of specification, replace by a new. ring.

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

vmr2006.Q2 1-035_a

1. Retaining ring 1. Sharp edge of cam retainer to engine side

2. Counters haft spline
2. To rque gear
3. Inscription
3. Fixed sheave of driven pulley

Install cam no. 24.

Installation Install sliding sheave no. 21 into fixed sheave
For installation, reverse the removal procedure. no. 16.
Pay attention to the following details . Place spring behind sliding sheave then align driv-
Place O-ring no. 26 on countershaft splines and en pulley with cam.
move it with distance sleeve no. 25 in end posi-
tion.
CAUTION: Chamfer on inside diameter of the
distance sleeve must face gearbox side.

vmr2006-02 1-040_a

1. Q·ring 1. Cam
2. Distance sleeve 2. Sprin g
3. Chamfered area of distance sleeve 3. Driven pulley

Install cam retainer on countershaft end the right With your hand, push the driven pulley on the shaft
way. to compress the spring. Install the driven pulley
screw and thrust washer.

Driven pulley is a spring loaded system.

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Section 07 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Installation
For installation reverse the removal procedure.

1. Driven pulley screw

2. Thrust washer
3. Drive n pulley fixed sheave

NOTE: Driven pulley end-play is 0 (zero).

Torque driven pulley screw.

CVT AIR GUIDE

Removal
Remove the drive pulley and the driven pulley.
Unscrew the clamps retaining the CVT air hoses.
Remove CVT air guide.

Inspection
Clean CVT air guide from contamination
Check O-rings if brittle, hard or damaged. Replace
if necessary.

vm, 2006-02 1..Q47 _"

1. CVT air guide

2. O-rings

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

FRONT DRIVE
SERVICE TOOLS
Description Part Number Page
CV boot clamp pliers ..... .. .. .. ... ......... ........ ... ...................... .... . 295000069 ......... .......... .. .. .. .. .. ............ 312
pliers Oetiker 1099 ..................... .. .. .... ...... .. ............. ..... ...... .. 295 000 070 ...... ..... ...... .... ............ ........ 312
differential spanner socket ....... ....... ....... .. ... .............. ..... ..... . 529 035 649 .. ...... .... .. ...... ... ......... .. ....... 314
backlash measurement tool ........ .. .......... ............... .... ........ .. 529035665 ............. .......... .................. 315
joint extractor tool. ......... ............... ... ......... .............. .... ......... . 529036005 .................... .. ........ .. ...... ... 312

SERVICE PRODUCTS
Description Part Number Page
xp-s synthetic grease .. ......... ....... ................ .. .. ............... ... ... 293550010 .. ......... .... ...... .... 311,316,318
XP-S synthetic gear oil ................. .. ................... .... .... ........... . 293 600 043 ............. .. .......................... 313
Loctite 277 ...... .. ............. ... .... ... .. .... ........... ....... .................... . 293 800 073 ..... .. .. ... .. .. ... .. ..... ............. .. 316

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

)7 32 Nom

~
(24Ibfoft)

~,~

~
~ " '~
~, .
XP-S ~ 23
synthetic 18 34 Nom
grease / (25Ibf°ft)
~~
~~, / 15
~~d6
~(, ({{!;JZa XP-S
synthetic
180 Nom grease
(133 Ibf°ft) 22 '____ ,,~~
20 21 """ ()if '----,
19~~\)& 1 "1 ·
Xp.S synthetic grease & ~ & Loctite 277
j
I (66
7.5~.m
Ibfoin)
./
./
./
./
./
./ 22 Nom
./ . ./. ~ / 8 (16 Ibf0ft)
' ../ qf
/"'-1.m"\lI1\",~

xp-s synthetic grease ~~ .

XP-S 14 10~ ~~1

synthetic~ ~ IQl ~ 3
greas~ ~ w 12
42 Nom
(31 Ibfoft)
11

~~42Nom ) ~.~
~ (31 Ibfoft)
XP-S
~
205 Nom
synthetic grease (151 Ibfoft)

vmr200B-066-001 _a

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

GENERAL
The procedure explains below is the same for the
RH and LH sides unless otherwise instructed .
During assembly/installation, use torque values
and service products as in the exploded views.
Clean threads before applying threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure .

& WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced CAUTION: Always use the recommended
with new ones. wheel nuts. Using a different nut could cause
damages to the rim.

WHEEL NUT TORQUE

PROCEDURES
70 N-m
All steel wheels
TIRES AND WHEELS (52 Ibf-ft)
All alum inum wheels 100 N-m
& WARNING (except fo r Outland er MAX 800 Ltd) (74 Ibf-ft)
When the tires are replaced, never install a Out lander MAX 800 Ltd 70 N-m
bias tire with a radial tire. Such a combina- (BLAC K aluminum wheels) (52 Ibf-ft)
tion could create handling and/or stability
problems. Outlander 650 and 800 Series and
Do not mix tires of different size and/or de- Renegade Models
sign on the same axle.
On these models, wheel balancing is necessary.
Front and rear tire pairs must be the identical
To perform this operation, use a wheel balancer
model and manufacturer.
and adhesive weights .
For unidirectional tread pattern, ensure that
the tires are installed in the correct direction
of rotation. WHEEL HUB
The radial tires must be installed as a com-
plete set. Wheel Hub Removal
Severe injury or death can result if these Raise the front of vehicle, support it securely on
instructions are not followed. jack stands and remove front wheel.
Apply parking brake or select 4WD position and
The tires are directional and their rotation must be place transmission lever on P.
kept in a specific direction for proper operation .
Remove cotter pin and discard it.
Using the next table, torque wheel nuts in accor-
dance with the following illustration. Unscrew the castellated nut.
Remove the Belleville washer.

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

RENEGADE MODELS
1. Wheel hub
2. Wear ring
TYPICAL
1. Cotter Pin
2. Castella ted nut
3. Belleville washer Wheel Hub Installation
Renegade Models The installation is the reverse of removal proce-
dure.
Remove caliper from knuckle. Refer to BRAKES.
Install Belleville washer so that the inside diameter
All Models protrudes outward and contacts the nut.
Pull wheel hub no. 1 to remove it. Tighten the castellated nut on the drive shaft end
to 205 N-m (151 Ibf-ft) and further tighten until
Wheel Hub Inspection one of its grooves is aligned with a cotter pin hole .
Check wheel hub for cracks or other damages. Install a NEW cotter pin and the wheel cap. Fold
one pin of cotter pin over drive shaft end.
Check inner splines fo r wear or other damages.
If any damage is detected on wheel hub, replace
it with a new one.
Check wear ring. If damage is apparent, replace
the wear ring.

V07HOCA

FRONT DRIVE SHAFT

Drive Shaft Removal
Remove the appropriate wheel hub no. 1, see
above.
V07 H08A 2 Outlander 500 Series
TYPICAL - FOR ALL OUTLANDER Unscrew bolts holding strut to knuckle.
1. Wheel hub
2. Wear ring

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

Outlander 650/800 Series and Renegade Drive Shaft Inspection

Models Inspect the condition of boots no. 4. If there is any
Remove bolt that attach the shock absorber to the damage or evidence of leaking lubricant, replace
upper suspension arm . them. Refer to DRIVE SHAFT BOOTfurther.
Detach upper suspension arm from knuckle . Check splines for excessive wear. Replace if nec-
essary.
All Models
Remove ball joint retaining bolt or ball joint nut NOTE: If the splines on plunging joint no. 5 are
from knuckle. worn, a check of differential inner splines should
be done.
Check the stop ring no. 6 at the end of drive shaft.
If wear is apparent, replace the wear ring no. 7.
Check if the bearings in knuckle move freely and
smoothly. If not, replace them. Refer to STEER-
ING SYSTEM

Drive Shaft Installation

Apply XP-S synthetic grease (PIN 293 550 010)
to the splines and insert the end of drive shaft
in differential and pull joint a little to make sure
V07H09A 2 that the stop ring is locked in differential side gear
groove.
ALL OUTLANDER MODELS
1. Ball joint retaining bolt
2. Lower suspension arm 1

1. Stop ring
vmr2007-055-005_a
The wear ring should be closed to the differential.
RENEGADE MODELS
1. Knuckle
2. Lower ball joint
3. Lower suspension arm

Separate knuckle from lower suspension arm.

Move CV joint no. 2 out of knuckle then place the
knuckle and the tie-rod out of way.
All Outlander Models
Remove caliper. Refer to BRAKES.
All Models
Pull drive shaft out of differential no. 3.
NOTE: Pull drive shaft strongly.

V07HOBA

TYPICAL

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

Insert the other end of drive shaft in the knuckle

and install the knuckle to the lower suspension
arm. Install and torque the ball joint retaining bolts
to 45 N-m (33 Ibf·ft).
Install all other removed parts .

DRIVE SHAFT BOOT

Boot Inspection
Check bearing in plunging joint no. 5 or CV joint
no. 2. If bearing is hard to move, change plunging
joint or CV joint. TYPICAL - CV JOINT SHOWN
1. Joint ex tractor tool
Check circiip for damage, change as necessary.
With an hammer, hit on the tool to separate joint
Boot Removal from shaft.
Remove clamps from rubber boot using CV boot When joint and shaft are separated, remove boot
clamp pliers (PIN 295 000 069) and pliers Oetiker from drive shaft.
1099 (PIN 295000 070) . Remove and discard the circlip. A new one is in-
Remove the large end of the boot from plunging cluded in the boot kit.
joint no. 5 or CV joint no. 2.
Separate the joint from the shaft. Two procedures Boot Installation
can be done. For installation, reverse the removal procedure.
Pay attention to the following details .
Without the Special Tool
Insert the small clamp and the small end of boot
Clamp joint housing in a vise. on shaft.
Align shaft with joint. Install the NEW circlip.
Pull hard on shaft to remove from joint. Install the joint in a vise (joint facing up).
Remove boot from drive shaft. Center circlip on shaft.
Remove and discard the circlip. A new one is in- Carefully insert shaft into joint and push hard to
cluded in the boot kit. engage circlip.
With the Special Tool Pack bearing area with grease (included with the
Place drive shaft in vice with the joint downward. new boot kit).
Install the joint extractor tool (PIN 529 036 005) on NOTE: Do not use or add other grease.
bearing. Install all other removed parts.

FRONT DIFFERENTIAL
Oil Level
Clean filler plug prior to checking oil level.
529036005

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

1 2

V07HODB
ALL MODELS EXCEPT RENEGADE
1. Filler plug ALL MODELS EXCEPT RENEGADE
1. Drain plug
2. Filler plug

RENEGADE MODELS
1. Filler plug
RENEGADE MODELS
1. Filler plug
With vehicle on a level surface, check oil level by 2. Drain plug
removing filler plug no. 8. Oil level must reach the
lower edge. Clean drain plug area then reinstall plug.
Add oil if necessary. Use XP-S synthetic gear oil Lower vehicle.
(PIN 293 600 043) or a 75W90 synthetic oil (API Use a funnel and refill front differential with
GL-5). 500 mL (17 oz. US) of XP-S synthetic gear oil
(PIN 293 600 043). If the XP-S synthetic gear oil
Oil Change is not available, use a 75W90 synthetic oil (API
Place vehicle on a level surface. Set transmission GL-5) .
in park position. Reinstall filler plug.
Lift LH side of vehicle.
Clean drain plug area. Removal
Drain the differential.
Place a drain pan under differential drain plug area.
Raise front of vehicle, support it securely on jack
Remove drain plug no. 9.
stands and remove front wheels.
Unscrew filler plug.
On both sides, remove the drive shafts (refer to
FRONT DRIVE SHAFT above) .
Remove both upper suspension arms.

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

Remove bolts that attach winch bracket to the

frame (XT models).
Remove the upper differential bolts .

Remove the differential no. 3 from the right side

of vehicle.

Inspection
Remove the differential support bolts.
Check backlash and drag torque, see AOJUST-
MENTfurther in this section.
Check if oil seals are brittle, hard or damaged. Re-
place if necessary.

Disassembly
Ring Gear Carrier/Ring Gear
Unscrew the TORX screws no. 17, then separate
half housings .

1. Differential support
2. Differential support bolts

Remove the lower differential bolts.

NOTE: Be careful to keep track of shims on each

end of ring gear carrier.
Extract ring gear carrier no. 15 with ring gear
no. 16 out of half housing.
Remove the differential support, by the left side. Unscrew Allen socket screws no. 18 then sepa-
Remove the Oetiker clamp no. 10 that attach pro- rate ring gear from ring gear carrier.
peller shaft bellows no. 14 to the propeller shaft Pinion Gear
adaptor no. 13.
Remove oil seal no. 19.
Unscrew the pinion nut no. 20 . Use the differen-
tial spanner socket (P/I\! 529035649).

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

529035649

Remove the bearing no. 21 at the same time as

the pinion gear no. 22. Be careful to keep track of
shims.
NOTE: The pinion gear and bearing can be easily vmr2006-{J2J-009_8

removed using the following suggested tool: 1. Backlash side

2. Preload side
pipe 3-1/2 in diameter x 5 in (1)
- screwed rod M 10 x 1.25, 7 in length (1) Assemble the differential and check backlash as
- nut M10 x 1.25 (3) well as preload .
- flat bar (1 ). Backlash
Adjustment Using a dial indicator and the backlash measure-
ment tool (P/N 529 035 665). measure the back-
A shimming procedure must be done when ring
lash . Place the backlash measurement tool at the
gear carrier, pinion gear, ring gear or housing is
end of pinion gear.
(are) changed.
From center of bolt, measure 25.4 mm (1 in) and
Measure the old pinion shim stack. If the shims
scribe a mark on the tab .
measure over 1 mm (.039 in). install shim stacks
on the differential components as per CHART" A".
If the old pinion shim stack measurement is under
1 mm (.039 in), install a .5 mm (.02 in) shim on the
differential components as per CHART" B" .

I :
CHART "A" CHART "B"
1.85 mm
PINION PINION
(.073 in)
.5 mm
BACKLASH 1 mm BACKLASH (.02 in)

PRELOAD (.039 in) PRELOAD

NOTE: The procedure above sets the pinion shim

thickness and should not be modified thereafter. ~A
Any changes should be done on the preload and/or
backlash side(s). 1. Tab of backlash measurement tool
2. Mark on tab
A. 25.4 mm (1 in)

Position the dial indicator tip against the tab at a

90° angle and right on the previously scribed mark.
Gently, move the tab back and forth . Note the
result.

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

TYPICAL

If the drag torque is greater than 0.7 N-m

(6 Ibf-in). reduce preload shim by 0.05 mm
Rotate pinion gear 1/2 turn and check backlash (.002 in) and check drag torque again.
again . Note the result.
If the drag torque is less than 0.06 N-m (.5 Ibf-in).
Rotate pinion gear 1 turn and check backlash increase preload shim by 0.05 mm (.002 in) and
again. check drag torque again .
If backlash is below 0.05 mm (.002 in). increase
backlash shim by 0.05 mm (.002 in) and check the Assembly
backlash again.
Ring Gear Carrier/Ring Gear
If backlash is greater than 0.356 mm (.014 in). de-
To assemble, reverse the removal procedure. Pay
crease backlash shim by 0.05 mm (.002 in) and
check the backlash again. attention to the following details.
Verify condition of half housing seal no. 23.
Measure preload.
Change seal if necessary.
Preload Check all bearings and all oil seals . Change them
Screw the propeller shaft adaptor bolt no. 12 in if necessary.
pinion gear.
Pinion Gear
To install, reverse the removal procedure. Payat-
tention to the follow ing details .
Check O-ring no. 24 for damage . If so, change it.
Install the shim(s) then the ball bearing.
Install the nut no. 20. Apply Loctite 277 (P/N 293
800073) on threads nut then torque it to 180 N-m
(133 Ibf-ft).
Apply XP-S synthetic grease (P/N 293550010) in
the lips of the new oil seal no. 19 and install it.

TYPICAL
Installation
The installation is the reverse of the removal pro-
Using a needle torque wrench, measure the drag cedure.
torque .
FRONT PROPELLER SHAFT
Removal
Place vehicle on PARK position and select 4WD.
Remove the RH footrest.
Unscrew propeller shaft bolt on engine side .

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

Remove the Oetiker clamp no. 10 that attach pro-

peller shaft bellows no. 14 to the propeller shaft
adaptor no. 13. Discard clamp.
V01HOYA

1. Snap ring

Support inner yoke in vice and drive other yoke

down with a soft hammer.

Remove LH drive shaft.

Unscrew lower and upper differential bolts .
Remove them and move the differential forwards.
Remove front propeller shaft no. 11.

Inspection
Check: Support U-joint in vice and drive inner yoke down
- splines for wear or damage to remove remaining bearing caps.
- if U-joint moves freely in all direction Remove U-joint cross.
- bellows for holes or brittleness.
Installation
Installation Install new U-joint cross in inner yoke.
Installation is the reverse of removal procedure. Install new bearing cap by hand.
NOTE: Carefully install U-joint cross with grease
PROPELLER SHAFT U-JOINT fitting properly positioned .

Removal
Remove internal snap ring from bearing caps .

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Section 08 DRIVETRAIN
Subsection 01 (FRONT DRIVE)

Tighten vise to force bearing caps in.

Using a suitable tappet, fully seat bearing cap in

one side . Continually, check for free movement
of bearing cross as bearing caps are assembled.

Install snap ring.

Repeat procedure for other sides .
Grease U-joint. using a grease gun with XP-S syn-
thetic grease (PIN 293 550 010).

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Section 08 DRIVETRAIN
Subsection 02 (REAR DRIVE)

REAR DRIVE
SERVICE TOOLS
Description Part Number Page
CV boot clamp pliers ...... .... ............................ .. ................... .. 295 000 069 ................................. .... .... 323
pliers Oetiker 1099 .. .. .... .... ........................ .. .. ...... ................ . 295 000 070 .... ............................... .. .... 323
differential spanner socket .......... .... .. .... .. .. .................. ........ . 529 035 649 ......................................... 327
backlash measurement tool ............ ...... ........ .. .... ............ .... . 529 035 665 .... .... ................... ... ..... ...... 328

SERVICE PRODUCTS
Description Part Number Page
xp-s synthetic grease ....... ... ......... ................. ........... ........... . 293 550 010 ...... ..... ...... 322, 325-326, 329
XP-S synthetic gear oil ........ .... .................... ....... .................. . 293 600 043 ...... .. ......................... ..... ... 326
Loctite 277 ......... ..... ........ ... ... ....... ............. ....... ................. .. .. 293 800 073 .. .. .. ... ................. .. .......... ... 329

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Section 08 DRIVETRAIN
Subsection 02 (REAR DRIVE)

xp-s synthetic grease

xp-s XP-S
synthetic 8 synthetic
grease grease
~

iL-----:--~ Loctite ,~~

277 16 % 14 7.5 N-m
XP-S ~ ""-..~~ 13 (66 Ibf-in)

synthetic ~ 12 180 N-m

grease .,,1' (133Ibfeft)
11 (Left hand threaded)
70 N-m

xp-s
synthetic
grease& ~,

~
~ '42 N-m XP-S
& ' ~" (311 ) synthetic
Xp-s 45 N-m 1F=IiiO=-...\-,.. grease
synthetic grease (33 Ibfeft)
I~
2.5 N-m "8
(22 Ibf-in)

mDl
~
205 N-m
(151 Ibf-ft)
\l mr2008 ·06 7~01_a

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Section 08 DRIVETRAIN
Subsection 02 (REAR DRIVE)

GENERAL
During assembly/installation, use torque values
and service products as in the exploded views .
Clean threads before applying a thread locker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure .

& WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced
with new ones.
CAUTION: Always use the recommended
wheel nuts. Using a different nut could cause
PROCEDURES damages to the rim.

TIRES AND WHEELS WHEEL NUT TORQUE

70 N.m
& WARNING All steel wheels
(52 Ibf·ft)
When the tires are replaced, never install a All aluminum wheels 100 N.m
bias tire with a radial tire. Such a combina- (except for Outlander MAX 800 Ltd) (74 Ibf.ft)
tion could create handling and/or stability
problems. Outlander MAX 800 Ltd 70 N·m
(BLACK aluminum wheels) (52 Ibf·ft)
Do not mix tires of different size and/or de-
sign on the same axle.
Front and rear tire pairs must be the identical Outlander 650/800 Series and Renegade
Models
model and manufacturer.
For unidirectional tread pattern, ensure that On these models, wheel balancing is necessary.
the tires are installed in the correct direction To perform this operation, use a wheel balancer
of rotation. and adhesive weights .
The radial tires must be installed as a com-
plete set. WHEEL HUB
Severe injury or death can result if these
instructions are not followed. Wheel Hub Removal
Remove the appropriate wheel.
The tires are directional and their rotation must be
kept in a spec ific direction for proper operation . Remove and discard the cotter pin.
Using the next table, torque wheel nuts in accor- Unscrew the castellated nut.
dance with the following illustration. Remove the Belleville washer.
Pull wheel hub to remove it .

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Section 08 DRIVETRAIN
Subsection 02 (REAR DRIVE)

vm r2007 -054-002_a

1. Cotter pin
2. Castellated nut
3. Belleville washer
4. Wheel hub

V07 HOCA
Wheel Hub Inspection
Check wheel hub for cracks or other damages.
DIFFERENTIAL PROTECTOR
Check inner splines for wear or other damages.
If any damage is detected on wheel hub, replace Differential Protector Removal
it with a new one. Remove bolts retaining the protector to the frame .
Check wear ring. If it is loose on hub, replace the
wear ring.

1. Protector bolts
2. Differential protector

V07H1SA 2 Differential Protector Installation

1. Wheel hub The installation is the reverse of removal proce-
2. Wear ring
dure.

Wheel Hub Installation DRIVE SHAFT

The installation is the reverse of removal proce-
dure. Pay attention to the following . Drive Shaft Removal
Apply XP-S synthetic grease (PIN 293 550 010) on Remove the appropriate wheel hub and the
drive shaft splines. footrest on this side.

Install Belleville washer in correct orientation . In- Remove the lower shock absorber bolt.
side diameter must protrude outward . Remove trailing arm . Refer to REAR SUSPEN-
SION.
Torque castellated nut to 205 N-m (151 Ibf-ft) and
further tighten until one of its grooves is aligned Pull drive shaft no. 1 out of differential no. 2.
with a cotter pin hole. Install a NEW cotter pin. NOTE: Pull drive shaft strongly.
Fold one pin of cotter pin over drive shaft end .

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Section 08 DRIVETRAIN
Subsection 02 (REAR DRIVE)

Drive Shaft Inspection

Inspect the condition of boots . If there is any dam-
age or evidence of leaking lubricant, replace them.
Refer to DRIVE SHAFT BOOT.
Check shaft splines . Replace drive shaft if neces-
sary.
Check wear ring no. 3 on drive shaft end. Replace
if necessary.

Drive Shaft Installation

Insert the end of drive shaft in differential and
pull joint a little to make sure that the stop ring
is locked in differential gear groove .

V01HOXA 2
1. Circlip
2. Shaft

Remove boot from drive shaft.

Boot Inspection
Check bearing in plunging joint no. 5 or CV joint
no. 6. If bearing is hard to move, change plunging
V01HOFA joint or CV joint.
1. Stop ring Check circlip for damage, change as necessary.

NOTE: Make sure do not interchange LH and RH Boot Installation

drive shafts. The shafts are different lengths. For installation, reverse the removal procedure.
Install the other parts in the reverse order of re- Pay attention to the following details.
moval procedure. Refer to the appropriate sec- Insert boot, do not forget the small clamp .
tions to apply the proper torque .
Insert shaft and push firmly.
DRIVE SHAFT BOOT Pack bearing area with grease (including with the
new boot kit).
Boot Removal NOTE: Do not use any other grease.
Remove the drive shaft from vehicle. Install all other removed parts .
Remove the clamps from rubber boot no. 4 using
CV boot clamp pliers (PIN 295 000 069) and pliers REAR PROPELLER SHAFT
Oetiker 1099 (P/I\J 295 000 070) .
Remove the large end of the boot from plunging Propeller Shaft Removal
joint no. 5 or CV joint no . 6. Install a jack stand to support the vehicle during
Move apart circlip and pull out the shaft from bear- the procedure.
ing. Do not remove circlip . Remove rear wheels.
Remove caliper screws and suspend caliper out of
the way.

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Section 08 DRIVETRAIN
Subsection 02 (REAR DRIVE)

vmr2007-054-007 _a

1. Differential protector
CAUTION: Do not let caliper hang by the hose
and do not stretch or twist hose. Unscrew and remove lower and upper differential
bolts.
Unscrew the rear propeller shaft screws (engine
and differential sides).

1. Differential bolts
ENGINE SIDE
Loosen hitch plate bolts.

vmr2007-054-009_8

DIFFERENTIAL SIDE Move the differential no. 2 backward.

NOTE: The propeller shaft bolts are different, they Unplug the propeller shaft no. 7 from the differen-
must be reinstalled in same location. tial then remove it from vehicle.

Remove the differential protector. Propeller Shaft Inspection

Check yoke U-joint no. 8 for wear, backlash or axial
play, replace if necessary.
Inspect engine seal for damage or leaks. Replace
if necessary.
Inspect brake disc (refer to HYDRAULIC BRAKES).

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Section 08 DRIVETRAIN
Subsection 02 (REAR DRIVE)

Propeller Shaft Installation

Installation is essentially the reverse of removal
procedure. Pay attention to the following details .
Apply XP-S synthetic grease (PIN 293550010) on
engine drive shaft spl ines .
Install the propeller shaft screw (engine side) and
torque it to 45 Nem (33 Ibf-ft).
Apply XP-S synthetic grease (P/I\I 293 550010) to
splines before insert the end of the propeller shaft
into differential. Torque propeller shaft screw to
34 N-m (25 Ibf-ft) .
Reinstall all other removed parts .
Grease U-joint from rear propeller shaft. Use a
grease gun with XP-S synthetic grease (PIN 293 Support U-joint in vice and drive inner yo ke down
550 010). to remove remaining bearing caps .
Remove U-joint cross .
REAR PROPELLER SHAFT
U-JOINT U-Joint Installation
Remove the brake disc before working on differ- Install new U-joint cross in inner yoke .
ential side of propeller shaft. Install new bearing cap by hand.
NOTE: Carefully install U-joint cross with grease
U-Joint Removal fitting properly positioned.
Remove internal snap ring from bearing caps .

Tighten vise to force bearing caps in .

VOl HOYA

1. Snap ring

Support inner yoke in vice and drive other yoke

down with a soft hammer.

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Section 08 DRIVETRAIN
Subsection 02 (REAR DRIVE)

Using a suitable tappet, fully seat bearing cap in When replacing the oil in the differential, it is eas-
one side . Continually, check for free movement ier to measure the right quantity of oil to add in
of bearing cross as bearing caps are assembled. order to reach the proper level. Refer to OIL RE-
PLACEMENT.
Add oil if necessary.

Rear Differential Oil Replacement

Ensure vehicle is on a level surface.
Clean drain plug area.
Place a drain pan under rear differential drain plug
area.
Unscrew filler plug.
Remove drain plug .

Install snap ring.

Repeat procedure for other sides.
Grease U-joint. using a grease gun with XP-S syn-
thetic grease (PIN 293 550 010).

REAR DIFFERENTIAL
Rear Differential Oil Level
Place bottom of frame horizontally.
Clean filler plug prior to check oil level. Check oil
level by removing filler plug .

1. Drain plug
2. Filler plug

Clean drain plug area then reinstall drain plug.

Use a funnel and refill rear differential at the proper
level with recommended oil.

MODEL CAPACITY RECOMMENDED OIL

XP-S synthetic gear
250 mL oil (PIN 293 600 043)
All models
(8.5 U.S. oz) or REDLINE pump oil
75W90 (API GL5)

Reinstall filler plug .

Rear Differential Removal

1. Filler plug
Install a jack stand under differential to support the
The rear differential oil is not level with the filler vehicle during the following procedure .
plug threads. Remove rear wheels .
It is possible to verify the oil level by inserting a Remove both trailing arms. Refer to REAR SUS-
wire with a 90 0 bend through the oil filler hole . PENSION.
Oil level is between 25 to 32 mm (1 to 1-1/4 in) Remove both drive shafts.
from the bottom of oil filler plug threads when the
vehicle is level on ground. Remove the differential protector.
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Section 08 DRIVETRAIN
Subsection 02 (REAR DRIVE)

Unscrew and remove lower and upper differential CAUTION: The pinion nut is left hand threaded.
bolts . Unscrew by turning clockwise.
Remove the propeller shaft screw and its washer Remove the bearing no. 13 at the same time as
(differential side). the pinion gear no. 14. Be careful to keep track of
Remove the differential no. 2. shims.
NOTE: The pinion gear and bearing can be easily
Rear Differential Inspection removed using the following suggested tool:
Turn rear differential gear with a finger; it should - pipe 3-1/2 in diameter x 5 in (1)
turn smoothly. Replace if necessary. - screwed rod M 10 x 1.25, 7 in length (1)
Check backlash and drag torque, see ADJUST- - nut M10 x 1.25 (3)
MENTfurther in this section. - flat bar (1) .
Check if oil seals are brittle, hard or damaged. Re-
place if necessary. Rear Differential Adjustment
A shimming procedure must be done when pinion
Rear Differential Disassembly gear, ring gear or housing is (are) changed.
Ring Gear Measure the old pinion shim stack. If the shims
measure over 1 mm (.039 in), install shim stacks
Unscrew the TORX screws no. 10, then separate
on the differential components as per CHART" A" .
half housings.
If the old pinion shim stack measurement is under
1 mm (.039 in), install a .5 mm (.02 in) shim on the
differential components as per CHART" B" .

CHART "A" CHART "B"

2.1B mm
PINION PINION
(.OB6 in)

.94 mm
BACKLASH
.5 mm
BACKLASH
(.037 in) (.02 in)

PRELOAD
1.37 mm PRELOAD
(.054 in)

NOTE: The procedure above sets the pinion shim

thickness and should not be modified thereafter.
Any changes should be done on preload and/or
backlash side(s).
TYPICAL - FRONT DIFFERENTIAL SHOWN

NOTE: Be careful to keep track of shims on each

end of ring gear no. 9.
Extract ring gear out of half housing.
Pinion Gear
Remove oil seal no. 11 .
Unscrew the pinion nut no. 12 . Use the differen-
tial spanner socket (P/N 529 035 649) .

529035649

vmr2006-024-Ql0_8

1. Backlash side
2. Preload side

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Section 08 DRIVETRAIN
Subsection 02 (REAR DRIVE)

Assemble the differential. If backlash is greater than 0.356 mm (.014 in), de-
crease backlash shim by 0.05 mm (.002 in) and
Backlash check the backlash again.
Using a dial indicator and the backlash measure- Measure preload.
ment tool (PIN 529 035 665), measure the back-
lash. Place the backlash measurement tool at the Preload
end of pinion gear. Screw the propeller shaft adaptor bolt in pinion
From center of bolt, measure 25 .4 mm (1 in) and gear.
scribe a mark on the tab.

TYPICAL - FRONT DIFFERENTIAL SHOWN

",m r20C6-023·Q15 _a
f.--A Using a needle torque wrench, measure the drag
torque.
1. Tab of backlash measurement tool
2. Mark on tab
A. 25.4 mm (1 in)

Position the dial indicator tip against the tab at a

90° angle and right on the previously scribed mark.
Gently, move the tab back and forth. Note the
result.

TYPICAL - FRONT DIFFERENTIAL SHOWN

If the drag torque is greater than 0.7 N.m

(6 Ibf·in), reduce preload shim by 0.05 mm
(.002 in) and check drag torque again .
If the drag torque is less than 0.06 N·m (.5Ibf.inl.
increase preload shim by 0.05 mm (.002 in) and
check drag torque again.

Rear Differential Assembly

Ring Gear
Rotate pinion gear 1/2 turn and check backlash
again. Note the result. To assemble, reverse the removal procedure. Pay
attention to the following details.
Rotate pinion gear 1 turn and check backlash
again. Verify condition of half housing seal no. 15.
Change seal if necessary.
If backlash is below 0.05 mm (.002 in), increase
backlash shim by 0.05 mm (.002 in) and check the Check all bearings and all 011 seals. Change them
backlash again. if necessary.

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Section 08 DRIVETRAIN
Subsection 02 (REAR DRIVE)

Pinion Gear
To install, reverse the removal procedure . Pay at-
tention to the following details .
Check O-ring no. 16 for damage. If so, change it.
Install the shim then the ball bearing .
Install the nut no. 12. Apply Loctite 277 (PIN 293
800 073) on threads nut then torque it to 180 N-m
(133 Ibf-ft) .
Apply XP-S synthetic grease (PIN 293 550 010) in
the lips of the new oil seal no. 11 and install it.

Rear Differential Installation

The installation is the reverse of the removal pro-
cedure .

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sa,les@.mldwe, ' manrUI,a s.c,o,m

www.lm idwestlm aln uas.com

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Section 09 STEERING SYSTEM
Subsection 01 (STEERING SYSTEM)

STEERING SYSTEM
SERVICE TOOLS
Description Part Number Page
steering alignment tool ...... ........ ... .. ... .. .... ........ .. .... .. ... ..... ..... 529036 059 .. .......... .. ... ............ ... .. .. ..... 340

SERVICE TOOLS - OTHER SUPPLIER

Description Part Number Page
Smoothflow™ tapered tip ....... ....... ................ .. ...... .. ... ......... 16 ga .... .. ...... .... .. ... .. .... .... ... ... ... . 333
#511 rtt-b

SERVICE PRODUCTS
Description Part Number Page
Loctite 406 (glue) ... .... ...... ... ..... .. .... ....... .. ..... ...... ... ...... ... .... ... 293 800 100 ... .. .... ............ ... .. .. ... .. .. .. .... 333
pu Iley flange cleaner ....... ..... .... .............. ... ........ .......... ..... .... . 413 711 809 ..... ..... ........ .... .... .... ... .... .... 333
Xp-s synthetic grease ... ..... .. .... .............. ...... ...... ........ ... ... .... . 529550010 .. .. ... .... ....... ... .. .... ..... .... .. .. . 335

I -

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Section 09 STEERING SYSTEM
Subsection 01 (STEERING SYSTEM)

r - - - - - - - ... r ------- - --- - -- -- ---- - ,

XTI
:STD~ !
1
1

!fJJU 1

1 7 1
1 ______ - - ,

...... _ _ _ ___ __ _ J

3
/

2
r
0.4 Nom
(3.5 Ibfoin)
&XP-S synthetic
~-"" _ grease
15
-~ \O)
18 16

/ :.;.,
6
72NomJ 10Nom /
(53 )bl·ft) • (89 )bl·in) 222~
13
/

21 ~ 23

l_______ 72 Nom
mm-.. 20 (53 Ibfoft)
-------19 1>
72 Nom
mm~- (53 Ibfoft)

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Section 09 STEERING SYSTEM
Subsection 01 (STEERING SYSTEM)

GENERAL HANDLEBAR COVER

During assembly/installation, use the torque val- Removal
ues and service products as in the exploded
views . On models without XT package, just pull the
handlebar cover no. 7 to remove it.
Clean threads before applying a thread locker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure .

& WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced
with new ones.

On XT models, unscrew both plastic U-clamps

PROCEDURES that attach handlebar cover no. 8 to the handlebar
no. 9.
HANDLEBAR GRIP
Removal
Loosen the screw no. 2 at the end of handlebar
grip no. 1.
Remove the handlebar grip cap no. 3.
Cut and remove the handlebar grip.

Installation
Remove all rubber residues of the old grip before
installing the new.
Clean the handlebar with pulley flange cleaner 1. Plastic U-clamp
(P/N 413 711 809) or alcohol to remove any greasy
matter on it.
Inspection
Install handlebar grip by blowing compressed air
between handle grip and handlebar. Check covers for cracks or other damages . Re-
place if necessary.
Install a Smoothflow™ tapered tip (P/N 16 ga
#511 rtt-b) from EFD Inc on a bottle of Loctite 406 Installation
(glue) (P/N 293 800 100) .
The installation is the reverse of removal proce-
Lift a part of the grip using a small screwdriver and dure.
inject glue (about 4 spots per side).
NOTE: The glue dries quickly. Do not apply it be- HANDLEBAR
fore installing grip.
Apply pressure on the grip for approximately Removal
30 seconds to set the glue. All Models except Renegade
Install the handlebar grip cap and torque screw Remove handlebar cover.
0.4 N-m (3 .5 Ibf-in) .
Remove handlebar grips no. 1.
Remove throttle and brake handles as well as mul-
tifunction switch (see below in this section).

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Section 09 STEERING SYSTEM
Subsection 01 (STEERING SYSTEM)

NOTE: Remove handlebar grips, throttle handle, STEERING COLUMN

brake handle and multifunction switch only if the
handlebar is defective and replace with a new. Removal
Remove steering clamp mounting bolts no. 10 and Remove both footrests .
steering clamps no. 11. Remove central panel and dash board.

1. Cen tral panel

2. Dash board

TYPICAL - OUTLANDER 800 SHOWN Remove the air intake silencer. Refer to AIR IN-
TAKE SYSTEM.
Remove the handlebar no. 9 .
Remove handlebar.
Renegade Model Remove the cotter pin (discard it), the elastic stop
Remove handlebar grips, throttle and brake han- nut and the washer to bottom end of steering col-
dles as well as multifunction switch. umn.
NOTE: These items should be removed only if the
handlebar is defective and/or replaced with a new.
Unscrew the four socket screws securing the
moulded handlebar support.

TYPICAL
1. Cotter pin
1. Moulded handlebar support 2. Elastic nut
2. Socket screws 3. Washer

Remove handlebar. Separate steering column no. 12 and tie-rods

no. 13. Refer to TIE-ROD, further in this section.
Inspection Remove half bushing bolts no. 14, stopping plate
Inspect the handlebar for damage, cracks or bend- or module support no. 15, half bushing no. 16 and
ing, replace if any of these problems is detected . bushings no. 17.
Pullout steering column.
Installation
For the installation, reverse the removal proce- Inspection
dure. Inspect steering column for wear, cracks or bend-
ing, replace if any of these problems is detected.
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Section 09 STEERING SYSTEM
Subsection 01 (STEERING SYSTEM)

Check if steering column O-rings no. 18 are brittle,

hard or otherwise damaged. Replace if necessary.
At the same time, check steering column bear-
ing condition. It must turn smoothly and freely.
If not. refer to STEERING COLUMN BEARING for
replacement procedure.

Installation
For the installation, reverse the removal proce-
dure. Pay attention to the following.
Apply XP-S synthetic grease (PIN 529550010) on
O-rings and on bushings.
- ..
Install NEW cotter pins. Both ends of cotter pins v mr20()6.0 25-007

must be folded. TYPICAL

STEERING COLUMN BEARING Pull up steering column.

Remove bolts no. 22 and bearing flanges no. 23.
Removal
Remove bearing no. 24.
Place vehicle on jack stands and remove one
wheel. Installation
Remove both footrests, central panel and dash- For installation, reverse the removal procedure.
board (refer to BODY). Pay attention to the following details.
Remove the air intake silencer. Refer to AIR IN- Place bearing flanges collars outward.
TAKE SYSTEM. NOTE: Install both bearing flanges on top of frame
Separate tie-rods no. 13 from steering column support.
no. 12. Refer to TIE-ROO section .

V07100A 2
TYPICAL
V0710NA 1. Bearing flange
2. Bearing
TYPICAL

Install bearing flange bolts no. 22.

Remove cotter pin no. 19 (discard it), elastic nut
no. 20 and flat washer no. 21 to bottom end of Install the steering column, flat washer, elastic nut
steering column no. 12 . and a NEW cotter pin . Both ends of cotter pin
must be folded.

TIE-ROD
NOTE: Use the same procedure for RH and LH
side .

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Section 09 STEERING SYSTEM
Subsection 01 (STEERING SYSTEM)

Removal KNUCKLE
Place the vehicle on jack stands and remove the
appropriate wheel. Removal
Remove cotter pin (discard it). elastic nut and hard- Place vehicle on jack stands and remove the ap-
ened washers from steering column and knuckle. propriate wheel.
Separate tie-rod no. 13 from knuckle.

TYPICAL
1. Cotter pin
2. Elastic nut
3. Hardened washers
OUTLANDER 500

Inspection
Inspect ball joint ends for wear or looseness, if
excessive, replace.

Installation
For the installation, reverse the removal proce-
dure. Pay attention to the following details.
When installing a tie-rod, screw threaded end of
tie-rod into bali joint. The maximum length for tie-
rod groove to ball joint end must match value UAU
in the following chart:
OUTLANDER 650 AND 800

vmr2006-025-009_b

MODEL "A"
mm 17.5 ± 5
ALL
in 11/16 ± 3/16

NOTE: Torque the ball joint lock nut no. 6.

Install NEW cotter pins. Both ends of cotter pins
must be folded. RENEGADE

Remove wheel hub. Refer to FRONT SUSPEN-

SION.

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Section 09 STEERING SYSTEM
Subsection 01 (STEERING SYSTEM)

Outlander 500 Using a hammer, hit on the knuckle tip to separate

Remove strut bolts. ball joint from knuckle. A ball joint remover can be
used if the ball joint is jammed into knuckle .

1. Hit here

CAUTION: Never hit on upper suspension arm.

Permanent damages could be caused to arm
and its replacement would be necessary.
V07JOBA
Remove bolt that attaches lower ball joint to
TYPICAL knuckle .

Remove bolt that attaches lower ball joint to

knuckle.

V07100A

Remove knuckle.
V07100A
Renegade
Remove knuckle . Unscrew the upper ball joint nut and separate up-
Outlander 650 and 800 per ball joint to knuckle.
Unscrew the upper ball joint nut and separate up-
per ball joint to knuckle .

Using a hammer, hit on the knuckle tip to separate

ball joint from knuckle. A ball joint remover can be
used if the ball joint is jammed into knuckle .

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Section 09 STEERING SYSTEM
Subsection 01 (STEERING SYSTEM)

NOTE: First, check if ball joint is loose. ' If neces-

sary repair all defective parts before checking the
wheel bearing condition. Be careful not to mis-
judge loose in the ball joint and loose in the wheel
bearing.

Removal
Remove knuckle from vehicle, (see above).
1. Hit here Remove and discard knuckle seal.

CAUTION: Never hit on upper suspension arm.

Permanent damages could be caused to arm
and its replacement would be necessary.
Remove nut that attaches lower ball joint to lower
suspension arm .

1. Knuckle
2. Lower ball joint
3. Lower suspension arm TYPICAL

Remove knuckle. Remove the circlip .

Inspection 1
Check knuckle for cracks or other damages. Re-
place if necessary.
Check if wheel bearing turns freely and smoothly.
See WHEEL BEARING below if the replacement
is necessary.

Installation
The installation is the reverse of removal proce-
dure.

WHEEL BEARING
Inspection V0710SA

Raise the front of vehicle. TYPICAL

1. Circlip
Hold the wheel by the top and the bottom and
move it. Check for lateral play. Using a press machine, push the bearing out of
If there is any loose, replace the wheel bearing. knuckle.
NOTE: It may be necessary to heat the knuckle to
remove the bearing .

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Section 09 STEERING SYSTEM
Subsection 01 (STEERING SYSTEM)

& WARNING Remove screws.

Clean all grease, outside and inside, from 1
knuckle before heating it.

Installation
Place the bearing in a freezer for 10 minutes be-
fore installing.
Place the knuckle in oven to 100°C (212°F) for
30 minutes maximum to ease bearing installation.
When knuckle is cold, install the circiip and the
NEW seal.
Install the other parts in the reverse order of re-
moval procedure.

MULTIFUNCTION SWITCH V07l0FA

TYPICAL
1. Remove screws
Test
Refer to LIGHTS, GAUGE AND ACCESSORIES for Separate throttle handle from handlebar no. 9.
Hi-Lo Beam button. Slide rubber protector back to expose throttle
Refer to IGNITION SYSTEM for engine run/stop cable adjuster.
switch and start button.

Removal
Remove multifunction switch screws.

V0710GA 1 2 3 4
TYPICAL
1. Remove the screws 1. Cable protector
2. Throttle cable adjuster
3. Lock nut
Separate multifunction switch from handlebar 4. Throttle lever housing
no. 9.
Remove central panel. Refer to BODY. Loosen lock nut and screw in the throttle cable
adjuster.
Unplug multifunction switch connector. The con-
nector is located under central panel. Remove inner housing protector.

Installation
For installation, reverse the removal procedure.

THROTTLE HANDLE
Removal
Remove central panel and unplug the 2/4WD
switch connector (except on CE models).

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Section 09 STEERING SYSTEM
Subsection 01 (STEERING SYSTEM)

vmr2008-068-004_a

TYPICAL
1. Remove the screws

Separate handle brake from handlebar no. 9 .

V0710HA Hose Removal

1. Inner housing protector Refer to HYDRAULIC BRAKES for specifics in-
structions.
Slide cable in clip slot and remove the end of the
cable from clip. Installation
For installation, reverse the removal procedure.

ADJUSTMENT
STEERING ALIGNMENT
Place vehicle on level surface .
Check that handlebar is straight.
Check pressure in each tires. Always follow rec-
ommended pressure.
Remove two wheel nuts and install the steering
alignment tool (PIN 529 036 059).
Move the vehicle to place the tool on a level with
the ground .

';:-"
r.' ~~J.~ \
,,- -. ';~~
" .~ (9'\
. .

··iI· " , ,
Remove throttle cable from housing. . '" (:)
.,.. .
I "'~
,
/.,,- ' .'-- . ' ,_'_"
--
.'- .
!I
.
Installation 1 '" '< _\ ' _- .

~~j
For installation, reverse the removal procedure.
After throttle cable installation, the reset of TPS
must be performed. Refer to ENGINE MANAGE- ..~; /~
MENT.
1. Steering adjustment tool
HANDLE BRAKE 2. Angle gauge or level

Removal Place a rope around the vehicle and using an elas-

tic, link both ends together.
Remove screws.
The rope must be place at the center of the
wheels.

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Section 09 STEERING SYSTEM
Subsection 01 (STEERING SYSTEM)

From the front of vehicle, near the front of rim,

move rope so that it does not touch the first spacer
of tool.

TYPICAL - REAR OF WHEEL

Refer to the following chart to know the difference

between the rear and the front measurement.

MODELS TOE·OUT

ALL OUTLANDER
o mm ± 4 mm
TYPICAL (0 in ± .157 in)
RENEGADE 2 mm (.79 in)
Then, bring the rope back until it touches the spac-
er.
Set alignment of wheel by adjusting tie-rod.
Repeat the procedure for the other side of vehicle .

TYPICAL

Keep this position and measure the distance be-

tween the rope and the rim, to the front and to
the rear of wheel.

TYPICAL - FRONT OF WHEEL

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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

FRONT SUSPENSION
SERVICE TOOLS
Description Part Number Page
Supertanium drill bit.. ........ ................................................... . 529031 800 .............. ................. ... .... ... 349
shock/spring remover ... ...... .. ..... .. ... ..................................... . 529036007 .......... .... .... .. .......... .... ...... . 348
ball joint installer .. ............................ .... ............ ....... .. ........... . 529036020 ..... ............................ 351,355

SERVICE PRODUCTS
Description Part Number Page
suspension grease ............................................................ .... 293550033 .. .... ... .... ...... ...... .. ...... 351-352
Loctite 243 (blue) ............. .. .... ........ .. .. .. .. .......... .. .. .... .... ...... .. . 293800060 .. .. .. .. ................................. 349

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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

Outlander 500 Series

61 Nom
(45 Ibf°ft)
I 2.5 Nom
~ (22 Ibfoin)

\ ,//\
.-/\, ~' \// //'t
,

&?'
"\ 1 ,, '/
~
. !, '/
/'
\ / '
i
48 Nom
/ 25 Nom (35Ibfoft)
-( (18 Ibfoft)
61 Nom
(45Ibf°ft)

I/ ,I'/
11
~
~4

r ,
;
j' /•
vmr2008-069-002_8

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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

Outlander 650/800 Series

80 I\lom ~
(59 Ibfaft) ~

25 Nom

~
18Ibfaft)
3 Nom 25 Nom
(27 Ibfoin) (18 Ibf°ft) , 61 Nom

~ft)
Suspension
grease
3 Nom & " 'J',' c-.. , ,,,,)
(27 Ibfoin) ~
. ~
t? , /" , ........... ,

~~
'J"" <......
/' h '

· r-
61 Nom
~- (45 Ibf°ft)

2.5 Nom
(22 Ibfoin)
~lj~~~
I &
61 Nom Suspension ---~

e/
I
48 Nom (45 Ibf0ft) gre,ase ,
45 Nom 4
61 Nom
(35Ibfoft) 3 Nom I (33 Ibf°ft)
(45 Ibf°ft) o 25 Nom (27 IbNn) ) (
~118Ibf.ftl
~ ~ ID1J

~
! d
vmr2006-026-002 _c

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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

Renegade Models

80 N-m
(59Ibfoft)

~
w \
\, '
.

3 N-m
(27 Ibf-in)
Suspension 25 N-m
grease (18Ibfoft)
~

~
Suspension ---I
6'1 N-m
grease
~
(45Ibfoft)
45 N-m
(33 Ibfoft)
3 N-m
(27Ibf-in)
45N-m
(33 Ibfoft) r
vmr2008-069--001_a
mm

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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

GENERAL Unscrew bolts retaining strut to the knuckle.

The procedure explained below is the same forthe
RH and LH sides unless otherwise noted .
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure .

.& WARNING 1. Strut bolts

Torque wrench tightening specifications 2. Strut
3. Knuckle
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic Remove the circlip and unscrew the strut nut.
stop nuts, cotter pins, etc.) must be replaced
with new ones.

PROCEDURES
TIRES AND WHEELS
& WARNING
When the tires are replaced, never install a
bias tire with a radial tire. Such a combina-
tion could create handling and/or stability
problems.
Do not mix tires of different size and/or de-
sign on the same axle.
Front and rear tire pairs must be the identical
model and manufacturer.
For unidirectional tread pattern, ensure that V07J03A 2
the tires are installed in the correct direction
of rotation. 1. Circlip
2. Strut nut
The radial tires must be installed as a com-
plete set. Remove strut from vehicle.
Severe injury or death can result if these
instructions are not followed. Outlander 650/800 Series and Renegade
Models
The tires are directional and their rotation must be Loosen wheel nuts of the appropriate wheel.
kept in a specific direction for proper operation . Lift the front of the vehicle until shock absorber is
fully extended then install a jack stand under the
SHOCK ABSORBER AND SPRING frame to support the vehicle off the ground.
Remove wheel.
Removal
Outlander 500 Series Remove lower bolt securingshock absorber to up-
per suspension arm.
Loosen wheel nuts of the appropriate wheel.
Lift front of vehicle until front struts are fully ex-
tended then install a jack stand under the frame to
support the vehicle off the ground.
Remove wheel.
Remove the front rack and the cap on the top of
the front fender.
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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

Position the shock absorber in the tool and install

the spring compressor pins.

1. Shock absorber 's lower bolt

2. Upper suspension arm

Then the upper bolt from shock absorber support.

vmr2 006.Q26-Ql0

Tighten the shock spring remover screw until the

spring is sufficiently compressed to remove spring
locking devices.
Remove spring stopper and its cap then release
1. Shock absorber 's upper bolt
2. Shock absorber support the shock spring remover screw.

When the shock absorber is removed from upper

arm, pay attention not to mislay the both metallic
bushings .

vm,2006-026-009_8

Disassembly Inspection
To remove spring from the shock absorber, use Inspect the spring for damage. Replace if neces-
the shock/spring remover (P/I\J 529036007). sary.
Inspect shock for oil leakage. Extend and com-
press the piston several times over its entire
stroke. Check that it moves smoothly and with
uniform resistance with rod up. Any of the fol-
lowing conditions will denote a defective shock:
529036007 - A skip or hang up when reversing stroke at mid
travel.
Place the tool in a vise.
- Seizing or binding conditions except at extreme
end of either stroke.
- A gurgling noise after completing one full com-
pression and extension stroke.

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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

Replace shock if any of these conditions are Remove the protector.

found .
Installation
Assembly and Installation The installation is the reverse of removal proce-
For assembly and installation, reverse the disas- dure.
sembly and removal procedures .
Outlander 500 Series LOWER SUSPENSION ARM
Apply Loctite 243 (blue) (P/N 293 800 060) on Inspection
threads of strut nut and tighten it to 55 N-m
(41 Ibf-ft). Check lower suspension arms for distortion or
damage . Replace suspension arms if necessary.
LOWER SUSPENSION ARM Move lower suspension arm from side to side.
There should be no noticeable loose. Replace
PROTECTOR bushings if necessary.
Inspection Move lower suspension arm up and down. There
Check protector for cracks or other damages. Re- should be no noticeable loose. Replace bushings
if necessary.
place if necessary.
The following items are performed when the low-
Removal er suspension arm is removed .
Outlander Models Inspect pivot bushings and cushions for wear or
Remove bolts then the protector. damages. Replace bushings and/or cushions if
necessary.

1. Bolts
2. Protector

Renegade Models
V07J 07A
Using a Supertanium drill bit (P/N 529 031 8001.
TYPICAL
drill rivets securing protector to lower suspension 1. Pivo t bushing
arm .
Check ball joint bellows on lower suspension arm
for cracks or any other damage. Inspect ball joint
end for damage. Ensure it's moving freely. Re-
place ball joints as required, see below for proce-
dure .

Removal
Remove wheel.
Remove bolt or nut retaining ball joint to the knuck-
le .

1. Rivets
2. Protector
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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

V07JOSA 2 3 4
TYPICAL - OUTLANDER MODELS V07J09A 2 1 2
1. Lower suspension arm
2. Ball joint bolt TYPICAL - ALL OUTLANDER MODELS
3. Ball joint 1. Lower suspension arm
4. Knuckle 2. Remove bolts

RENEGADE MODELS
vmr2007-055-005_a
1. Lower suspension arm
2. Lower suspension arm bolts
RENEGADE MODELS
1. Knuckle
2. Lower ball joint Remove lower suspension arm from vehicle.
3. Lower suspensio n arm

Separate lower suspension arm from knuckle . Installation

Remove bolts retaining lower suspension arm to For assembly, reverse the disassembly procedure.
frame. However. pay attention to the following.
Install lower suspension arm to frame.
Install lower suspension arm bolts as per following
illustration .

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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

Unscrew bolts retaining ball joint to lower suspen-

sion arm.
Extract the ball joint by pulling it out of lower sus-
pension arm.

vmr2007-056-003_a

OUTLANDER SERIES

vmr2008.o69-0 13_8

1. Bolts securing ball joint

2. Ball joint

Renegade Models
Remove knuckle from vehicle . Refer to STEER-
ING SYSTEM.
Remove the circlip.

vm r2008-069-012_8

RENEGADE MODELS
1
Torque lower suspension arm bolts to 61 N-m
(45 Ibf-ft) .
Use suspension grease (PIN 293550033) to lubri-
cate both lower suspension arms. There are two
grease fitting on each arm . vmr2007.()56-004_8

Attach lower suspension arm to knuckle . 1. Circlip

2. Ball joint
Install wheel. Refer to STEERING SYSTEM for 3. Knuckle
proper torque.
Using a press and a small piece of pipe, extract the
LOWER BALL JOINT ball joint. Support the knuckle properly to avoid
damaging ball joint location.
Inspection
Check lower ball joint for damage, pitting, loose-
Installation
ness and roughness . If so, replace it. The installation is the reverse of removal proce-
dure.
Check ball joint bellows for cracks. Change if nec-
essary. Renegade Models
To install the ball joint properly, use the ball joint
Removal installer (PIN 529 036 020) .
Outlander Series
Remove appropriate wheel.
Remove bolt securing ball joint to knuckle.

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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

Replace all defective parts .

Removal
Remove appropriate wheel.
Renegade Models
Unscrew bolts securing brake hose on the suspen-
sion arm .

529036020

Support the knuckle before pressing the ball joint

into its location.

UPPER SUSPENSION ARM

Outlander 650/800 Series and Renegade
Models All Models
Remove cotter pin retaining upper ball joint nut.
Lubrication Discard cotter pin .
Use suspension grease (P/N 293550033) to lubri-
cate both upper suspension arms. There are two
grease fitting on each arm .

Unscrew upper ball joint nut.

TYPICAL - OUTLANDER SERIES SHOWN, SAME ON

RENEGADE

Inspection
Check upper suspension arm for cracks, pitting,
distortion or other damages. Replace as required .
Near upper suspension arm bracket, move upper
suspension arm up and down then from side to
side. There should be no noticeable play. Replace Using a hammer, hit on the knuckle tip to separate
pivot bushings and/or cushions if necessary. ball joint from knuckle .
The following items are performed when the up- !'JOTE: A ball joint remover can be used if the ball
per suspension arm is removed . joint is jammed into knuckle.
- Inspect pivot bushings and cushions for wear.
- Check ball joint bellows for crack or wear.
- Inspect ball joint end for damages . Ensure it is
moved freely.

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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

1. Hit here TYPICAL - RENEGADE SHOWN

CAUTION: Never hit on upper suspension arm. Attach the upper suspension arm to knuckle.
Permanent damages could be caused on arm When hardened washer and upper ball joint nut
and its replacement will be necessary. are installed, tighten nut to 45 N-m (33 Ibf-ft).
Remove shock absorber lower bolt from upper
suspension arm.

1. Hardened washer
Unscrew bolts that attach upper suspension arm 2. Ball joint nut
to upper suspension arm bracket.
Install a NEW cotter pin. Both end of cotter pin
must be folded .
Install the shock absorber lower bolt and torque it
to 61 N-m (45 Ibf-ft) .
Install wheel.

UPPER SUSPENSION ARM

BRACKET
Removal
Remove both front wheels.
1. Upper suspension arm bolts
2. Suspension arm bracket Outlander 650/800 Series
Unscrew the left caliper and attach it out of way.
Remove upper suspension arm from vehicle.

Installation
Position the upper suspension arm and install its
bolts. Torque to 61 N-m (45 Ibf-ft).

vmr200S'()69
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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

1. Left caliper

Renegade Models 1. Upper differential bolts

2. Front bracket retaining bolts
Unscrew bolts securing brake hose on the upper
suspension arm. Slide bracket backward then pull it by the left side.

Inspection
Check the upper suspension arm bracket for crack
or other damages. Replace as required.

Installation
The installation is the reverse of the removal pro-
cedure.
NOTE: Install bolts holding bracket to frame and
upper differential bolts before tightening them .

UPPER BALL JOINT

All Models
Outlander 650/800 Series and Renegade
Unscrew upper suspension arms from the upper Models
suspension arm bracket.
Inspection
Check upper ball joint for damage, pitting, loose-
ness and roughness. If so, replace it.
Check ball joint bellows for cracks. Replace as
required.

Removal
Remove upper suspension arm.
Remove the circlip.

1. LH upper suspension arm

2. Upper suspension arm bracket

Remove differential upper bolts .

Remove front bolts that attach the upper suspen-
sion arm bracket to frame.

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Section 10 SUSPENSION
Subsection 01 (FRONT SUSPENSION)

Using a press and a piece of pipe, remove the ball

joint.
CAUTION: Support upper suspension arm
properly to avoid damaging ball joint location.

Installation
To install the upper ball joint properly, use the ball
joint installer (PIN 529 036020) .

529036020

Support the upper suspension arm before press-

ing the ball joint into its location.
Install the upper suspension arm.
Install wheel.

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sa,les@.mldwe, ' manrUI,a s.c,o,m

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Section 10 SUSPENSION
Subsection 02 (REAR SUSPENSION)

REAR SUSPENSION
SERVICE TOOLS
Description Part Number Page
Bearing extractor/installer .................................................... . 529035918 ..... .............................. ...... 363
Bearing extractor/installer .... .... ............. ... ........ ... .... .... ..... ... .. 529 035 920 ...... .. ........................ .. .. ..... 363
trailing arm support .... .. ........ ........ ........ ............... .......... ... ... .. 529 035 922 .. ........ .................... ... ...... .. 363
spanner wrench ................................................................... . 529 035 925 .... .. .... ................... ............ 362
shock spring remover ...... .... .......... .. .............. .. .... .. .. .. .. .. ...... . 529 036 007 ......................................... 359

SERVICE PRODUCTS
Description Part Number Page
Loctite 243 (blue)......................... .......... ...... .. ....................... 293 800 060 ...................................... .. . 362

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Section 10 SUSPENSION
Subsection 02 (REAR SUSPENSION)

531\1 o m
, . -(39 Ibfoft)

53 Nom
(39 Ibfoft)

-"- ~

-"-oj
!i"--,,-
1 , -
L: 190 Nom
(140Ibfoft)
See
pr~)Ce:dure
inside
,I 0
~~I~!iln
1
01

l.L /;;;J
0

&
1

Looti,. 1
~ 271

r r~ Q
mm
vm r2008 ·070-001_8

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Section 10 SUSPENSION
Subsection 02 (REAR SUSPENSION)

GENERAL
The procedure described below is the same for
the RH and LH sides, unless otherwise instructed .
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

& WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic CAUTION: Always use the recommended
stop nuts, cotter pins, etc.) must be replaced wheel nuts. Using a different nut could cause
with new ones. damages to the rim.

REAR SHOCK
PROCEDURES
Removal
TIRES AND WHEELS Lift rear of vehicle until rear shock absorbers are
fully extended .
& WARNING Install jack stands or blocks under the frame to
When the tires are replaced, never install a support the vehicle .
bias tire with a radial tire. Such a combina- Remove upper and lower bolts retaining shock ab-
tion could create handling and/or stability sorbers.
problems.
Do not mix tires of different size and/or de- Disassembly
sign on the same axle.
Front and rear tire pairs must be the identical Use the shock spring remover (P/N 529 036 007).
model and manufacturer.
For unidirectional tread pattern, ensure that
the tires are installed in the correct direction
of rotation.
The radial tires must be installed as a com-
plete set. 529036007
Severe injury or death can result if these
instructions are not followed. Place the tool in a vise.
Position the shock absorber in the tool and install
The tires are directional and their rotation must be the spring compressor pins.
kept in a specific direction for proper operation.
Torque wheel nuts in accordance with the follow-
ing illustration.

vmr2006-026-010

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Section 10 SUSPENSION
Subsection 02 (REAR SUSPENSION)

Tighten the shock spring remover screw until the NOTE: Install cap opening at 180 0 from spring
spring is sufficiently compressed to remove spring stopper opening.
locking devices.
Remove spring stopper and its cap then release TORSION BAR
the shock spring remover screw.
Removal
Apply parking brake and lift rear of vehicle until rear
shock absorbers are fully extended.
Install a jack stand or blocks under the frame to
safely support the vehicle.
Remove both footrests .
Remove and discard both protective cover
clamps .

Remove spring from shock .

Inspection
Secure the end of shock body in a vise with its rod
upward.
1

¢~I~=n=a=~Q
1. LH protective cover clamp

Remove protective covers.

A14FOBA

TYPICAL
1. Clamp here

CAUTION: Do not clamp directly on shock

body.
Examine each shock for leaks. Extend and com-
press the piston several times over its entire
stroke. Check that it moves smoothly and with
uniform resistance with its rod upward .
Pay attention to the following conditions that will
1. Protective cover
denote a defective shock:
- A skip or a hang back when reversing stroke at Remove both elastic nuts (discard them) and both
mid travel. flat washers.
- Seizing or binding condition except at extreme
end of either stroke.
- Oil leakage .
- A gurgling noise, after completing one full com-
pression and extension stroke.
Replace if any faults are present.

Assembly and Installation

Assembly and installation are essentially the re-
verse of disassembly and removal procedures .
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Section 10 SUSPENSION
Subsection 02 (REAR SUSPENSION)

Installation
Insert the torsion bar into the frame and install the
torsion bar lever (one on each side).
NOTE: Ensure torsion bar lever is aligned with the
cut-outs on the swing arm and arrow is pointing
up .

1. Elastic nut
2. Flat washer

Remove torsion bar levers.

Install the flat washer and a NEW elastic nut.

1. Torsion bar lever
First torque the right hand side elastic nut to
Remove the torsion bar. 55 N-m (41 Ibf-ftl. then the left hand side to
120 N-m (89 Ibf-ft).
Reinstall both torsion bar covers with NEW
clamps.

TRAILING ARM
Removal
Apply parking brake and lift rear of vehicle until rear
shock absorbers are fully extended.
Install a jack stands or a blocks under the frame to
safely support the vehicle.
Remove wheel hub (refer to REAR DRIVE).
Inspection Remove the protective cover, the elastic nut and
Check torsion bar for cracks, bending or other the flat washer.
damages. Remove the torsion bar lever.
Verify splines for damages (torsion bar and torsion Remove the circlip securing the trailing arm.
bar lever).
Check torsion bar lever tabs for racking, cracks or
other damages.
NOTE: If a tab is damaged, check the trailing arm
for damages.
Replace all damaged parts.

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Section 10 SUSPENSION
Subsection 02 (REAR SUSPENSION)

Frame Side
Apply Loctite 243 (blue) (PIN 293 800 060) on trail-
ing arm nut threads .
Install the trailing arm nut and torque it to 190 N-m
(140 Ibf-ft).
Install circlip, torsion bar lever, washer and a NEW
elastic nut. Torque the left elastic nut to 120 N-m
(89 Ibf-ft) and the right elastic nut to 55 N-m
(41 Ibf-ft).
Install protective cover.
Unscrew the trailing arm nut.
Wheel Side
Install wheel hub, Belleville washer and castellat-
ed nut.
Torque castellated nut to 205 N-m (151 Ibf-ft) and
further tighten until its grooves align with the next
cotter pin hole.
Install a NEW cotter pin then the wheel cap.
NOTE: The longer end of cotter pin must be folded
over shaft end.

To do this, use the spanner wrench (PIN 529035

925) .

Torque the shock absorber bolt to 53 N-m

(39 Ibf-ft).
529035925
Install wheel.
Unscrew lower bolt of shock absorber.
Remove trailing arm . TRAILING ARM BEARINGS
Inspection Remove trailing arm. Refer to procedure above.
Check trailing arms for cracks, bending or other
Inspection
damages.
Check inner race of each trailing arm bearing with
Verify bearings for smooth and free operation.
your finger. The bearings should turn smoothly
Replace all damaged parts. and quietly. Remove and discard bearings if race
does not turn smoothly or quietly.
Installation
Insert drive shaft end into trailing arm. Removal
Install the trailing arm on frame. The same procedure can be used for both bear-
ings.
Install the lower shock absorber bolt to support
the trailing arm. Do not torque yet.
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Section 10 SUSPENSION
Subsection 02 (REAR SUSPENSION)

NOTE: Before extracting the bearing on wheel

side, remove the protector by drilling the pop riv-
ets with a 3/16" drill.

vmr2008-07Q.O08_s

Remove the circlip.

WHEEL SIDE

vmr2006-027-009_B

WHEEL SIDE

V07H10A

FRAME SIDE

Using a press and the proper bearing extractor/

installer, remove the bearing .

LOCATION TOOL
Bearing
WHEEL SIDE extractor/i nstaller
FRAME SIDE (PIN 529 035 918)
Bearing
Place the trailing arm support (P/N 529 035 922) FRAME SIDE extractor/i nstaller
on the end of trailing arm . (PIN 529 035 920)

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Section 10 SUSPENSION
Subsection 02 (REAR SUSPENSION)

....

V07H1PA
V07 H1RA

WHEEL SIDE WHEEL SIDE

V07H1OA

FRAME SIDE V07H1HA

FRAME SIDE

Installation Install the circlip. If the circ lip is slacked, replace

Clean the bearing housing . it with a new.
To install the bearing in its location, use the same Install all other removed parts .
tool as per removal procedure .

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

FRONT AND REAR BRAKES

SERVICE TOOLS
Description Part Number Page
vacuum/pressure pump ... .. ...... ........ .... ..... .... .... ". ""." .. " .. .... 529021 800 ..... ."" .... .. .. ... ,..,., ... .. " .,..... 370

SERVICE PRODUCTS
Description Part Number Page
dielectric grease ..... .. .. .... .. ........... .......... .... " .... , .. .... ,............ . 293 550004 .. .... ................ .... .. .... . 374, 377
XP-S synthetic grease .... ... .. .. ... .. ............ .. ....... ......... ... " .. ,.. ... 293 550 010 ...... .. .... ........ .. .. ......... 375, 380
GTLMA brake fluid ..... ......... ... .. ,... .... .... .... ... ... .. ... .... .... " .. " .. .. 293 600 062 .. .. ..... .. .......... ..... .. .. .... ....... 369

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Outlander Series

European
Community
models 14

, T5.
1- __________________ _

T1 48 N-m (35 Ibf.ft)

T2 38 N-m (28 Ibf.ft) 'T6 17 N-m (150 Ibf-in) T1 5.5 N-m (49 Ibf-in)
T3 34 N-m (25 Ibf.ft) T7 10 N-m (89 Ibt-in) T115 N-m (44 Ibt-in)
T4 28 N-m (21 Ibf.ft) TB. 8 N-m (71 Ibt-in) T12 2.5 N-m (22 Ibf-in)
,15 25 N-m (18 Ibf.ft) ,19 6 N-m (53 Ibt-in) T13 1 N-m (9 Ibt-in)
vmr2008-071-001.a

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Renegade Models (Front Brakes)

1 Nom
(9 Ibfoin)

o 0
OO 0:
o
o
o

00
a
00
0 0
0
0
0

"-....
38 Nom
(28 Ibfoft)
',-
~
I

28 Nom
(21 Ibfoft)

25 Nom
(18Ibf°ft)

/'Q),'"
,~ I
/

vmr2008-071-002...JJ
en~17N.m
~ (150Ibfoin) & Loctite 243

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Renegade Models (Rear Brake)

28 N·m
(21 IbHt)

\
\,
J
--- ---
25 N·m
~(18 IbHt)
~ Loctite 243

28 N·m \' Xp-s

5 N·m ~ ' synthetic
(44 Ibf·in) grease
~ ~
.------------------ \

European
Community
models
vmr200B-071-Q20_a

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

GENERAL 2
During assembly/installation, use the torque val-
ues and service products as in the exploded
view(s).
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure .

.& WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced
with new ones. V07K02A

CAUTIOI\!: Avoid spilling brake fluid on plas- TYPICAL

1. LH brake lever
tic, rubber or painted parts. Protect these parts 2. Press lever to activate parking brake
with a rag when servicing brake system.
CAUTION: To avoid serious damage to the
brake system, use only DOT 4 brake fluid from MAINTENANCE
a sealed container. Do not use brake fluid
taken from old or already opened containers,
nor mix different fluids for topping off.
BRAKE FLUID
CAUTION: Sealing washers must be discarded Recommended Fluid
and replaced with new ones every time a Banjo
Always use brake fluid meeting the specification
fitting is unscrewed.
DOT 4 only such as GTLMA brake fluid (P/N 293
Hydraulic Brakes System 600 062) sold by BRP.
The brake system consists of two circuits . Each Fluid Level
system has its own master cylinder and reservoir.
With vehicle on a level surface, check brake fluid
Both front and rear brakes are disc type. in reservoir for proper level. It should be above
MIN. mark .
.& WARNING
Clean filler cap before removing.
Periodically check the brake hoses for dam-
ages or leaks. Repair any damage before op- Add fluid as required. Do not overfill.
erating the vehicle. NOTE: A low level may indicate leaks or worn
brake pads.
Front Brake Fluid Reservoir
Parking Brake
Turn steering in the straight-ahead position to en-
The parking brake operates all brakes . It is activat-
sure reservoir is level. Check the brake fluid level,
ed by a locking mechanism on LH brake lever.
the reservoir is full when the fluid reaches the top
of window.

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Brake Fluid Replacement

& WARNING
A contaminated brake disc or pad reduces
stopping power. Discard contaminated pads
and clean a contaminated disc with a high
quality brake degreasing agent.

Brake Fluid Draining

Remove reservoir cover with its diaphragm.
V07KOAA
Connect a clear hose to bleeding screw.
Loosen bleeding screw and pump brake lever(s) or
Visually inspect lever boot condition . Check for brake pedal until no more fluid flows out of bleed-
cracks, tears, etc. Replace if damaged. ing screw.
Rear Brake Fluid Reservoir Brake Fluid Filling and Bleeding
Outlander Series Close bleeding screws .
Fill reservoirs with DOT 4 brake fluid.
Unscrew the bleeding screw on the top of rear
master cylinder until brake fluid comes out then
close it.

1. Bleeding screw

On each caliper, unscrew the bleeding screw until

the brake fluid comes out then close it.
UNDER FRONT ACCESS PANEL
Bleed system as per the following procedure.
Renegade Models
With a Vacuum Pump
Using a clear hose, install the vacuum/pressure
pump (P/N 529021 800) to bleeding screw. Place
the pump in vacuum position. See the manufac-
turer's operating instructions.
Pump vacuum pump loosen bleeding screw.
Close bleeding screw and refill reservoir when
the fluid level is low.
NOTE: Check fluid level often to prevent air from
being pumped into the system.
Repeat the procedure until no more air bubbles
appear in hose.
UNDER CONSOLE

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

NOTE: For the front brake system, switch to LH Test

and RH caliper. Turn handlebar to full RH side Outlander Series
when bleeding right caliper and turn to the LH side
for the left caliper. This helps to reach air into the Remove the LH footrest.
caliper. On Outlander series, the front and the Renegade Models
rear brakes must be bled at the same time . Remove the master cylinder cover.
Close bleeding screw and operate brake lever or
brake pedal. If it still feels spongy, bleed system
again.
Repeat the procedures until air bubbles do not ap-
pear in hose and lever or pedal is stiff.
Fill reservoirs to the upper level with DOT 4 brake
fluid.
Install diaphragms and covers on reservoirs.
Without a Vacuum Pump
If vacuum pump is not available, use the following
procedure.
Install a clear hose to bleeding screw. 1. Master cylinder cover

Open bleeding screw. Fill reservoirs and pump All Models

brake lever or brake pedal until fluid freely flows
out of the hose. Disconnect switch connector.
Close bleeding screw.
Pump up system pressure with brake lever or
brake pedal until lever or pedal resistance is felt.
Squeeze brake lever or depress brake pedal, open
bleeding screw and then close it.
NOTE: Do not release brake lever or brake pedal
until bleeding screw has been closed. For the
front brake system, switch to LH and RH caliper.
Turn handlebar to full RH side when bleeding
right caliper and turn to the LH side for the left
caliper. This helps to reach air into the caliper. On 1. Switch connector

Outlander series, the front and the rear brakes

Check switch operation as follows .
must be bled at the same time.
Release brake lever or brake pedal slowly. OUTLANDER SERIES
Repeat the procedure until no more air bubbles BRAKE LIGHT
appear in hose and lever or pedal is stiff. PIN RESISTANCE
SWITCH POSITION
Firmly pushed 0.2 Q max.
PROCEDURES 1 2
Released Infinite (OU
REAR BRAKE LIGHT SWITCH RENEGADE MODELS
BRAKE LIGHT
Inspection SWITCH POSITION
PIN RESISTANCE
First ensure brake light is good.
Firmly pushed 0.2 Q max.
Check brake light switch for dirt or corrosion . 1 3
Make sure it is operating properly. Released Infinite (OU

Depress brake pedal and check for brake light to

If switch is defective, replace with a new one.
turn on . Repeat with the brake lever(s}.
If the switch tests good, verify wire continuity be-
tween harness connector and ECM.

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

ECM HARNESS
CONNECTOR CONNECTOR RESISTANCE
PIN WIRES
8-23 RED/ORANGE Close to 0 n

Removal
The rear brake light switch is located on the rear
master cylinder and it cannot be adjusted.

UNDERNEATH RH BRAKE LEVER

1. Switch connectors
2 . Brake light switch

Check switch operation as follows.

BRAKE LIGHT
PIN RESISTANCE
SWITCH POSITION
Firmly pushed Switch 0.2 n max.
Released pins Infinite (Ol)

1. Brake light switch If switch is defective, replace with a new one.

If the switch test good, verify wire continuity be-
Disconnect switch connector. tween brake light switch and ECM.
Drain brake system.
Unscrew brake light switch from master cylinder. ECM
BRAKE LIGHT
Catch spilled fluid with a rag. COI\JI\JECTOR RESISTANCE
SWITCH PIN
PIN
Discard sealing washers.
8-23 RED/ORANGE Close to 0 n
Installation
For installation, reverse the removal procedure. Removal
Install two NEW sealing washers. The front brake light switch is located underneath
the RH brake lever and it cannot be adjusted.
FRONT BRAKE LIGHT SWITCH Disconnect switch connectors.
Renegade Models Unscrew brake light switch from brake lever then
remove it.
Inspection
Installation
First, ensure bulb is not burnt.
For installation, reverse the removal procedure.
Check brake light switch for dirt or corrosion.
Make sure it is operating properly. Tighten switch screw to 1 N.m (9 Ibf·in).
Depress front brake lever and check for brake light
to turn on. PARKING BRAKE IVIECHANISM
Test Removal
Disconnect switch connectors. I'JOTE: The parking brake mechanism is located
on the LH brake handle.
Unscrew nut under LH brake lever.
Remove screw, spring and brake lever lock.

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

·V07K07A 4 2
V07K09A
1. Brake lever lock
2. Spring 1. Brake lever
3. Screw 2. Screw
4. Nut 3. Nut

Installation Inspection
For installation, reverse the removal procedure. Check brake lever for bending, cracks or other
See the following illustration to install the spring damages . Replace if necessary.
properly.
Installation
For installation, reverse the removal procedure.

FRONT MASTER CYLINDER

Removal
Remove master cylinder cover and its diaphragm
then drain brake fluid until front master cylinder
reservoir is empty.
Remove banjo fitting and sealing washers retain-
ing brake hose to front master cylinder. Discard
the sealing washers.

BRAKE LEVER
Removal
Remove the parking brake mechanism (LH brake
handle only).
Unscrew the brake lever nut.
Remove the screw and the brake lever.

TYPICAL - RH MASTER CYLINDER SHOWN

1. Front master cylinder
2. Banjo fitting
3. Sealing washers

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Section 11 BRAKES
Subsection 01 (FRONT AI\ID REAR BRAKES)

When removing RH master cylinder, unplug brake Install brake lever and locking mechanism.
light switch connectors . Apply dielectric grease (P/I\! 293 550004) on lever
Remove screws from master cylinder holder and pivot bolt.
remove master cylinder from handlebar.
Installation
For the installation, reverse the removal proce-
dure, pay attention to the following details.
Place the brake lever assembly on the handlebar.
Position cylinder holding bracket with the UP mark
upward.
Install screws and tighten loosely.
With the handlebar in straight ahead position, posi-
tion cylinder reservoir parallel to the ground. Tight-
en upper screw first.

TYPICAL - RH MASTER CYLINDER SHOWN

7. Holde r screws

Disassembly
Remove brake lever.
Remove piston boot, snap ring, piston and spring.

Inspection and Lubrication

Discard any remaining fluid inside reservoir.
Clean reservoir, piston and master cylinder thor-
oughly with clean brake fluid.
Check:
- boot for crack
- spring for damage Connect brake hose to master cylinder with a Ban-
- piston cup for wear, deterioration or damages jo fitting and I\JEW sealing washers.
- master cylinder and piston for scoring, scratch- Bleed brake system.
es or other damages. Check for leaks and make sure the brakes operate
Change part(s) if necessary. normally before driving.
Check if the end cap a-ring is brittle, hard or dam-
aged . REAR MASTER CYLINDER
NOTE: If master cylinder housing is damaged or
Removal
leaking, replace as an assembly.
Drain brake fluid.
Assembly Outlander Series
Coat piston and piston cups with clean brake fluid . Remove LH and RH footrests.
Install spring onto piston.
Renegade Models
Install piston into master cylinder.
Remove the master cylinder cover.
Install the snap ring into groove in the master cylin-
der. All Models
Install boot into master cylinder and the groove in Unplug brake switch connector.
piston. NOTE: At this time, check hoses and fittings for
Apply dielectric grease (PIN 293 550 004) to the damages or leaks.
brake lever contacting surface of the piston .

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Disconnect reservoir flexible hose and plug the

end to avoid brake fluid spillage.
Unscrew brake light switch from master cylinder.
Discard sealing washers.

V07KOHA 3 2 1
1. End cap
2. Spring
3. Piston

Remove the boot, the snap ring and the push rod.

1. Brake switch Inspection and Lubrication

2. Reservoir hose
3. Rear hose Discard any remaining fluid inside reservoirs.

Unscrew front hose from master cylinder. Clean reservoirs, pistons and master cylinders
thoroughly with clean brake fluid.
Unhook push rod from brake pedal.
Check:
Remove bolts retaining master cylinder to the
- boots for crack
frame .
- springs for damage
- piston cups for wear, deterioration or damages
- master cylinders and pistons for scoring,
scratches or other damages.
Change part(s) if necessary.
Check the push rod lock for excessive wear, re-
place if necessary.
Check if the end cap O-ring is brittle, hard or dam-
aged.
NOTE: If master cylinder housing is damaged or
1. Front hose
2. Push rod lock leaking, replace as an assembly.
3. Master cylinder bolts
Assembly
Disassembly Apply XP-S synthetic grease (PIN 293 550 010) on
both ends of push rod.
Remove the end cap, the spring and the piston.
Install the push rod, the snap ring and the boot.
If push rod yoke has been removed, reinstall it
then adjust push rod length, see the following il-
lustration.

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

CALIPER
Removal
Loosen wheel nuts .
Raise vehicle and support it securely.
Remove appropriate wheel.
Remove the caliper screws then the caliper. If the
caliper is not being removed from the vehicle as
during brake pad replacement, simply hang the
caliper with a piece of wire to take the weight off
the brake hose.
CAUTION: Do not let caliper hangs by the hose
and do not stretch or twist the hose.
If the caliper is being removed for replacement,
drain brake system before removing the Banjo fit-
t ing and its sealing washers . Remove the caliper
V07KOIA
from the vehicle.
A. 44 ± 1 mm (1.732 ± .039 in)

Coat piston and piston cups with clean brake fluid.

The spring is conical. Install the smaller end on
piston.
Insert piston in the master cylinder.

FRONT CALIPER - OUTLANDER SERIES

1. Retaining screw

V07KOJA

Install the end cap . Do not forget the O-ring .

Installation
Install master cylinder to frame .
Hook push rod on brake pedal.
Connect front hose on master cylinder.
Connect reservoir flexible hose .
Install the rear hose and the brake light switch with
two NEW sealing washers .
IImr2 00 7.o58-003_a

Connect brake light switch connector. FRONT CALIPER - RENEGADE MODELS

Fill up reservoir with clean brake fluid .
Bleed brake system.
Check for leaks and make sure the brakes operate
normally before driving.

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Section 11 BRAKES
Subsection 01 (FROI\IT AND REAR BRAKES)

Coat piston with clean brake fluid and install into

cylinder with the closing toward caliper body.
Apply dielectric grease (PIN 293 550004) into slid-
ing bores and install slide pins .
NOTE: Make sure that rubber boots are correctly
installed in slide pins grooves.
Install pad spring, caliper bracket and pads.

Installation
For the installation, reverse the removal proce-
dure, pay attention to the following details.
Use NEW sealing washers when installing banjo
fitting retaining brake hose to caliper.
REAR CALIPER - ALL MODELS
1. Remove banjo fitting and sealing washers Install caliper in its original position.
2. Unscrew bolts
Torque screws in accordance with the following
Catch spilled fluid with a rag. Attach the brake table.
hose in a position to prevent the fluid from flowing
out. MODELS TORQUE
Discard all sealing washers. OUTLANDER SERIES 34 N-m (25 Ibf-ft)

Disassembly RENEGADE MODELS 24 N-m (17 Ibf-ft)

Remove brake pads, see further in this section . Bleed the brake system.
Remove slide caliper support and pad spring . Check for leaks and make sure the brakes operate
Place rag over piston . normally before driving.
Place caliper body with piston down and apply
small squirts of air pressure to the fluid inlet to re- BRAKE PADS
move piston.
Removal
& WARNING Raise vehicle and support it securely.
Do not use high pressure air or bring nozzle Remove appropriate wheel.
too close to inlet.
Loosen pad pins.
Remove piston seal.
CAUTION: Be careful notto damage piston slid-
ing surface.
Clean piston grooves, caliper cylinder and piston
with clean brake fluid .
Clean slide pins with brake cleaner and a rag.

Inspection
If boots are deteriorated or hard, replace the
caliper.
Check caliper cylinder for scratches, rust or other
damages. If so, replace caliper.
Check piston for scratches, rust or other damages.
If so, replace caliper.

Assembly
Coat piston seal with clean brake fluid and install
it into piston grooves in caliper.
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

3 & WARNING
Avoid getting oil or grease on brake pads.
Contaminated brake pads can affect stopping
capacities.

CAUTION: Brake pads must always be replaced

in pairs.

Installation
Clean the visible portion of piston with clean brake
fluid.
Push caliper pistons inward before installing brake
pads.
NOTE: Use a C-clamp or another suitable tool. To
avoid damaging the piston, use an old pad to push
it into the caliper.
V07KOMA 2
Make sure that pad spring is in position.
1. Pad pins
2. Caliper
3. Pad

Remove caliper from its support or from knuckle .

Unscrew pad pins then remove pads. Discard pad
pins.
CAUTION: Do not let the caliper hang by the
hose and do not stretch or twist the hose.

Inspection
CAUTION: Do not clean brake pads in petrole-
um based solvent. Use brake system cleaner
only. Soiled brake pads must be replaced with V02KOBA 1 2
new ones. 1. Pad spring
2. Piston
Measure brake pad lining thickness .
Brake pads must be replaced when lining is 1 mm Install new brake pads .
(1/32 in) thick or less, or look the hollow places on
Install NEW pad pins by pushing in the pads
both sides on the pad lining.
against pad spring to align pad slots in the pads
There are four hollow places on one set of brake and caliper body.
pads. When the pad wear reaches one of the hol-
Install brake caliper so the disc is positioned be-
low places, the pad must be changed even if the
tween pads.
pad wear does not reach another hollow place.
NOTE: Be careful not to damage pads and make
sure pads are correctly inserted in their location.
After the job is completed, firmly depress the
brake lever a few times to bring the pads in con-
tact with the disc.
Check for leaks and make sure the brakes operate
normally before driving . The pads must rest flat
on the disk.
1. Hollow place

BRAKE PAD MINIMUM

THICKNESS
1 mm (1/32 in)

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

BRAKE DISC Remove caliper as described previously. Do not

disconnect brake hose from cal iper.
Inspection After removing the caliper, suspend it out of the
Brake discs can be inspected without removing way.
them from the vehicle. CAUTION: Do not let the caliper hang by the
Raise vehicle and support it securely. Remove hose and do not stretch or twist the hose.
wheels and visually inspect disc surfaces for Remove wheel hub with brake disc. Refer to
scratches or grooves. Make sure to check both FRONT DRIVE.
sides of disc.
Heat up brake disc around screw to break the
Measure thickness of the disc. threadlocker. Remove and discard brake disc
screws .
DISC MINIMUM THICKNESS
FRONT 3.5 mm (.138 in)
REAR 4 .3 mm (.170 in)

Replace disc if not within specifications.

CAUTION: Brake discs should never be ma- 1
chined. 1
Turn the disc by hand and check warpage.

MAXIMUM DISC WARPAGE 2

FRONT
0.2 mm (.01 in) I/mr 2007.QS8-005_8
REAR
1. Brake disc screws
2. Brake disc
Removal
Rear Brake Disc
Front Brake Disc
Remove rear wheels .
Outlander Series
Remove the caliper and suspend it out of the way.
Apply parking brake and raise the front of the ve-
hicle. CAUTION: Do not let the caliper hang by the
hose and do not stretch or twist the hose.
Remove the appropriate wheel.
Unscrew and remove the rear propeller shaft
Remove wheel hub. Refer to FRONT DRIVE.
screw from differential.
On Outlander 650 and 800 series, remove the
Remove the differential protector.
shock absorber.
Separate knuckle from lower A-arm .
Remove drive shaft from knuckle.
Attach upper A-arm or strut out of way.
Unscrew brake disc screws.
Keep the Belleville washers .
Release parking brake and remove caliper. Sus-
pend caliper out of the way.
CAUTION: Do not let the caliper hang by the vmr2007.{)54-007 _a

hose and do not stretch or twist the hose. 1. Differential protector

Remove brake disc. Pay attention not to cut the
CV boot. Remove the differential bolts.
Renegade Models Loosen hitch plate bolts .
Remove appropriate wheel. Move the differential backward .
Disconnect propeller shaft from differential.
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Unscrew brake disc screws. Heat up brake disc

around screws to facilitate removal. Discard brake
disc screws.

Installation
Front Brake Disc
Renegade Models
The installation is the reverse of the removal pro-
cedure.
Outlander Series
The installation is the reverse of removal proce-
dure . However, pay attention to the following de-
tails. V07KONA 3 2
Do not forget Belleville washers when installing 1. Return spring
2. Push rod hook
brake disc screws . Place the concave side of 3. Brake pedal
washers towards brake disc.
Remove bolt retaining the brake pedal to frame.
& WARNING
Never substitute Belleville washer with an-
other type of washer (flat, lock, etc.).

Tighten brake disc screws to 38 N-m (28 Ibf-ft) in

a criss-cross sequence.
Rear Brake Disc
All Models
Install brake disc on propeller shaft and tighten
NEW screws to 34 N-m (25 Ibf-ft) in a criss-cross
sequence.
1. Brake pedal bolt
BRAKE PEDAL 2. Brake pedal

Removal
Inspection
Remove RH footwell.
Check brake pedal for cracks or distortion.
Detach the return spring from the brake pedal.
Check if O-rings are brittle, hard or otherwise dam-
Open the master cylinder push rod hook. aged .
Replace any defective parts .

Installation
For installation, reverse the removal procedure.
Apply XP-S synthetic grease (PIN 293 550 010) on
both O-rings and into brake pedal.

BRAKE HOSES
Inspection
Brake hoses should be inspected frequently for
leaks and damages.
Check if the hoses are crushed or damaged. Any
deformation can restrict the proper flow of fluid
and cause braking problems.
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Check hoses for cracking or scrapes. This dam-

age can cause hose failure under pressure.
When hoses are removed or disconnected, clean-
liness must be observed. Clean all joints and con-
nections before disassembly. New hoses should
be cleaned with brake fluid before installation to
remove any contamination.
Replace any defective parts.

Removal
NOTE: Before removing any hoses, drain brake
system .
Remove all necessary parts to reach the hoses.
Thoroughly clean the area around the joints that
will be disconnected.
Place a drain pan under the joint that will be dis-
connected .
Disconnect any retaining clips or brackets holding
the hose and remove the defective part(s).

Installation
Install the new hose.
Make sure the piece will not rub against any other
part.
When there is a banjo fitting securing the hose to
the caliper or to the master cylinder, always re-
place the sealing washers with new ones .
2

V07KOPA

FRONT MASTER CYLINDER SHOWN

1. Banjo fitting
2. Sealing washers

Install any retaining clips or brackets .

Refill and bleed the system.

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Section 12 BODV/FRAME
Subsection 01 (BODY)

BODY
SERVICE TOOLS
Description Part Number Page
pliers Oetiker 1099 ........ .. .. ........ ............ .... ... ............ ... ..... .. .. 295 000 070 ....... .... .. ... .. .. .. ..... ... ........ ... 393

sa,les@midwe,
-. - - .-. -, ", . -tLr- - - -, . - - ..
.- - - - - . i!!
WWW.. ml ·· We.S maln U3. S.COm
d~ '

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Section 12 BODY/FRAME
Subsection 01 (BODY)

OUTLANDER SERIES
Body Parts (Front View)

"""- ·«>=--8

4.5 Nom
(40 Ibfoin) 3 4 -

-6

1 2.5 Nom
(22 Ibfoin) 3 6 -
/

39<·~1I11=itJ;§~
20 Nom
(15Ibfoft) .

'\\ 20 Nom
39( 15 Ibf0ft)

2.5 Nom
(22Ibfoin)

8 Nom 2.5 Nom

(71 Ibfoin) (22 Ibfoin)
vmr 2006·029-004 _aen

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Section 12 BODY/FRAME
Subsection 01 (BODY)

Body Parts (Rear View)

4.5 Nom
-- _-----.34 (40 Ibfoin)

-35

4.5 Nom =-------_"'"

(40Ibfoin) t
'---- 2.5 Nom
(22 Ibfoin)

'---- 4.5 l\lom

(40Ibfoin)

-40
I
20 Nom
(15 Ibfoft)
vmr2006-029-005_aen

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Section 12 BODY/FRAME
Subsection 01 (BODY)

Body Parts (Side View)

OUTLANDER
OUTLANDER XT

21
1~ /
~-14
~ : I 11- 15

,I '. -13

OUTLANDER MAX
OUTLANDER MAX XT

-12

21
1 /

~~1
13

5.5 Nom
(49 Ibfoin) --=-=-.i
vmr2006-029-026_aen

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Section 12 BODY/FRAME
Subsection 01 (BODY)

Seat
OUTLANDER
OUTLANDER XT

~ , _ 6.5 Nom
, I' (58 IbNn)
,I

OUTLANDER MAX
OUTLANDER MAX XT

.-:""-.

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Section 12 BODY/FRAME
Subsection 01 (BODY)

XT Package

f 11 N-m
I 28 (97 Ibf-in)

I
I

11 N-m
(97 Ibf-in)
25

8 N-m
(71 Ibf-in)

16 N-m
(142Ibf-in)

vmr2006-029-006_aen

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Section 12 BODV/FRAME
Subsection 01 (BODY)

RENEGADE MODELS
Body Parts (Front View)

24

1.5N"m
(13Ibfoin)
t
r
~ (13Ibfoin)
2 Nom '-----*
(22Ibfoin) 1.5Nom

32

2.5 Nom
(22Ibfoin)

2.5 Nom

,J"m
1.5 Nom (22 Ibfoin)
Pf;::.~"/,4.5 Nom (Ibf· )
~)bfoin) '/~I
\.

~2.5 Nom
(22 Ibfoin) u;;;.~~~~ I
.' " i
1-~~~~ ~ ,-'" 1.5 Nom
(13Ibfoin)
t
'",
5N",,!
(44Ibfom)

2 5 Nom 2.5 No~

32 (22 Ibfoin) (22 Ibfom)
vmr200B-072-Q01_a

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Section 12 BODV/FRAME
Subsection 01 (BODY)

Body Parts (Rear View)

~':!!?-'?_~'!~ _C;9..'!'.'!lunity models

-- --- -- --.- ------------------------------

,
I 20 Nom
, (15 Ibf°ft)

,,,
,
,, ;0
,,, --~
,
,, 4.5 Nom
(40 Ibfoin)-~ , 4.5 Nom
~------------------~~----~
2.5 Nom
(22 Ibf-in)
j
'
:,
,,
,
L1 '
! i~ (40 Ibfoin)
25 Nom
4.5 Nom (18Ibf°ft)
(40Ibfoin)
25 Nom
(18Ibf°ft)

,
~

vmr20oa-072.002_1

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Section 12 BODY/FRAME
Subsection 01 (BODY)

Body Parts (Side View)

RH side LH side

~--11

~
, ff
~14
14~ I
I,
.....-'"!:.oo>I\

:~
13

13

5.5 Nom
(49Ibfoin)

5.5 Nom
(49Ibfoin)

vmr2008-072-003_a

vmr200a-Q72
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Section 12 BODY/FRAME
Subsection 01 (BODY)

Seat

6.5 Nom
~-(58Ibfoin)

vmr2008-072-004_a

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Section 12 BODY/FRAME
Subsection 01 (BODY)

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded
views .
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

& WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced
with new ones. V06L08A 2
TYPICAL
1. Pliers
2. Plastic rivet
Vehicle Care
Clean the vehicle thoroughly, removing all dirt and
grease accumulation . PROCEDURES
To clean use a soft clean cloth and either soapy
water or isopropyl alcohol. DECALS
To remove grease, oil or glue use isopropyl alco-
hol. Decal Removal
CAUTION: Do not apply isopropyl alcohol or Using a heat gun warm up one end of decal for a
acetone directly on decals. few seconds until decal can roll off when rubbing
with your finger.
The following products must not be used to clean
or wax any of the plastic components used on the Pull decal slowly and when necessary apply more
vehicles: heat to ease removal on the area that has to be
- gasoline peeled off.
- brake fluid If decal tears while pulling off, it has to be heated
for a few seconds longer. If decal tends to stretch
- kerosene
while pulling off, stop heating and wait a few sec-
diesel fuel onds to let it cool, then peel it off.
- lighter fluid
- varsol Decal Installation
- naphtha Using isopropyl alcohol, clean the surface and dry
- acetone thoroughly.
- strong detergents Apply liquid soap to new decal and carefully po-
- abrasive cleaners sition it. Using a sponge or a squeegee, remove
- waxes containing an abrasive or a cleaning the air bubbles and surplus water working from
agent in their formula . the center toward the edges. Allow to air dry.
CAUTION: Do not apply isopropyl alcohol or
Plastic Rivet solvent directly on decals. Use these products
Plastic rivets no. 1 are used in the riveting of the in a well ventilated area.
various body parts. Plastic rivets can be removed
carefully with pliers Oetiker 1099 (P/N 295 000 SEAT
070).
NOTE: Reuse the plastic rivets. Seat Cleaning
It is recommended to clean seat(s) with a solution
of warm soapy water, using a soft clean cloth.

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Section 12 BODY/FRAME
Subsection 01 (BODY)

CAUTION: Avoid use of harsh detergents such

as strong soaps, degreasing solvents, abrasive
cleaners, paint thinners, etc. that may cause
damage to the seat cover.

Seat Removal
Passenger's Seat
Outlander MAX/MAX XT Models
Pull one of the passenger's seat latch levers no. 4.
Those levers are located underneath the RH or LH
rear end of seat.

OUTLANDER/OUTLANDER XT
1. Seat latch

TYPICAL - LH SIDE
1. Seat latch lever

Gently lift the rear of seat no. 3.

OUTLANDER MAX/OUTLANDER MAX XT
Pull seat rearwards. 1. Seat latch
Continue lifting movement until you can release
the front retaining device then completely remove
passenger's seat.
Operator's Seat
Outlander MAX/MAX XT Models
Remove passenger's seat no. 3 as mentioned
above.
All Models
To remove seat no. 2, move latch lever no. 5 up-
ward while gently lifting rear of seat.

RENEGADE MODELS
1. Seat latch

Pull seat rearward. Continue lifting movement un-

til you can release the front retaining device then
completely remove seat.

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Section 12 BODY/FRAME
Subsection 01 (BODY)

Seat Installation
Insert front tabs of seat into frame hooks. When
seat rests in its position, firmly push seat down to
latch.

A35HOHA

TYPICAL
1. Piece of wood
2. ETN-50 (electric)

After cover installation cut all around the excess

of material.

V07L05A 2 CENTRAL PANEL

1. Insert these tabs in hooks
2. Hooks Central Panel Removal
Outlander Series
NOTE: A distinctive snap will be felt. Double
check that the seat is secure by giving it a tug to Remove seat(s).
confirm proper latching. Come off the plastic studs from the grommets.

& WARNING
Make sure seat is securely latched before rid-
ing.

Seat Cover Replacement

Remove the old seat cover. Check the foam and
replace if necessary.
Install staples with an electric tacker such as Ar-
row tacker no. ETN-50 or with a manual tacker
such as Arrow tacker no. T-50.
NOTE: For an easier installation, it's highly recom- Pull central panel no. 6 to separate its tabs from
mended to use an electric tacker. front fender no. 7.
Ensure that the seat rest firmly against a hard sur-
face such as a piece of wood. This is done to get
the staples completely pushed in place.

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Section 12 BODY/FRAME
Subsection 01 (BODY)

DASH BOARD
Dash Board Removal
Remove central panel.
Lift up dash board no. 8.
Disconnect speedometer, 12-volt power outlet
and ignition switch (Outlander Series).

Dash Board Installation

For installation, reverse the removal procedure.

SIDE PANEL
Side Panel Removal
Renegade Models NOTE: Use the same procedure for the LH and
Remove seat. RH side panels no. 11 and no. 12.
Lift the front part of the central panel no. 6. Remove seat(s) and central panel no. 6.
Come off the plastic studs from the grommets.

1. Lift here vmr2006-G29-009

Come off the plastic studs from the grommets. Unhook the side panel from footrest.

Remove central panel.

Remove side panel from vehicle.
Central Panel Installation
Side Panel Installation
The installation is the reverse of the removal pro-
cedure. The installation is the reverse of removal proce-
dure.

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Section 12 BODY/FRAME
Subsection 01 (BODY)

FOOTREST
Footrest Removal
Outlander Series
Remove footpeg(s) no. 14 and all bolts that attach
the footrest no. 13 to fenders .

INNER FENDER ON RH SIDE

1. Plastic rivets

On MAX and MAX XT models, remove the

footrest support retaining screws no. 15.
Renegade Models
Remove the footpeg and all bolts securing footrest
to front and rear fender.

INNER FENDER ON LH SIDE

1. Plastic rivets

On the RH side, detach coolant hoses from inner

fender no. 21.

Inner Fender Installation

Footrest Installation The installation is the reverse of removal proce-
The installation is the reverse of removal proce- dure.
dure.
HEAVY DUTY BUIVIPER
INNER FENDER Outlander XT Package
Inner Fender Removal Bumper Removal
Outlander Series
Front Bumper
Remove the plastic rivets that attach inner fenders
no. 20 and no. 21 to footrest and frame. Remove bolts no. 22 retaining the heavy duty
bumper no. 23 to the front bumper no. 24.

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Section 12 BODV/FRAME
Subsection 01 (BODY)

FRONT BUMPER/FRONT SKID

PLATE/FRONT FASCIA
Removal
Outlander Series
NOTE: On XT models, remove hook at the end of
winch cable and the front heavy duty bumper.
Remove front fender.
Unplug headlamps connectors.
Unscrew bolts no. 29 that attach front bumper
Remove screws no. 25 that attach the heavy duty no. 24 to fender support no. 30.
bumper to the rack.

Unscrew bolts retaining the bottom of bumper to

Remove the heavy duty bumper. frame.
Rear Bumper Remove front bumper with front skid plate no. 31
Unscrew bolts no. 26 retaining the rear heavy duty and front fascia no. 32 assembly.
bumper no. 27 to the rear bumper. Disassemble all parts if necessary.
Remove screws no. 28 that attach the heavy duty Renegade Models
bumper to the rack.
Unscrew bolts no. 29 securing the front bumper
no. 24 to the bumper bracket no. 30.

vmr2007-059-012_a

Bumper Installation 1. Upper bumper bolts

2. Front bumper
The installation is the reverse of the removal pro- 3. Bumper bracket
cedure.
Unscrew bolts retaining the bottom of front
bumper to frame.

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Section 12 BODY/FRAME
Subsection 01 (BODY)

Remove luggage rack.

7. Lower bumper bolt
2. LH lower suspension arm
3. Front bumper Rack Installation
The installation is the reverse of removal proce-
Remove front bumper. dure.
Installation
The installation is the reverse of removal proce-
FENDER
dure. Fender Removal
Outlander Series Front Fender
Install a washer no. 33 under each plastic rivet Outlander Series
located at the both ends of fascia.
Remove both side panels no. 11 and no. 12.
Remove bolts that attach both footrests to the
fender.
Remove plastic rivets retaining front fender no. 7
to front fascia.
Remove luggage rack.
Unscrew and remove fender bolts no. 36.

V07L 13A

LUGGAGE RACK
Outlander Series
NOTE: Use the same procedure for front or rear 1. Luggage rack
luggage racks. 2. Fender bolts

Rack Removal Unscrew the brake fluid reservoir bolt.

NOTE: On XT models, heavy duty bumpers (front
and rear) must be removed to allow luggage racks
removal.
Remove storage or service compartment cover.
Unscrew the four (4) bolts no. 34 retaining the rack
no. 35.

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Section 12 BODY/FRAME
Subsection 01 (BODY)

Remove the coolant reservoir support bolt. Lift up fender and place it in a safe place to avoid
scratches .
Renegade Models
Remove central panel, dash board and both side
panels .
Remove the screw at the bottom of the front plas-
tic grid .

Remove both inner fenders.

Detach dash board no. 8 from fender.

Remove the screw located between radiator cap

and coolant tank.

Remove push nuts retaining fender to frame .

Remove screws attaching front fender to both

footrests .

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Section 12 BODY/FRAME
Subsection 01 (BODY)

Unplug all headlamps. 1. Seat

2. RH side panel
Remove fender and store it safely to avoid scratch-
es .
Remove screws attaching the bottom of rearfend-
Rear Fender er no. 37 to both footrests.
Outlander Series
Remove seat(s) .
Remove both side panels.
Remove luggage rack no. 35.
Remove all screws retaining the footrests to rear
fender no. 37 .

Remove anchorage hooks on the top of rear fend-

er.

V0710KA

Unscrew the fuel tank cap.

Lift and remove fender. Place it in a place to avoid
scratches.
Reinstall the fuel tank cap.
Renegade Models
Remove seat and both side panels .

Remove fuel tank cap.

Lift and remove fender. Store it safely to avoid
scratches .
Reinstall the fuel tank cap .

Fender Installation
The installation is the reverse of removal proce-
dure.

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Section 12 BODY/FRAME
Subsection 01 (BODY)

FENDER SUPPORT
Outlander Series

Fender Support Removal

Front Fender Support
Remove front fender.
Unscrew front bumper bolts no. 29 and radiator
mounting bolts.

Fender Support Installation

The installation is the reverse of removal proce-
dure.

1. Radiator bolts
2. Bumper bolts

Remove bolts no. 39 retaining the fender support

no. 30 to the frame .

V07l1 1A

Rear Fender Support

Remove rear fender.
Remove bolts that attach fender support no. 40 to
frame.
Unscrew the exhaust support bolt.

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Section 12 BODY/FRAME
Subsection 02 (FRAME)

FRAME
Outlander 500/650/800 Series and Renegade Models

48 Nom
(35 Ibfoft)
25NO~­ 5
(18Ibfoft)

11
48 Nom
(35 Ibfoft)

vmr2006-030-003_b

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Section 12 BODY/FRAME
Subsection 02 (FRAME)

Outlander MAX 500/650/800 Series

34 Nom
(25Ibfoft)
10
h
,-e-- _."
I -~
i I~_

~
6 25 Nom 25 Nom
~tJ(~:foft~ (~ Ibfoftl
4 , r"'~
r'"
25 Nom

5
9
25 Nom
(18Ibfoft)
vmr2006-000-0D4 _b

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I .
Section 12 BODY/FRAME
Subsection 02 (FRAME)

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure .

.& WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced OUTLANDER MAX
with new ones.

Footrest Support Inspection

PROCEDURES Check footrest support(s) for cracks, bending or
other damages . Replace if necessary.
FOOTREST SUPPORT
Footrest Support Installation
NOTE: Use the same procedure for RH or LH
The installation is the reverse of remova l proce-
footrest supports .
dure.
Footrest Support Removal NOTE: Install all bolts before tightening.
Front Footrest Support
BATTERY SUPPORT
To remove the front support no. 1, do the follow-
ing . Battery Support Removal
Remove the appropriate footrest. Remove battery (refer to STARTING SYSTEM) .
Unscrew bolts no. 2, no. 3 and no. 4. Remove bolts no. 10 retain ing the battery support
no. 11 to frame no. 9.

Remove the front footrest support.

Rear Footrest Support
To remove the rear footrest support no. 5, use
same procedure than front footrest support but TYPICAL
remove bolts no. 6 instead of bolts no. 2.
Remove upper differential bolts .
Passenger Footrest Support
All MAX/MAX XT Models
Remove both footrests .
Unscrew bolts no. 7 then remove passenger
footrest support(s) no. 8.

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Section 12 BODY/FRAME
Subsection 02 (FRAME)

1. Differential protector bolts

TYPICAL 2. Lower differential bolts
3. Hitch bolt
Remove bolts that attach fuel tank and its protec-
tor to frame. Remove hitch from vehicle.

Hitch Inspection
Check hitch for cracks, bending or other damages.
Replace if necessary.

Hitch Installation
The installation is the reverse of removal proce-
dure.

RECOVERY HOOK
Renegade Models

Hook Removal
Remove battery support from vehicle . Remove the differential protector.
Battery Support Inspection Unscrew bolts retaining the recovery hook to
frame.
Check battery support for cracks or other dam-
ages. Replace if necessary. Remove lower differential bolts.

Battery Support Installation

The installation is the reverse of removal proce-
dure.

HITCH
Outlander Models

Hitch Removal
Remove the differential protector.
Unscrew bolts retaining the hitch to frame.
Remove lower differential bolts.
TYPICAL
1. Differential protector bolts
2. Lower differential bolts
3. Hitch bolt

Remove recovery hook from vehicle.

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Section 12 BODY/FRAME
Subsection 02 (FRAME)

Hook Inspection
Check hitch for cracks, bending or other damages.
Replace if necessary.

Hook Installation
The installation is the reverse of removal proce-
dure .

FRAME
Frame Cleaning
Clean frame no. 9 with appropriate cleaners and
rinse with high pressure hose.
NOTE: Clean the draining holes under frame . The
drain holes are located at the rear of bottom side
of frame.
Touch up all metal spots where paint has been
scratched off. Spray all bare metal parts of vehicle
with metal protector.

Frame Welding
CAUTION: Before performing electrical weld-
ing anywhere on the vehicle, unplug the
multiple connector at the electronic module
connector. Also unplug the negative cable
and the voltage regulator. This will protect the
electronic module and battery against damage
caused by flowing current when welding.
Use the following specifications for electric weld-
Ing:
- amperage : 70 - 110 A
- voltage : 20 - 24 V
- rod: E-7014 (3/32 in).
NOTE: Install the ground as close as possible from
the reparation area.
CAUTION: If welding is to be done near plastic
material, it is recommended to either remove
the part from the area or to protect it with alu-
minum foil to prevent damage.

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER SERIES)

OUTLANDER SERIES
MODEL OUTLANDERTM 500 OUTLANDERTM 650 OUILANDERTM 800
'ENBlNE
ROTAX® V490 ROTAX® V660 ROTAX® V810
Engine type
4-stroke, Single Over Head Camshaft (SOHCl. liquid cooled
Number of cylinders 2
Number of valves 8 valves (mechanical adjustment)
Bore mm(in) 82.03 (3.23) 91 (3.58)
Stroke mm (in) 47.3 (1.86) 61 .5 (2.42)
Displacement cm 3 (in 3) 500 (30.51) 650 (39.67) 800 (48.82)
Compression ratio 10.7:1 10.3:1 10.3:1
Decompressor type NA
Maximum HP RPM RPM 7250 6750
Type Wet sump. Replaceable oil filter
Oil filter BRP Rotax paper type, replaceable
Engine oil
Minimum 350 kPa (51 PSI) at 6000 RPM
Lubrication pressure
Capacity (oil change
2 L (2.11 quarts)
with filter)
Engine oil
SAE 5W30 API classification SM, SL or SJ
Recommended
see OIL VISCOSITY CHART in LUBRICATION SYSTEM
Intake valve opening 3° BTDC 5° BTDC
Intake valve closing 34° ABDC 45° ABDC
Exhaust valve opening 39° BBDC 50° BBDC
Exhaust valve closing 2° ATDC 0° ATDC
Chain tensioner plunger protrusion Service limit mm (in) 20.0 (.7874)
Intake mm(in) 0.06 to 0.14 (.0024 to .0055)
Valve clearance
Exhaust mm(in) 0.11 to 0.19 (.0043 to .0075)
New mm(in) 4.966 to 4.980 (.1955 to .1960)
Intake
Service limit mm(in) 4.930 (.1941)
Valve stem diameter
New mm(in) 4.956 to 4.970 (.1951 to .1957)
Exhaust
Service limit mm(in) 4.930 (.1941)
Intake and New mm(in) 0.005 (.0002)
Valve out of round
exhaust Service limit mm(in) 0.06 (.0024)
New mm (in) 4.998 to 5.018 (.1968 to .1976)
Valve guide diameter
Service limit mm(in) 5.050 (.1988)
New mm (in) 40.81 (1.607)
Valve spring free length
Service limit mm(in) 39.00 (1.535)
New mm (in) 1.05 to 1.35 (.041 to .053)
Intake
Service limit mm (in) 1.8 (.070)
Valve seat contact width
New mm(in) 1.25 to 1.55 (.049 to .061)
Exhaust
Service limit mm(in) 2 (.078)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER SERIES)

MODEL OUTLANDERTM 500 OUTLANDERTM 650 OUTLANDERTM 800

IENGINE{cont'd}
New mm (in) 12.036 to 12.050 (A739 to A744)
Rocker arm bore diameter
SeN ice limit mm (in) 12.060 (A748)
New mm (in) 12.000 to 12.018 (A724 to A731)
Rocker arm shaft diameter
SeNice limit mm (in) 11.990 (A72o)
81.950 to 81.966 90.950 to 90.966
New mm(in)
Piston measurement (3.2264 to 3.2270) (3.5807 to 3.5813)
SeNice limit mm (in) 81.850 (3.2224) 90.850 (3.577)
New mm(in) 0.057 (.0022) 0.027 (.0011)
Piston/cylinder clearance
SeNice limit mm (in) 0.130 (.0051) 0.100 (.0040)
1S t Upper compression ring. rectangular
Piston ring type 2nd Lower compression ring. tapered face
3rd Oil scraper ring
Rectangular 0.20 to 0.40 (.008 to 016)
Tapered face New mm (in) 0.20 to DAD (.008 to .016)
Ring end gap
Oil scraper ring 0.20 to 0.70 (.008 to .028)
All SeNice limit mm(in) 1.5 (.059)
Rectangular 0.03 to 0.070 (.0012 to .0028)
Tapered face New mm (in) 0.02 to 0.060 (.0008 to .0024)
Oil scraper ring 0.01 to 0.018 (.0004 to .0007)
Ring/piston groove clearance
Rectangular 0.15 (.0059)
Tapered face SeNice limit mm (in) 0.15 (.0059)
Oil scraperring 0.25 (.0098)
82.023 to 82.037 90.993 to 91.007
Cyl inder bore New mm (in)
(3.2292 to 3.2298) (3.5823 to 3.5829)
Maximum
mm (in) 0.038 (.0015)
Cylinder taper New
SeNice limit mm (in) 0.090 (.0035)
Maximum
mm (in) 0.015 (.0006)
Cyl inder out of round New
SeNice limit mm (in) 0.020 (.0008)
Timing chain New mm (in) 34.959 to 34.975 (1.3763 to 1.3770)
side SeNice limit mm (in) 34.950 (1.3760)
Camshaft main bearing journal
Spark plug New mm (in) 21.959 to 21.980 (.8645 to .8654)
side SeNice limit mm (in) 21.950 (.8642)
Timing chain New mm (in) 35.000 to 35.025 (1.3780 to 1.3789)
Camshaft main bearing journal side SeNice limit mm (in) 35.040 (1.3795)
bore Spark plug New mm (in) 22.000 to 22.021 (.8661 to .8670)
side Wear limit mm (in) 22.040 (.8677)
31.830 to 32.030 32.11 to 32.31
New mm (in)
Intake valve (1.2531 to 1.2610) (1.2642 to 1.2721)
SeNice limit mm (in) 31.810 (1.2524) 32.09 (1.2634)
Camshaft lobe
31.730 to 31.930 31.94 to 32.14
New mm (in)
Exhaust valve (1.2492 to 1.2571) (1.2575 to 1.2654)
SeNice limit mm (in) 31.710 (1.2484) 31.92 (1.2567)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER SERIES)

MODEL OUTLANDERTM 500 OUTLANDERTM 650 IOUTLANDERTM 800

-, .. '
"'

.~N,GJN~ Jconfd) <-

. .. .. .,

Crankshaft main journal diameter MAG/PTO New mm(in) 42.024 to 42.040 (16545 to 1.6551)
side Service limit mm(in) 42.000 (16535)
Crankshaft radial play MAG/PTO side Service limit mm (in) 0.07 (.0031)
Crankshaft main journal diameter PTO support New mm (in) 34.024 to 34.040 (1.3395 to 1.3402)
bearing Service limit mm (in) 34.010 (1.3390)
Crankshaft radial play PTO support bearing Service limit mm (in) 0.10 (.0039)
35.064 to 35.080 40.009 to 40.025
New mm (in)
Crankshaft pin diameter (1.3805 to 1.3811) (1.5752 to 15758)
Service limit mm (in) 35.050 (1.3800) 39.990 (15744)
Crankshaft deflection MAG/PTO side New mm(in) 0.050 (.002)
Crankcase plain bearing MAG/PTO side Service limit mm (in) 42.100 (1 .6575)
PTO cover plain bearing Service limit mm(in) 34.120 (1 .3433)
Connecting rod big end diameter Service limit mm(in) 35.150 (1.3839) 40.100 (1 .579)
Connecting rod big end radial play Service limit mm(in) 0.09 (.0035)
New mm(in) 0.200 to 0.500 (.008 to .020)
Connecting rod big end axial play
Service limit mm(in) 0.600 (.024)
18.010 to 18.020 20.010 to 20.020
New mm (in)
Connecting rod small end diameter (.7091 to .7095) (.7878 to .7882)
Service limit mm (in) 18.060 (.7110) 20.060 (.7898)
17.996 to 18.000 19.996 to 20.000
New mm (in)
Piston pin diameter (.7085 to .7087) (.7872 to .7874)
Service limit mm (in) 17.980 (.7079) 19.980 (.7866)
Connecting rod/piston pin clearance (radial
Service limit mm (in) 0.080 (0035)
play)
GEARBOX
Type Dual range (HI-LO) with park, neutral and reverse
Capacity 400 mL (14 U.S oz)
Gearbox oil
Recommended XP-S chaincase oil
New mm(in) 0.10 to 0.20 (.0039 to .0079)
Output shaft backlash
Service limit mm(in) 0.25 ( 0098)
New mm(in) 0.02 to 0.15 (.0008 to .0059)
Bevel gear axial play
Service limit mm(in) 0.19 (.0075)
New mm (in) 5.25 to 5.35 (.207 to .211)
Shifting sleeve groove width
Service limit mm (in) 5.50 (.217)
New mm (in) 4.95 to 5.05 (.195 to .199)
Shifting fork claw thickness
Service limit mm (in) 4.80 (.189)
Shift fork claw thickness New mm (in) 4.80 to 4.90 (189 to .193)
(for high gear shifting) Service limit mm(in) 4.70 (185)
Shift fork claw thickness New mm (in) 5.10 to 5.20 (.201 to .205)
(for low/reverse gear shifting) Service limit mm(in) 5.00 (.197)
New mm (in) 6.920 to 6.970 (.272 to .274)
Shift fork pin diameter
Service limit mm(in) 6.850 (.270)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER SERIES)

MODEL OUTLANDERTM 500 I OUTLANDERTM 650 I OUTLANDERTM 800

-
ENGINE (coord) , -- - - ~
,c

Gap of shift fork engagement groove New mm (in) 5.00 to 5.10 (.197 to .201)
(high gear shifting) Service limit mm (in) 5.20 (.205)
Gap of shift fork engagement groove New mm (in) 5.30 to 5.40 (.209 to 213)
(low/reverse gear shifting) Service limit mm (in) 5,50 (.217)
New mm (in) 29.000 to 29.013 (1.1417 to 11422)
Diameter free pinions
Service limit mm (in) 29.015 (1,1422)
New mm (in) 24.979 to 25,000 (.983 to .984)
Intermediate gear shaft
Service limit mm (in) 24.977 (.983)
Right side 17.990 (.708)
Free pinion
Counters haft Service limit mm (in) 24.970 (.983)
bearing
CVT side 24.970 (.983)
Free pinion
Bevel gear shaft Service limit mm (in) 24,984 (.984)
bearing
COOLING SYSTEM
Ethyl glycol/water mix (50% coolant. 50% water).
Type Use premixed coolant sold by BRP (P/N 219 700 362) or
Coolant coolant specifically designed for aluminum engines
Capacity 2.5 L (2.65 quarts)
Thermostat Opening temperature 65°C (149°F)
ELECTRICAL SYSTEM
"
Magneto generator output 400 W @ 6000 RPM
Ignition system type 101 (Inductive Discharge Ignition)
Ignition timing Not adjustable
Quantity 2
Spark plug Make and type NGK DCPR8E
Gap mm (in) 0.6 to 0.7 (.024 to ,027)
Crankshaft position sensor (CPS) rl 774 to 946 @ 20°C (68 OF)
Forward RPM 8000
Engine RPM limiter setting
Reverse RPM 3200
Type Dry battery type
Voltage 12 volts
Battery
Nominal rating 18 A-h
Power starter output 0.7 KW
Headlamp W 2 x 35
Taillight W 7/29
Director indicator (European Community models) W 10
Indicator lights LEOS. 0.7 V approximately (each)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER SERIES)

MODEL OUTLANDERTM 500 I OUTLANDERTM 650 I OUTLANDERTM 800

ELECTRICAL SYSTEM (cant'd)
Accessories 20 A
Fan 20 A
Main 30 A
Ignition coils 5A
Fuel injectors 5A
Fuses Speedometer/speed
7.5 A
sensor/tail lamp
Fuel pump 7.5 A
Engine control module
5A
(ECM)
Main accessories 30 A
iFUeLsYSTEM'
Electronic Fuel Injection (EFI), DeLorto 46 mm throttle
Fuel delivery Type
body, 1 injector per cylinder
Type Bosch
Fuel pump
Model Electrical (in fuel tank)
Idle speed RPM ± 50 1250 (not adjustable)
Type Regular unleaded gasoline
Inside North
(R+M)/2 87 or higher
America
Fuel
Octane no. Outside
l'Jorth RON 92 or higher
America
Fuel tank capacity 20 L (5.3 U.S. gal)
Remaining fuel in fuel tank when display light turns ON ± 6 L ('1.6 U.S. gal)
..

:PRIK~,TRA!r-J~ =" = <. ,""",, . ~' -. ." ~ '- .< '"" (!, - ...",.~ >

Front drive Shaft driven/Auto-lock differential (shear pump)

Front drive ratio 3.6:1
Rear drive Shaft driven/locked differential
Rear drive ratio 3.6:1
Front 500 mL (17 U.S. oz)
Capacity
Rear 250 mL (8.5 U.S. oz)
Differential oil
BRP differential oil (P/N 293 600 043) or
Recommended
synthetic oil 75W90 (API GL5)
CV joint grease CV joint grease (P/N 293 550 019)
Propeller shaft grease XP-S synthetic grease (P/N 293 550 010)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER SERIES)

MODEL OUTLANDERTM 500 OUTLANDERTM 650 I OUTLANDERTM 800

TRANSMISSION
Type CVT (Continuously Variable Transmission)
Engagement RPM ± 100 RPM 1750
CVT
Drive belt width Service limit mm (in) 30.00 (1.181)
New mm (in) 13.70 to 13.80 (.539 to .543)
Governor cup roller outer diameter
Service limit mm (in) 13.20 (.519)
New mm (in) 8.05 to 8.15 (.317 to .321)
Governor cup roller inner diameter
Service limit mm (in) 9.00 (.354)
New mm (in) 6.078 to 6.100 (.239 to .240)
Centrifugal lever pivot bolt diameter
Service limit mm (in) 6.000 (.236)
Centrifugal lever bore diameter Service limit mm (in) 6.200 (.244)
Drive pulley sliding half centrifugal lever pivot New mm (inl 6.113 to 6.171 (.241 to .243)
bolt bore diameter Service limit mm (in) 6.300 (.248)
New mm (in) 55.000 to 55.040 (2.165 to 2.167)
Drive pulley sliding half large bushing
Service limit mm (in) 55.200 (2.173)
New mm (in) 32.000 to 32.040 (1.260 to 1.261)
Drive pulley sliding half small bushing
Service limit mm (in) 32.200 (1.268)
New mm (in) 30.060 to 30.100 (1.183 to 1.185)
Driven pulley sliding half bushing
Service limit mm (in) 30.200 (1.189)
New mm (in) 30.060 to 30.100 (1.183 to 1.185)
Driven pulley sliding fixed bushing
Service limit mm (in) 30.200 (1.189)
Torque gear on driven pulley Service limit mm (in) 7.500 (.295)
STEERING
Standard 2.16 m (7 ft)
Turning radius
MAX 4.80 m (7 ft 9 in)
Total toe (vehicle on ground) mm (in) o (01
Camber angle 0°
Tie-rod maximum length unengaged mm (in) 17.5 ± 5 (11/16 ± 3/16)
...

SUSPENSION .. ..

FRONT
Suspension type MacPherson Double A-Arm
Suspension travel mm (in) 178 (7) 203 (8)
Qty 2
Shock absorber
Type Oil
Standard mm (in) 372 (14-5/8) 349 (13-3/4)
XT mm (in) 387 /15-1/4) 359 (14-1/8)
Spring free length MAX mm (in) 372 (14-21/32) 358 (14-3/32)
MAXXT mm (in) 387 (15-15/64) 369 (14-17/321
LTD mm (in) - - I 369 (14-17/32)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER SERIES)

MODEL OUTLANDERTM 500 OUTLANDERTM 650 JOUTLANDERTM 800

- - -" .
~USPENSION (cont'dl
Standard Si Iver/Blue/Gold Green/Gold/Green
XT White/Blue/Gold White/Red/Gold
Spring color code MAX Silver/Blue/Gold GoldlYeliow/Blue
MAXXT White/Blue/Gold Silver/Red/Gold
LTD - - I Silver/Red/Gold
Front preload adjustment I\I.A. 5 settings
REAR
Suspension type TIITM independent
Suspension travel mm(in) 229 (9)
Oty 2
Shock absorber
Type Oil
Standard
mm(in) 354 (13-15/16)
and XT
Spring free length MAX and
mm(in) 364 (14-21/64)
MAXXT
LTD mm(in) - - I 364 (14-21/64)
Standard and XT Gold/Blue/Gold
Spring color code MAX and MAX XT Gold/Green/Gold
LTD - - I Gold/Green/Gold
Rear preload adjustment 5 settings
. - -- " " ,. '"' _. '" .
8RA~ES
Oty 2
Front brake
Type Hydraulic, discs
Oty 1
Rear brake
Type Hydraulic, disc
Capacity 180 mL (6.1 U.S. oz)
Brake fluid
Type DOT 4
Parking brake Hydraulic lock-4 wheels
Caliper Floating
Front Organic
Brake pad material
Rear Metallic
Minimum brake pad thickness mm(in) 1 (.04)
Front mm (in) 3.5 (.138)
Minimum brake disc thickness
Rear mm(in) 4.3 (.17)
Maximum brake disc warpage mm(in) 0.2 1.01)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER SERIES)

MODEL OUTLANDERTM 500 OUTLANDERTM 650 OUTlANDERTM 800

TIRES AND WHEELS ,
TIRES
kPa Maximum: 34.5 (5) Maximum: 48 (7)
Front
(PSI) Minimum: 31 (4.5) Minimum: 31 (4.5)
l-UP Models
kPa Maximum: 34.5 (5) Maximum: 48 (7)
Rear
(PSI) Minimum: 31 (4.5) Minimum: 31 (4.5)
Pressure
kPa Maximum: 34.5 (5) Maximum: 48 (7)
Front
(PSI) Minimum: 31 (4.5) Minimum: 31 (4.5)
2-UP Models
kPa Maximum: 34.5 (5) Maximum: 48 (7)
Rear
(PSI) Minimum: 31 (4.5) Minimum: 31 (4.5)
Minimum tire thread depth mm (in) 3 (0.118)
Front 25 x 8 x 12 26 x 8 x 12
Size 25 x lOx 12
Rear 26 x 10 x 12
XT: 25 x 11 x 12
WHEELS
Front 12 x 6
Size
Rear 12 x 7.5
DIMENSION ", '.'

Standard m (in) 2.18 (86)

Overall length
MAX m (in) 2.39 (94)
Overall width m (in) 1.17 (46)
Overall height m (in) 1.14 (45)
Standard kg (lb) 287 (634) 295 (649) 290 (639)
Dry weight
MAX kg (lbl 310 (684) 318 (699) 313 (689)
Standard m (in) 1.30 (51)
Wheel base
MAX m (in) 1.50 (59)
Front mm (in) 965 (38)
Wheel track
Rear mm (in) 914 (36)
Ground clearance mm (in) 279 (11)
lOADlNG CAPACITY
51/49
Weight distribution Front/rear %
MAX: 48/52
Rear storage box (included with rear rack weight) kg (Ib) 10 (22)
Front kg (lb) 45 (100)
Rack 90 (200)
Rear kg (lb)
(including rear storage box and tongue weight)
Total vehicle load allowed (including driver. all Standard kg (lb) 235 (517)
other loads and added accessories) MAX kg (Ib) 272 (600)
553 (1220)
Standard kg (Ib) 584 (1287)
Gross vehicle weight rating XT: 584 (1287)
MAX kg (Ib) 558 (1228) 649 (1430)
Towing capacity kg (Ib) 591 (1300)
Tongue capacity (included with rear rack weight) kg (lb) 23 (50)

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Section 13 TECHNICAL SPECIFICA"nONS
Subsection 01 (OUTLANDER SERIES)

MODEL OUTLANDERTM 500 I OUTLANDERTM 650 I OUTLANDERTM 800

MATERIAL " .- . .'

Material Steel
Frame
Color Black
All
except Aluminum
Camo
Material
Camo/
Camo Steel
XT
Wheel
All
except Aluminum
Camo
Color
Camo/
Camo Black
XT
Material Steel
Front/rear rack
Color Black
Material Aluminum
Front bumper
Color Aluminum
Material High density polyethylene
Front/rear fender
Color Yellow!Laurentian greenNiper red/Camo/Steel grey metallic
Material High density polyethylene
Fuel tank protector(s)
Color Black
Material High density polyethylene
Steering cover
Color Black
Material Polypropylene (glass fiber-reinforced)
Storage compartment cover
Color Black
Material High density polyethylene
Front fascia
Color Yellow!Laurentian greenNiper red/Camo/Steel grey metallic
Material High density polyethylene
Front skid plate
Color Black
Material High density polyethylene
Side panel
Color Yellow!Laurentian greenNiper red/Camo/Steel grey metallic
Material High density polyethylene
Foot rest
Color Black
Material High density polyethylene
Central panel
Color Yellow/Laurentian greenNiper red/Camo/Steel grey metallic
Material Polypropylene (glass fiber-reinforced)
Air filter housing cover
Color Black
Material Polypropylene (glass fiber-reinforced)
Air filter housing
Color Black
Material Polypropylene (glass fiber-reinforced)
Transmission lever locator
Color Black
Material Polypropylene
A-arm protector
Color Black

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER SERIES)

MODEL OUTLANDERTM 5001 OUTLANDERTM 650 IOUTLANDERTM 800

MATERIAl, (co~.t'~) , '- " ." ---- ~+ . ~
" - ¥_.T •__._ __ ....
~ ~_.,_ 'K~ '.· " .,w_ "". -
Material High density polyethylene
Engine cover
Color Black
Material Polypropylene
Seat base
Color Black
Material Thermoformed vinyl
Seat cover Black
Color
LTD models: Steel grey metallic and Black

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 02 (RENEGADE MODELS)

RENEGADE MODELS
MODEL RENEGADETM 500 RENEGADETM 800
,. ,'~ ' • ·on

"
ENGINE . .''' ..
ROTAX® V49D ROTAX® V81D
Engine type
4-stroke, Single Over Head Camshaft (SOHC), liquid cooled
Number of cylinders 2
Number of valves 8 valves (mechanical adjustment)
Bore mm (in) 82.03 (3.23) 91 (3.58)
Stroke mm (in) 47.3 (1.86) 61.5 (2.42)
Displacement cm J (in 3) 500 (30.51) 800 (48.82)
Compression ratio 10.7:1 10.3:1
Decompressor type N.A.
Maximum HP RPM RPM 7250 6750
Type Wet sump. Replaceable oil filter
Oil filter BRP Rotax paper type, replaceable
Engine oil
Minimum 350 kPa (51 PSI) at 6000 RPM
Lubrication pressure
Capacity (oil change
2 L (2.11 quarts)
with filter)
Engine oil
SAE 5W30 API classification SM, SL or SJ
Recommended
see OIL VISCOSITY CHART in LUBRICA nON SYSTEM
Intake valve opening 3° BTDC 5° BTDC
Intake valve closing 34° ABDC 45° ABDC
Exhaust valve opening 39° BBDC 50° BBDC
Exhaust valve closing 2° ATDC 0° ATDC
Chain tensioner plunger protrusion Service limit mm (in) 20.0 (.7874)
Intake mm (in) 0.06 to 0.14 (.0024 to .0055)
Valve clearance
Exhaust mm (in) 0.11 to 0.19 (.0043 to .0075)
New mm (in) 4.966 to 4.980 (.1955 to .1960)
Intake
Service limit mm (in) 4.930 (.1941)
Valve stem diameter
New mm(in) 4.956 to 4.970 (.1951 to .1957)
Exhaust
Service limit mm (in) 4.930 (.1941)
Intake and New mm (in) 0.005 (.0002)
Valve out of round
exhaust Service limit mm (in) 0.06 (.0024)
New mm (in) 5.006 to 5.018 (.1971 to .1976)
Valve guide diameter
Service limit mm (in) 5.050 (.1988)
New mm(in) 40.81 (1.607)
Valve spring free length
Service limit mm (in) 39.00 (1535)
New mm (in) 1.05 to 1.35 (.041 to .053)
Intake
Service limit mm (in) 1.8 (.070)
Valve seat contact width
New mm (in) 1.25 to 1.55 (.049 to .061)
Exhaust
Service limit mm (in) 2 (.078)

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Section 13 "rECHNICAL SPECIFICA"nONS
Subsection 02 (RENEGADE MODELS)

MODEL RENEGADETM 500 RENEGADETM 800

, ". ~ ....." ...., ,.,., ', "'. - -", ...... ,>-_ .• -.. > ., .. - '. -~ .. -
ENGINE (confd)
New mm(in) 12.036 to 12.050 (.4739 to 4744)
Rocker arm bore diameter
Service limit mm(in) 12.060 (.4748)
New mm(in) 12.000 to 12.018 (.4724 to .4731)
Rocker arm shaft diameter
Service limit mm (in) 11.990 (.4720)
81.950 to 81.966 90.950 to 90.966
New mm (in)
Piston measurement (3.2264 to 3.2270) (3.5807 to 3.5813)
Service limit mm (in) 81.850 (3.2224) 90.850 (3.577)
New mm (in) 0.057 (.0022) 0.027 (.0011)
Piston/cylinder clearance
Service limit mm (in) 0.130 (.0051) 0.100 (.0040)
1st Upper compression ring, rectangular
Piston ring type 2nd Lower compression ring, tapered face
3rd Oil scraper ring
Rectangular 0.20 to 0.40 (008 to .016)
Taper-face New mm(in) 0.20 to 0.40 (.008 to .016)
Ring end gap
Oil scraper ring 0.20 to 0.70 (008 to .028)
All Service limit mm(in) 1.5 (.059)
Rectangular 0.03 to 0.070 (.0012 to .0028)
Taper-face New mm (in) 0.02 to 0.060 (.0008 to .0024)
Oil scraper ring 0.01 to 0.018 (.0004 to .0007)
Ring/piston groove clearance
Rectangular 0.15 (.0059)
Taper-face Service limit mm (in) 0.15 (.0059)
Oil scraper ring 0.25 (.0098)
82.023 to 82.037 90.993 to 91.007
Cyl inder bore New mm (in)
(3.2292 to 3.2298) (3.5823 to 3.5829)
Maximum
mm (in) 0.D38 (.0015)
Cyl inder taper New
Service limit mm(in) 0.090 (.0035)
Maximum
mm (in) 0.015 (.0006)
Cylinder out of round New
Service limit mm (in) 0.020 (.0008)
Timing chain New mm(in) 34.959 to 34.975 (1.3763 to 1.3770)
side Service limit mm(in) 34.950 (1.3760)
Camshaft main bearing journal
Spark plug New mm (in) 21.959 to 21.980 (.8645 to .8654)
side Service limit mm (in) 21.950 (.8642)
Timing chain New mm (in) 35.000 to 35.025 (1.3780 to 1.3789)
Camshaft main bearing journal side Service limit mm (in) 35.040 (1.3795)
bore Spark plug New mm (in) 22.000 to 22.021 (.8661 to .8670)
side Wear limit mm (in) 22.040 (.8677)
31.830 to 32.030 32.11 to 32.31
New mm (in)
Intake valve (1.2531 to 1.2610) (1 .2642 to 1.2721)
Service limit mm(in) 31.810 (1.2524) 32 .09 (1 .2634)
Camshaft lobe
31.730 to 31.930 31 .94 to 32.14
New mm(in)
Exhaust valve (1.2492 to 1.2571) (1 .2575 to 1.2654)
Service limit mm(in) 31.710 (1 .2484) 31 .92 (1 .2567)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 02 (RENEGADE MODELS)

MODEL RENEGADETM 500 RENEGADETM 800

,-- , . ,, ".

ENGINE (co~(~) . .. ~ . . . ,- . J
Crankshaft main journal diameter MAG/PTO New mm (in) 42.024 to 42.040 (1.6545 to 1.6551)
side Service limit mm (in) 42.000 (1.6535)
Crankshaft radial play MAG/PTO side Service limit mm(in) 0.07 (.0031)
Crankshaft main journal diameter PTO support New mm(in) 34.024 to 34.040 (1.3395 to 1.3402)
bearing Service limit mm (in) 34.010 (1.3390)
Crankshaft radial play PTO support bearing Service limit mm (in) 0.10 (.0039)
35.064 to 35.080 40.009 to 40.025
New mm (in)
Crankshaft pin diameter (13805 to 1.3811) (1.5752 to 1.5758)
Service limit mm(in) 35.050 (1 .3800) 39.990 (1.5744)
Crankshaft deflection MAG/PTO side New mm(in) 0.050 (.002)
Crankcase plain bearing MAG/PTO side Service limit mm (in) 42.100 (1 .6575)
PTO cover plain bearing Service limit mm (in) 34.120 (1.3433)
Connecting rod big end diameter Service limit mm (in) 35.150 (1.3839) 40 .100 (1579)
Connecting rod big end radial play Service limit mm(in) 0.09 ('0035)
New mm lin) 0.200 to 0.500 ('008 to .020)
Connecting rod big end axial play
Service limit mm (in) 0.600 (,024)
18.010 to 18.020 20.010 to 20.020
New mm(in)
Connecting rod small end diameter (.7091 to .7095) (.7878 to .7882)
Service limit mm (in) 18.060 (.7110) 20 .060 (.7898)
17.996 to 18.000 19.996 to 20.000
New mm (in)
Piston pin diameter (.7085 to .7087) (.7872 to .7874)
Service limit mm(in) 17.980 (.7079) 19.980 (.7866)
Connecting rod/piston pin clearance (radial
Service limit mm (in) 0.080 (.0035)
play)
GEARBOX
Type Dual range (HI-LO) with park, neutral and reverse
Capacity 400 mL (14 U.S. oz)
Gearbox oil
Recommended XP-S chaincase oil
New mm (in) 0.10 to 0.20 (.0039 to .0079)
Output shaft backlash
Service limit mm (in) 0.25 (.0098)
New mm (in) 0.02 to 0.15 (.0008 to .0059)
Bevel gear axial play
Service limit mm(in) 0.19 (,0075)
New mm lin) 5.25 to 5.35 (.207 to .211)
Shifting sleeve groove width
Service limit mm (in) 5.50 (.217)
New mm (in) 4.95 to 5.05 (.195 to .199)
Shifting fork claw thickness
Service limit mm (in) 4.80 (.189)
Shift fork claw thickness New mm (in) 4.80 to 4.90 (.189 to .193)
(for high gear shifting) Service limit mm(in) 4.70 (.185)
Shift fork claw thickness New mmlin) 5.10 to 5.20 (.201 to .205)
(for low/reverse gear shifting) Service limit mm (in) 5.00 (.197)
New mm (in) 6.920 to 6.970 (.272 to .274)
Shift fork pin diameter
Service limit mm (in) 6.850 (.270)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 02 (REI\IEGADE MODELS)

MODEL RENEGADETM SOD I RENEGADETM 800

EN.G!NE ~cont'd) . - - -~-
'. , ".". ' .. ~~ '" ,. ..-..' ... " ' , , M.~ ... ,.~., • •

Gap of shift fork engagement groove New mm (in) 5.00 to 5.10 (.197 to .201)
{high gear shifting} Service limit mm(in} 5.20 (.205)
Gap of shift fork engagement groove New mm (in) 5.30 to 5.40 (.209 to 213)
(low/reverse gear shifting) Service limit mm (in) 5.50 (.217)
l\Iew mm (in) 29.000 to 29.013 (1.1417 to 1.1422)
Diameter free pinions
Service limit mm (in) 29.015 (1.1422)
New mm (in) 24.979 to 25.000 (.983 to .984)
Intermediate gear shaft
Service limit mm (in) 24.977 (.983)
Right side 17.990 (.708)
Free pinion
Countershaft Service limit mm{in) 24.970 (.983)
bearing
CVT side 24.970 (.983)
Free pinion
Bevel gear shaft Service limit mm (in) 24.984 (.984)
bearing
COOLING SYSTEM
Ethyl glycol/water mix (50% coolant, 50% water).
Type Use premixed coolant sold by BRP (P/N 219 700 362) or
Coolant coolant specifically designed for aluminum engines
Capacity 2.5 L (2.65 quarts)
Thermostat Opening temperature 65°C (149°F)
ELECTRICAL SYSTEM
Magneto generator output 400 W @ 6000 RPM
Ignition system type 101 (Inductive Discharge Ignition)
Ignition timing Not adjustable
Quantity 2
Spark plug Make and type NGK DCPR8E
Gap mm (in) 0.6 to 0.7 (.024 to .027)
Crankshaft position sensor (CPS) n 774 to 946 @ 20 °C (68 OF)
Forward RPM 8000
Engine RPM limiter setting
Reverse RPM 3200
Type Dry battery type
Voltage 12 volts
Battery
Nominal rating 18 A-h
Power starter output 0.7 KW
Headlamp W 2 x 35
Taillight W 7/29
Director indicator (European Community models) W 10
Indicator lights LEOS, 0.7 V approximately (each)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 02 (RENEGADE MODELS)

MODEL RENEGADETM SOO I RENEGADf'M 800

ELECTRICAL SYSTEM (cont'd) .~

Accessories 20 A
Fan 20 A
Main 30 A
Ignition coils 5A
Fuel injectors 5A
Fuses Speedometer/speed
7.5 A
sensor/tail lamp
Fuel pump 7.5 A
Engine control module
5A
(ECM)
Main accessories 30 A
-, -~,. ,"". , .... ", ,

FUEL SYSTEM
Electronic Fuel Injection (EFI), Delorto 46 mm throttle
Fuel delivery Type
body, 1 injector per cylinder
Type Bosch
Fuel pump
Model Electrical (in fuel tank)
Idle speed RPM ± 50 1250 (not adjustable)
Type Regular unleaded gasoline
Inside North
(R+M)f2 87 or higher
America
Fuel
Octane no. Outside
North RON 92 or higher
America
Fuel tank capacity 20 l (5.3 U.S. gal)
Remaining fuel in fuel tank when display light turns ON ± 6 l (1 .6 U.S. gal)
" " ""

DRIVETRAIN . ..
- ..~" . ' - . • ••~ -." .~.," u ".'.- - -' ", -
Front drive Shaft driven/Auto-lock differential (shear pump)
Front drive ratio 3.6:1
Rear drive Shaft driven/locked differential
Rear drive ratio 3.6:1
Front 500 ml (17 U.S. oz)
Capacity
Differential oil Rear 250 ml (8.5 U.S. oz)
BRP differential oil (P/N 293 600 043) or
Recommended
synthetic oil 75W90 (API Gl5)
CV joint grease CV joint grease (P/N 293 550 019)
Propeller shaft grease XP-S synthetic grease (P/N 293 550 010)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 02 (RENEGADE MODELS)

MODEL
'.'
RENEGADETM 500 I RENEGADETM 800
TRANSMISSION ",

Type CVT (Continuously Variable Transmission)

Engagement RPM ± 100 RPM 1750
CVT
Drive belt width Service limit mm (in) 30.00 (1 .181)
New mm (in) 13.70 to 1180 (.539 to 543)
Governor cup roller outer diameter
Service limit mm (in) 13.20 (.519)
New mm (in) 8.05 to 8.15 (.317 to .321)
Governor cup roller inner diameter
Service limit mm (in) 9.00 (.354)
New mm (in) 6.078 to 6.100 (.239 to 240)
Centrifugal lever pivot bolt diameter
Service limit mm(in) 6.000 (236)
Centrifugal lever bore diameter Service limit mm(in) 6.200 (.244)
Drive pulley sliding half centrifugal lever pivot New mm (in) 6.113 to 6.17 1 (241 to .243)
bolt bore diameter Service limit mm (in) 6.300 (.248)
New mm (in) 55.000 to 55.040 (2165 to 2.167)
Drive pulley sliding half large bushing
Service limit mm (in) 55.200 (2.173)
New mm (in) 32.000 to 32.040 (1.260 to 1.261)
Drive pulley sliding half small bushing
Servic e limit mm (in) 32.200 (1268)
New mm (in) 30.060 to 30.100 (1 .183 to 1.185)
Driven pulley sliding half bushing
Service limit mm(in) 30.200 (1.189)
New mm (in) 30.060 to 30.100 (1.183 to 1.185)
Driven pulley slid ing fixed bushing
Service limit mm (in) 30.200 (1.189)
Torque gear on driven pulley Service limit mm (in) 7.500 (.295)
..:
.STEERING ~ ,,v"_,,'" ' ...
Turning radiu s Standard 2.16m(7ft)
Total toe (vehicle on ground) mm(in) 0(0)
Camber angle 0°
Tie-rod maximum length unengaged mm(in) 17.5 ± 5 (11/16 ± 3/16)
SUSPENSION I;
FRONT
Suspension type Double A-Arm
Suspension travel mm (in) 229 (9)
Qty 2
Shock absorber
Type Oil I Gas
Spring free length mm(in) 319 (12-9/16)
Spri ng color code Silver/White/Green
Front preload adjustment 5 setti ngs
REAR
Suspension type TTITM independent
Suspension travel mm (in) 254 (10)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 02 (RENEGADE MODELS)

MODEL RENEGADETM 500 RENEGADETM 800

SUSPENSION (cont'd) ". ' ... .-

Oty 2
Shock absorber
Type Oil Gas
Spring free length mm (in) 381 (15) 348 (13-45/64)
Spring color code Si Iver/Red/White Gold/Gold/Green
Rear preload adjustment 5 settings
BRAKES
Oty 2
Front brake
Type Hydraulic, discs
Oty 1
Rear brake
Type Hydraulic, disc
Capacity 180 mL (6.1 U.S. oz)
Brake fluid
Type DOT 4
Parking brake Hydraulic lock-4 wheels
Caliper Floating
Front Organic
Brake pad materia I
Rear Metallic
Minimum brake pad thickness mm(in) 1 (.04)
Front mm(in) 3.5 (.138)
Minimum brake disc thickness
Rear mm (in) 4.3 (.17)
Maximum brake disc warpage mm (in) 0.2 (.01)
'i.
•..'" , ~ . ,
-
TIRES AND WHEelS
TIRES
Maximum: 48 kPa (7 PSI)
Front
Minimum : 34.5 kPa (5 PSI)
Pressure
Maximum: 48 kPa (7 PSI)
Rear
Minimum: 38 kPa (55 PSI)
Minimum tire thread depth mm (in) 3 (0.118)
Front 25 x 8 x 12
Size
Rear 25 x lOx 12
WHEELS
Front 12 x 6
Size
Rear 12 x 7.5
..
DIMENSION .. " .~ ~ "

Overall length m (in) 2.18 (86)

Overall width m (in) 1.17 (46)
Overall height m (in) 1.14 (45)
Dry weight kg (Ib) 275 (607)
Wheel base m (in) 1.30 (51)
Front mm (in) 965 (38)
Wheel track
Rear mm (in) 914 (36)
Ground clearance mm (in) 279 (11)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 02 (RENEGADE MODELS)

MODEL RENEGADETM 500 I RENEGADETM 800

LOADING CAPACITY
Weight distribution Front/rear % 51/49
Rear storage box kg (Ib) 3.7 (1)
Rack Rear kg (lb) 16 (35)
Total vehicle load allowed (including driver. all other loads
kg (Ib) 141 (310)
and added accessories)
Gross vehicle weight rating kg (Ib) 476 (1050)
Towing capacity kg (Ib) 591 (1300)
",

MATERIAL
Material Steel
Frame
Color Black
Material Aluminum
Wheel
Color Aluminum
Material Aluminum
Front bumper
Color Aluminum
Material High density polyethylene
Front/rear fender
Color Yellow
Material High density polyethylene
Fuel tank protector(s)
Color Black
Material Aluminum
Steering cover
Color Aluminum
Material Polypropylene (glass fiber-reinforced)
Rear storage compartment
Color Black
Material High density polyethylene
Front grid
Color Black
Material High density polyethylene
Front skid plate
Color Black
Material High density polyethylene
Side panel
Color Black
Material High density polyethylene
Foot rest
Color Black
Material High density polyethylene
Central panel
Color Yellow
Material Polypropylene (glass fiber-reinforced)
Air filter housing cover
Color Black
Material Polypropylene (glass fiber-reinforced)
Air filter housing
Color Black
Material Polypropylene (glass fiber-reinforced)
Transmission lever locator
Color Black
Material Polypropylene
A-arm protector
Color Black

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 02 (RENEGADE MODELS)

MODEL RENEGADETM 500 I RENEGADETM 800

..

~~TERI~L (cont'd)
Material High density polyethylene
Engine cover
Color Black
Material Polypropylene
Seat base
Color Black
Material Thermoformed vinyl
Seat cover
Color Black

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Section 14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
Subsection 01 (ELECTRICAL CONNECTORS)

ELECTRICAL CONNECTORS
SERVICE TOOLS
Description Part Number Page
crimping pliers ..... .. ..... ....... ... ... .... ...... .... .... .. .. .. ..... .... .. ... ... ... . 529035730 ...... .... ...... .. .............. .... ... .. 435
crimper die .......... .. .......... ... ....... ... .... .. .... .... .......... .. ....... .. ..... . 529035906 .... ....... ....... .... .. .. ...... .... ..... 432
crimping tool .. ........ .... .. ... .. ..... .. ........ ...... ...... ...... ..... .. ....... .... . 529035909 .... ....... .... .. ....... ...... .... .. ... .. 432

SERVICE TOOLS - OTHER SUPPLIER

Description Part Number Page
Snap-on terminal remover .. .. ..... .. .. .... ...... .... ......... .. .... .. .... .... TT600-1 ...... .. ....... .... .. .. .. ....... .... ..... 432

DEUTSCH CONNECTORS Connector Disassembly

Deutsch connectors are used on some harnesses.

Removal from Engine Connector

Bracket
To remove Deutsch connectors from engine con-
nector bracket, slide a flat screwdriver between
the connector bracket and the Deutsch connector
and push out connector.

1. Male conn ector

2. Fe ma le conn ector
3. Secondary locks
4. Sealing cap

CAUTION: Do not apply dielectric grease on

terminal inside connector.
To remove terminals from connector, proceed as
follows :
- Using a long nose pliers, pullout the lock.

vm r2006·014-053 _a

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Section 14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
Subsection 01 (ELECTRICAL CONNECTORS)

V01GOOA

FEMALE CONNECTOR
V01GOOA
1. Retaining tabs

FEMALE CONNECTOR To install:

1. Female lock
- For insertion of a terminal, make sure the lock
is removed.
- Insert terminal into appropriate cavity and push
as far as it will go.

V01GOPA

MALE CONNECTOR
1. Male lock
1. Wire identification numbers
NOTE: Before extraction, push wire forward to - Pull back on the terminal wire to be sure the
relieve pressure on retaining tab. retention fingers are holding the terminal.
- Insert a 4.8 mm (.189 in) wide screwdriver blade - After all required terminals have been inserted,
inside the front of the terminal cavity. the lock must be installed.
- Pry back the retaining tab while gently pulling
wire back until terminal is removed. ECM CONNECTORS
There are two ECM connectors used and they are
connected on the ECM. The engine harness fe-
male connector is connected on the module male
connector "A" and the vehicle system control har-
ness female connector is connected to the mod-
ule male connector "B". The ECM connectors
have 41 pins.

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Section 14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
Subsection 01 (ELECTRICAL CONNECTORS)

F1SZ06A

1. Cover

Cut both tie raps that secure the harness to the

connector.
For probing techniques and tool, refer to ENGINE
MANAGEMENT.
CAUTION: Do not disconnect the ECM connec-
tors needlessly. They are not designed to be
disconnected/reconnected frequently.

Terminal Removal
Unlock the connector cover by pushing in the tabs
on top of the connector with a flat screwdriver to
be able to flip the top cover up.

F18Z07A

1. Tie raps

Turn the connector over and remove the orange

locking tab by pushing and then pulling toward the
wire harness.

1. Push in tab

Lift the cover by pushing it forward .

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Section 14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
Subsection 01 (ELECTRICAL CONNECTORS)

If the wire is in good condition but the terminal

is rusted or corroded, remove defective terminal
and crimp a new one. If wire and terminal are de-
Use a Snap-on terminal remover (PIN TT600-1) (or fective, replace with a new genuine wire and new
a 0.76 mm (.030 in) oxyacetylene torch tip clean- terminal and crimp them together as explained be-
er or a no. 68 drill bit) must be inserted into the low.
terminal cavity to release the locking tab from the IMPORTANT: Use genuine wires only. Otherwise
connector. wires will not fit properly.
CAUTION: Using a tool tip larger than 0.76 mm When re-inserting the terminal, the locking tab
(.030 in) may damage the terminal. must be installed facing the smaller cutout of the
Insert the tool tip into the terminal cavity as terminal cavity.
shown, and locate its wire in the back of the con-
nector. You may have to pry the tool tip against
the locking tab to release it, then remove the
terminal from the connector.

F18Z0XA

Insert the terminal, ensuring the locking tab snaps

into its cavity.
Re-install the orange locking tab, attach the 2 tie
raps, and close the connector cover.

Terminal Crimping (Kostal)

To crimp a new connector terminal, use the crimp-
ing tool (PIN 529 035 909) and the crimper die
(PIN 529 035 906).

F1azOVA

Check the locking tab on the terminal, it may have

to be bent out a little so it will lock in its cavity
when it is re-inserted.

52 9035909

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Section 14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
Subsection 01 (ELECTRICAL CONNECTORS)

529035906
'1\
To properly crimp the wires, strictly follow this pro-
cedure.
Strip the wire to a maximum of 3 mm (1/8 in). 1. Top of terminal tabs
2. Align tabs with pliers edge

Crimp terminal. Ensure no tiny wire goes out of

terminal. This might cause strange problems of
the electrical system.

Lubrication
Do not apply any product to the pins of the con-
nector on the ECM.

MULTIFUNCTION SPEEDOMETER
TYPICAL CONNECTOR
A. 3 mm (1/8 in) max.
Firmly push down tab and hold to unlock connec-
Position wire in terminal. tor while pulling it out.
Squeeze the terminal tabs with your fingers to
temporarily retain terminal in place.

Insert terminal with wire in crimping pliers and po-

sition so that top of terminal tabs are flush with
pliers edge or a little bit lower as shown.

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Section 14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
Subsection 01 (ELECTRICAL COI\II\IECTORS)

Lift the top plastic lock of the female terminal to

be removed and hold in position. Lift the female
terminal to unlock from the housing and push out
of housing.

CONNECTOR PINOUT

Push on both tabs to remove retainer.

TYPICAL
1. Lift and hold plastic lock
2. Lift to unlock and push out

BATTERY AND STARTER CABLE

TERMINALS
Crimping
Carefully strip the wire approximately to 10 mm
(3/8 in) in length, using a wire stripping tool or
sharp blade/knife.

A33Z01A 2
TYPICAL
1. Retainer
2. Tab (one on each side)

Open housing by lifting 4 tabs .

A32E2OA

A. 10 mm (3/8 in)

NOTE: Make sure not to cut wire strands while

stripping the wire.
Install the appropriate terminal on the wire ac-
cording to the requirement. Refer to appropriate
A33Z02A PARTS CATALOG.
TYPICAL
1. Tabs (2 on each side)

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Section 14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
Subsection 01 (ELECTRICAL CONNECTORS)

INSTALLATION OF TERMINAL

Follow the instructions provided with the crimping

pliers (PIN 529035 730) to select the proper posi-
tion of the tool.
529035730
A32E2TA

CRIMPING OF WIRE

NOTE: Different wires require different crimping

pliers settings, so make sure to follow the instruc-
tion supplied with the tool.

PROPERLY CRIMPED WIRE

To verify, if the wire is properly crimped, apply

some pulling force on wire and the terminal at the
same time from both directions .
CAUTION: Never weld the wire to the terminal.
Welding can change the property of the wire
and it can become brittle and break.
Install the protective heat shrink rubber tube on
the terminal. Heat the heat shrink rubber tube us-
ing the heat gun so that it grasps the wire and the
A32E2SA terminal.
POSITIONING THE CRIMPING PLIERS CAUTION: Make sure that the protective heat
Step 1: Press
Step 2: Rotate
shrink rubber tube has been properly installed
and no part of wire is exposed.
After positioning the crimping pliers, crimp the ter-
minal already installed on wire.

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Section 14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
Subsection 02 (WIRING DIAGRAMS)

WIRING DIAGRAMS
WIRING CONNECTORS CODING
2 345

-,~-~,~»~-I-t
XX/XX-18 2-BF-A
VOOGOFA

1, Wire colors
2, Wire gauge
3, Connector housing area
4, Connector identification
5, Wire location in connector V07AOHA

Wire Colors AREA LOCATION

It identifies the color of a wire . When a 2-color 1 Steering area
scheme is used, the first color is the main color
2 Service compartment
while the second color is the tracer color.
3 Front of vehicle

~
.,,/,//1 XX/XXJ
/ ~
4 Engine area

--~
I XXIXX~~I~~'~"~--~»~------
,.,,·,,·"~'18 2-BF-A
5 Rear of vehicle

V06G1FA
Connector Identification
THE SHADED PART INDICATES THE WIRE COLOR
Indicates the connector's function. If there are
Example: YUBK is a YELLOW wire with a BLACK many connectors in the same area, this helps to
stripe. identify which wire is in which connector.

Wire Gauge
The number after wire color indicates the gauge
XX/XX-18 » "'fD?l
...... ·2-J5Ej-A
of a wire,
V06G1JA
[~f]..//
[j]J'\,., THE SHADED PART INDICATES A CONNECTOR
... .
----~~"~\~.\~-----+»~-----
xx/Xx~· ·. .M1 2-BF-A
V06G1GA

THE SHADED PART INDICATES THE WIRE GAUGE

Example : YUBK is a YELLOW wire with a BLACK

stripe.

Connector Housing Area

XX/XX-18

V06G1HA

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Section 14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
Subsection 02 (WIRING DIAGRAMS)

ABBREVIATION DESCRIPTION Wire Location in Connector

BA Ignition coil This is the wire position in the connector. The
number or letter given refers to the physical iden-
BAT Battery
tification stamped on the connector.
BD 2WD/4WD switch
CA Magneto --------------~»~----~
XX/XX-18 2~.Bfrn
CAPS Camshaft position sensor
CC Ignition switch
V06G1KA
~J./:/
CI Multifunction speedometer
THE SHADED PART INDICATES THE CONNECTOR LOCATION
CPS Crankshaft position sensor IN HOUSING

CTS Coolant temperature sensor

CV Speed sensor 0( B
DB Diagnostic connector --1.--A
DC DC outlet B - - - .; ,.",.
ECM Engine control module A---+-"1IV
FP Fuel pump
FRA Brake light switch
FT Cooling fan B B
Harness interconnector A A
HIC
(engine/vehicle)
IDLE Idle bypass valve

~~
INJl and INJ2 Fuel injector
Manifold air pressure and B B
MAPTS
temperature sensor C 1~A A~r C
MD 2WD/4WD actuator
MG multifunction switch

~c
OPS Oil pressure switch
PD RH headlight D D
A A
PFl Fuse Holder (main)
PF2 Fuse Holder (near battery) AOOE4WB B
PG LH headlight TYPICAL
PRN Subtransmission switch
RD Voltage regulator/rectifier
SD 2WD/4WD actuator switch
SM Starter motor
SPKl and SPK2 Spark plug
SS Starter solenoid
SW Winch relay
SWW Winch switch
TPS Throttle position sensor
WM Winch motor

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ZONE # ZONE DESCRIPTION
I STEERING .AREA
2 MODULE AREA
3 FRONT OF VEHICLE
4 ENGINE AREA
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14
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2008 RENEGADE 800
ZONE # ZONE DESCRIPTION

N
INJECTION/IGNITION STEERING AREA
MODULE AREA
FRONT OF VEHICLE
N

SYSTEM ENGINE AREA

REAR OF VEHICLE

JT RD/GY

JT DR/GN
M M
N
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SPEEDOMffiR
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PF2 [f] a ..

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FUSE
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lOA

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IGNITlON
COil

., PF1
FUEL
~ PF1
ECM
J '"'" PUMP FUSE
FUSE (F6)
(F5) 5A
FP (212)
7.SA J"'" FUEl
LEVEL
SENSOR JT BE/GN
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15 16 17 18 19 20 21 22
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SWW SWRC
WINCH SWITCH REMOTE
WINCH SWITCH

B
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710001317F11 A

8 9 10 11 12 13 14
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2009
Shop Manual
Supplement

Outlander™ Series
500/650/800 REF I

Renegade ™ Series
500/800R EFI

con -oOl
 www.midwestmanuals.com

TABLE OF CONTENTS

SAFETY NOTICE ........................................................................................................ III

INTRODUCTION ......................................................................................................... IV

03 ENGINE AND GEARBOX (V490N660N810)

02 - AIR INTAKE SySTEM ....................................................................... . ................... .
PROCEDURES ......................................................... . ....................................... 2
AIR FILTER .................................................................................................. 2
07 - INTAKE MANIFOLD, CYLINDER HEAD AND CyLINDER................................................... 5
GENERAL ...............................................................•...................................... 9
PROCEDURES ................................................................................•................ 9
CAMSHAFT ................................................................................................. 9
09 - GEARBOX AND 4X4 COUPLING UNIT..................................................................... 11
GENERAL ....... ........ ..... ....... ............. ... ........... ................ ..... ....... ..... .... .... ..... 13
PROCEDURES............... ....... ........ ..... ... ........... ...•......... ..... ....... ... ..... ...•.... ..... 13
GEARBOX POSITION INDICATOR SWiTCHES........................................................... 13
4WD INDICATOR SWiTCH............................................... ..•....•........................ 14

04 ENGINE MANAGEMENT (V490N660N810)

03 - ADJUSTMENT AND REPAIR PROCEDURES...... ... ......... ... .... .... .... .... ..... ... ..... .... ........ 17
GENERAL........... ..... ....... ..... ........ ... ....... ...... ... ... ......... ..... ... ..... ........ ............ 17
PROCEDURES...... ........ ............ ..... ... ................ .... ........ ..... ... .... ......... ... .... ..... 17
FUEL INJECTOR......... ..... ....... ..... ... ......... ....... ......... ........ ....... ... ...... ... ......... 17
THROTILE CABLE....... ..... ... ......... ... .... ..... ...... ...... .... .... ........ ... ..... ... ........ ..... 18

05 FUEL SYSTEM
01 - FUEL TANK AND FUEL PUMP... ............... . ...... . .................................................... 21
GENERAL .................................................................................................... 23
SYSTEM DESCRiPTION......... . ................................................................. . ...... 23
INSPECTION ................................................................................................. 24
FUEL TANK LEAK TEST............................................................ . .... . ................. 24
FUEL PUMP PRESSURE TEST........................................................................... 26
PROCEDURES ............................................................................................... 27
FUEL HOSE AND OETIKER CLAMPS.................................................................... 27
FUEL TANK................................................................... . ........................... 28
FUEL PUMP.............................................................................................. 31
FUEL LEVEL SENSOR.................................................................................... 38

06 ELECTRICAL SYSTEM
03 - CHARGING SySTEM .......................................................................................... 41
GENERAL .................................................................................................... 41
PROCEDURES ............................................................. . ................................. 41
STATOR .................................................................................................. 41

10 SUSPENSION
02 - REAR SUSPENSiON........................................................................................... 43
GENERAL .................................................................................................... 45
PROCEDURES............................................................................................... 45
TORSION BAR............................................................................................ 45
TRAILING ARM........................................................................................... 45

11 BRAKES
01 - FRONT AND REAR BRAKES................................................................................. 47
GENERAL ............................................... . .... . ..............•................................ 53
SYSTEM DESCRiPTION.................................................................................. 53
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TABLE OF CONTEN TS

11 BRAKES (cont'd)
01 - FRONT AND REAR BRAKES (cont'd)
MAINTENANCE. ......... ............ .......... ... ... . ... .. . .. .. .. .. ....... . . .... . .... ... .. ... . .. .... ... . .. 54
BRAKE FLUiD .. . . . .. . . .. . .. . . . ..... . ....... . .... .. . . .. . .. . ...... . .. . ......... . . ........ . . .... .... ......... 54
PR 0 CEDU RES. .. .. . . . . . . .. . .. . . . .. . .. . .. .. .. .. .. .. . .. .. . .. . . .. .. .. .. . .. . .. .. .. .. .. . . .. .. .. . . .. .. .. .. .. .. .. .. 57
REAR BRAKE LIG HT SWITCH .......... .... ...... .. ...... ...... ........ .. .............. ...... ...... ...... 57
FRONT BRAKE LIGHT SWITCH ........ .. .......................... .. ............. .. .... ...... ........... 58
PARKING BRAKE MECHANISM ................................. . ........................................ 58
BRAKE LE VER............................. ........ ......... . ................ .. .. . ........................ 59
FRONT MASTER CYLINDER ............... .............. .. ...... ... ...... ... .... ........................ 59
REAR MASTER CYLINDER ............. .......... ... ................ .... ..... ...... . ..... .... .. .. .. ...... 60
CALIPER ...................................................... .. ..... ......... ...... ... ................... 62
BRAKE PADS ...... . . . ....... ... •. .. .. ... ... .. . . . . . .. . .. . . . .. . . . .. ... . . . •..... .. .. . .. . . . .. . ...... .. . . . .... 63
BRAKE DISC .. . .. . . .. . .. . .. . . . ......... . .. ........... .... . .. .. ... . . .. . ...... . ........... .. " . . . . . . .. . . . . . . 64
BRAKE PEDAL .. . . . . . . .. . . . . . . . . . . .. . . . .. . .. . . .. . . . . . . .. .. . . . . . . . . . . . . .. .. . . . . .. . . . . . . .. .. ... . .. . . .. • . . . . . 65
BRAKE CIRCU IT SPUTIERS IRENEG ADE CE MODELS} .. ...... . .. .. .......... . ........................ 66
BRAKE HOSES... .. . .. .. .. .. .. .. . . .. . . ............ . . ... ... .................... .. .. ......... .. .. .......... 67

12 BODY/FRAME
01 - BODy .................................................................................. .. ........................ 69
G ENE RA L ................ , . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . . . .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. • . .. . . . . . . . . .. 83
PROCEDURES... ... . .... .......... . .............. . ......... . ........................ .. ... . .... . ....... .. .... 83
CENTRAL PANEL ................................................................ .. ......... .. ............ 83
HEAVY DUTY BUMPER .. ......................................................... .... .......... .. .. .... .. 84
FRONT BUMPER/FRONT SKID PLATE/FRONT FASCiA................... ....... .. . ....... .. ...... .. .... 85

13 TECHNICAL SPECIFICATIONS
01 - OUTLANDER ........ ... .............. .. ..... ... .. ... .... ... ... . ..... ... . .. .. ..... ... ... ......... ... ... . .. .. . .... 87
02 - RENEGADE. . .... .. ...... .. . .. .... . ...... .... ..... .. . ....... .. .... . .... . .... .... .. .... ... ... ...... . .. . .. . .. ...... 97

II
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SAFETY NOTICE

SA FETY N OTICE
This manual has been prepared as a guide to cor- A WARNING
rectly service and repair 2009 Can-Am ATVs as de- Identifies an instruction which, if not fol-
scribe in the model list in the INTRODUCTION lowed, could cause serious personal injury
This SHOP MANUAL SUPPLEMENT must be including possibility of death.
used in conjunction with the 2008 CAN-AM
SHOP MANUAL (P/N 219 100 273). Refer to A CAUTION Denotes an instruction which, if
this manual when a particular system is not cov- not followed, could severely damage vehicle
ered in this supplement. components.
This edition was primarily published to be used by NOTE: Indicates supplementary information
mechanical technicians who are already familiar needed to fully complete an instruction.
with all service procedures relating to BRP prod-
ucts. Mechanical technicians should attend train- Although the mere reading of such information
ing courses given by B.RPT.I does not eliminate the hazard, your understand-
ing of the information will promote its correct
Please note that the instructions will apply only use. Always use common shop safety practice.
if proper hand tools and special service tools are
used. BRP disclaims liability for all damages and/or in-
juries resulting from the improper use of the con-
It is understood that this manual may be trans- tents. We strongly recommend that any services
lated into another language. In the event of any be carried out and/or verified by a highly skilled
discrepancy, the English version shall prevail. professional mechanic. It is understood that cer-
The content depicts parts and/or procedures appli- tain modifications may render use of the vehicle
cable to the particular product at time of writing. illegal under existing federal, provincial and state
Service and Warranty Bulletins may be published regulations.
to update the content of this manual Make sure
to read and understand these. It does not include
dealer modifications, whether authorized or not by
BRP, after manufacturing the product.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or ex-
act replicas of the parts.
The use of BRP parts is most strongly recom-
mended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.
The engines and the corresponding components
identified in this document should not be utilized
on product(s) other than those for which it was
designed.

A WARNING
Unless otherwise specified, engine should be
turned OFF and cold for all maintenance and
repair procedures.

This manual emphasizes particular information de-

noted by the wording and symbols:

vmr2009-002 III
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INTRODUCTION

INTRODUCTION
This shop manual supp lement covers the following BR P made 2009 Can-Am ATVs.
M ODEL COLOR ENGINE MODEL NUMBER
Outlander 500 Red, Ye ll ow V490 2T9A, 2T9B
Bla ck, Camo, 2U9A. 2U9B, 2U9C, 2U9 D,
Outlander 500 XT V490
Red, Yellow 2U 9E, 2U9F
Ou tlander MAX 500 Red V490 2W9A
Black, Cam o,
Outlande r MAX 500 XT V490 2X9A, 2X9B , 2X9C, 2X9 D,2 X9E, 2X9F
Red, Yel low
Outlander 65 0 Red, Yellow V660 2N9A. 2N9B, 2N9C
Black, Camo, 2P9A, 2P9B, 2P9 C, 2P9D, 2P9E,
Outlander 650 XT V660
Red, Yel low 2P9F, 2P9G, 2P9H, 2P9J
Outla nder MAX 650 Red, Yell ow V660 2R9A, 2R9B, 2R9C , 2R 9D,9
Black, Camo, 2S9A, 2S9B, 2S9C, 2S9D, 2S9E,
Outlander MAX 650 XT V660
Red, Yellow 2S9 ~ 2S9G, 2S9H, 2S9J

Outlander 800 Yellow V8 10 2H 9E

Black, Camo,
Outlander 800 XT V81 0 2J9J, 2J9 K, 2J9 L, 2J9 M, 2J9N, 2J9P
Red, Yell ow
Outlander Max 800 Red, Ye llow V810 2K9A, 2K89B, 2K9C, 2K9D
Black, Camo, 2L9A, 2L9 B, 2L9C, 2L9D, 219E,
Outlander MAX 800 XT V810
Red, Ye llow 2L9F, 2L9G, 2L9H, 2L9J
Outlande r MAX 800 Ltd Red V810 2M9A,2M9 B, 2M9C, 2M9D
Renegade 500 Red, Yellow V49 0 4E9A, 4E9B, 4E 9C, 4E9D
Renegade 800 Red, Ye llow V8 10 4B9A, 4B 9B, 4B9C,4B9 E, 4B9F
Renegade 800 X Black V810 4C8A, 4C8B, 4C8C

The informa tion and co mponent/system descriptions contained in thi s manual are co rrect at time of w ri t-
in g BRP however, mainta ins a policy of continuous im provement of its products without imposing upon
itse lf any ob ligation to in stall them on products prev iously manufact ured.
Du e to late cha nges, there may be some differences between the manufactured product and the de-
scription an d/or specification s in this document
BRP reserves th e right at any ti me to discontinue or change specificat ions, designs, fea tures, m odels or
eq uipment w ithout incurring obligati on.

IV vmr2009·002
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Section03 ENGINE AND GEARBOX (V490N660N810)
Subsection 02 (AIR INTAKE SYSTEM)

AIR INTAKE SYSTEM

SERVICE PRODUCTS
Description Part Number Page
AIR FILTER CLEANER .. 219700341 .......... 2

BOOR Models

6 Nom
153 IbNn) """----@

& Loctite 5910

Loctite 5910 &-----lll ~~

2.5 Nom
(22 IbHn)

vmrZ009.(109
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Section 03 ENGINE AND GEARBOX (V490N660N810)
Subsection 02 (AIR INTAKE SYSTEM)

PROCEDURES
AIR FILTER
INuilli" Never remove or modify any com-
ponent in the air filter hous ing. The engine
management system is ca librated to operate
specifically with these components. Other-
wise, engine performance degradation or
damage can occur.
If ve hicle is used in dusty area, inspect more fre-
quently than specified in MAINTENANCE CHART
BOOR ENGINE AIR FILTER SHOWN
If liquid or deposits are foun d, squeeze and dry the 1. Clamp
foam filter. Replace filter element if damaged. 2. Air filter

1i1[,)i@j Do not start engine if liquid or de- Remove foam prefilte r by carefu lly pushing the ex-
posit are found. If there is oil in the air filter tremities to ward the inside.
housing, check engine oil level. Oil level may
be too high,

Air Filter Removal

BOOR Models
Remove seat, side panels, central panel and dash-
board . Refer to BODY section .
Release clamps and remove air filter housing
cover.

1. Foa m prefilter extremities

1. Foam prefilter
2. Filter

Air Filter Cleaning

Foam Prefilter Cleaning
Loosen clamp and re move air filter. 1. Pour AIR FILTER CLEANE R (PIN 219 700 341) or an
equiva lent into a bucket.
2. Put the foam prefilter in to soa k.
3. Whi le foam prefilter soaks, clean inside the air
filter housing.
4. Rinse the foam prefi lter with warm w ater until
all cleaning solution disappears.
5. Let the foam prefilter dry completely.
2 vmr2009--009
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Section03 ENGINE AND GEARBOX (V490N660N81 0)

Subsecti o n 02 (AIR INTAKE SYSTEM)

Filter Cleaning
1. Shake the filt er vigorously to rem ove dust from
air filter.
2. If necessary, blow low pressure compressed air
from inside of filter to clean it.
lilt,,1l4Oj Do not wash the paper filter with any
cleaning solution.

Air Filter Installation

1. Properly reinstall removed parts in the reverse
order of their removal.

vmr2009·009 3
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4
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Section03 ENGINE AND GEARBOX (V490N660N810)

Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

INTAKE MANIFOLD, CYLINDER HEAD

AND CYLIN DER
INTAKE MANIFOLD

0.5 Nom
Ibfoin)
6 Nom
(53Ibfoin)
I
Loctite&
243

6 Nom
(53 Ibfoin)

" 20 Nom
(15Ibfoft)

/
o
Eng ne
oil
&Engine
oil

5
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Section 03 ENGINE AND GEARBOX (V490N660N810)

Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

CYLINDER HEAD NO.1

.,<--.-4Ir.,."'1
,
T8

En gine
oil
See

;:---·"Loctite
243

T4

T5-1/
r./'-., Loctite
648

Tl 60 N'm (44 Ibfoft) T7 6 N'm (53 Ibfoi n )

T2 30 N'm (22 Ibfoft) T8 4.5 N'm (40 Ibfoi n )
T3 120 N'm (15 Ibf·ft) T9 0.1 N'm (0.89 Ibfoi n )
T4 12 N'm (106 Ibfoi n ) Tl0 16 N' m (141 Ibfoin )
T5 ,10 N' m (89 Ibfoin ) Tl1 5 N'm (44 Ibfoi n )
T6 7 N'm (62 Ibfoin )
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Section03 ENGINE AND GEARBOX (V490N660N810)

Subsection 07 (INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

CYLINDER HEAD NO.2

T8 ~

I
Loctite 243

Engine oil!)

1~1
Engine oil /::, T5
!)Loctite
648
T4

~/. T7

~~~
8
Loctite 243
I\ "
Engine!)
T3 oil

no

T11 "iv
Engine
oil

T1 60 Nom (44 Ibfoft) T7 6 N'm (53 Ibfoin)

T2 30 N'm (22 Ibf°ft) T8 4.5 Nom (40 Ibfoin)
T3 20 N'm (15 Ibf·ft) IT9 0.1 N'm (0.89 Ibfoin)
T4 12 Nom (106Ibfoin) ' T10 16 N'm (141 Ibfoinl
T5 10 N'm (89 Ibfoin) ~ T11 5 N'm (44 Ibfoin)
T6 7 N'm (62 Ilbfoin)

vmrZOO9.(1 15 7
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Section 03 ENGINE AND GEARBOX (V490N660N810)

Subsection 07 (I NTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER)

CYLINDERS AND PISTONS

Engine oil
Engine oil
~

.~~~
Engine oil
~

~
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Section03 ENGINE AND GEARBOX (V490N660N81 0)

Subs ect ion 07 (IN TA KE MANIFOLD, CYLINDER HEAD AND CYLINDER )

GENERAL
Refer to the 2008 SHOP MANUAL (PIN 219 100
273) for topics not covered in thi s section.

PROC EDU RES

CAMSHAFT
Camshaft Inspection
V490
CAMSHAFT LOBE (EXHAUST)
31.730 - 31.930 mm
NEW
(1.2492 - 1.257 1 in)
SERVICE LI M IT 31 710 mm (1 2484 in)
CAMSHAFT LOBE (INTAKE)
31.830 - 32 .030 mm
NEW
(1. 2531 - 1.2610 in)
SERVICE LI M IT 31 .810 mm (12524 in)

V660
CAMSHAFT LOBE (EXHAUST)
31 .940 - 32.1 40 mm
NEW
(1 .2575 - 1.2654 in)
SERVI CE LIMIT 31 .920 mm (1.2567 in)
CAMSHAFT LOBE (INTAKE )
32 .110 - 32.310 mm
NEW
(1.2642 - 1.272 1 in)
SERVICE LIMIT 32090 mm (1.2634 in)

V810
CAMSHAFT LOBE (EXHAUST)
32 .950 - 33.150 mm
NEW
(1.2972- 1.3051 in)
SERVIC E LI MIT 32.930 mm (1.2965 in)
CAMSHAFT LOBE (INTAKE )
32.890 - 33.090 mm
NEW
(1.2949 - 1.3028 in)
SERVICE LI M IT 32.870 mm (1.2941 in)

vrm'2009'() 15 9
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Section03 ENGINE AND GEA RBOX (V490N660N810)

Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

GEARBOX AND 4X4 COUPLING UNIT

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 591 0 .. 293 800 081 ... .... 14-1 5

GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM

20 N'm .
(15Ibfoft) - ~ ()Loctlte 243

II
28-;i'~
25 N'm
(18IbNt)
2
() Loctite 243

Super Lube grease

(PIN 293 550 030) 29

Engine
9 oil
Bevel gear
backlash shim 18
14
31
/
15
Engine oil ()

16
32
50
17
Bevel gear
ax ial pl ay shim

vmr200S.Q17 11
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Section03 ENGINE AND GEARBOX (V490N660N810)

Subsection09 (GEARBOX AND 4X4 COUPLING UNIT)

GEARBOX HOUSING AND 4X4 ACTUATOR UNIT

Super Lube grease

(PIN 293 550030)
1.5 Nom G
(13Ibfoin)

~
41

Loctite 5910G~ 25 Nom

' - (18Ibfoft)

Loctite
5910

35 ~,
G
Engine 10 Nom
oil (89Ibfoin)

G 'trlll-47
Engine
oil

25 Nom G
(18Ibfoft) Super Lube
5 Nom grease
(44Ibfoin) 1.5 Nom

L
(PIN 293 550030)
44 (13 Ibfoin)
~ 40
20 Nom
•
0...
Loctite
5910
I
39 G
(15Ibfoft)
42 - .,,- 45
r "" G~ 10 Nom
(89 Ibfoin)
Super Lube _~ 25 Nom ,
grease / " (18 I
(PIN 293 550 030) 43

/ G
10 Nom
(89 Ibfoin) """ . Loctite
Engine
oil
'v
243 6 Nom
(53 Ibfoin)

12 IImr2 009-017
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Section03 ENGINE AND GEARBOX (V490N660N810)

Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

GENERAL
Refer to the 2 008 SHOP MA NUAL (PI N 219 100
273) for topics not cove red in thi s section.

PROCEDURES
GEARBOX POSITION INDICATOR
SWITCHES
NOTE: Th e gearbox remova l is not necessary to
rea ch the gearbox pos ition indicator switches .
1. Oetikef clamps
2. Gearbox position indicator switches
Indicator Switches Removal
Un screw switch.
Outlander 500/650 and Renegade 500
To reach the gea rbox position indicator switches Indicator Switches Test
no. 41, rem ove the rear engine cover. Check if gearbox position indica tor switches w ork
Rem ove screw retain ing indicato r switch w ire. properly as per follow ing procedure:
Disconnect w ires from switches.
NOTE: Remove in sulating paint to obtain correct
readings.
Put gearbox in park, re ve rse, neutra l, high and low
position.
Use a multimeter to measure the resista nce fro m
the indicator switch to engine ground. Compare
res u Its with the logic table below.
CORRESPONDING SWITCH WIRES
SHIFTER
POSITION BROWN I W HITEI ORANGEI
GREY GREY GREY
L X X
H X
N X X
R X
1, Gearbox position indicator switches P X X
2. BROWN/GREY wire
3. WHITE/GREY wire
4. ORANGE/GREY wire An "X" indicates switch is making ground contact,
thus the re should be continuity (R is close to 0
Unscrew sw itch . ohm s).
Outlander BOOR A blank spa ce indicate s switch is not makin g con-
tact, there should be no continuity (R = infinite).
To reach the gearbox position indicator switches
no. 41, remove the rear engine cover. If th e indicator switch is good, check the veh icle
harness andlor indicator lights.
Remove and di scard Oeti ker clamp retaining indi-
cator switch connector to the indicator switch. Indicator Switches Installation
Unpl ug indicator switch connector.
Outlander 500/650 and Renegade 500
For installation, reverse the rem oval procedure.
Pay attention to the foll owing details.
Take care do not damage shifting indicator
switches th rea ds during in sta llati on.
vmr2009"()17 13
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Section 03 ENGINE AND GEARBOX (V490N660N81 0)

Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

Apply carefullY some LOCTITE 5910 (PIN 293 800 Take care do not dam age shifting indicator
081) on threads of shifting indicator switches. switches threads during installation.
Apply carefully so me LOCTITE 5910 (PIN 293 800
A CAUTION Do not apply Loctite 5910 on 081) on threads of shifting indicator switches.
switch plunger, as it will lead to switch mal-
function. A CAUTION Do not apply Loctite 5910 on
If all switches are removed, make sure to put the switch plunger, as it will lead to switch mal-
wires back in the right location. function.
If all switches are removed, make sure to put the
wires back in the right location.
Sec ure conn ectors with NEW Oetiker clamps .

1. BROWN/ GRE Y w ire

2. WH fTEIGREY wire
3. ORANGE/GREY w ire

1. In dicator switches
2. BROWN/GREY w ire 4WD INDICATOR SWITCH
3. WHITE/ GREY wire
4. O RANGE/GREY wire NOTE: The gearbox rem oval is not necessary to
Spray a layer of electrica l insulating paint or va r- reach the 4WD indicator switch.
nish over switches to prevent shorts and corro-
4WD Indicator Switch Removal
sion.
To reach the 4W D indicator switch no. 40, remove
the rear engine cover.
Remove sc re w retaining 4WD indicator switch
wire.

vbs2006-QOO.-OO ,

Outlander BOOR
For installation, reverse the remova l procedure.
Pay attention to the following details.

14 vmr2009-0 17
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Section03 ENGINE AND GEARBOX (V490N660N810)

Subsection 09 (GEARBOX AND 4X4 COUPLING UNIT)

A CAUTION Do not apply Loctite 5910 on

switch plunger, as it will lead to switch mal-
function.
Spray a layer of electrical ins ulating paint or var-
nish over switch to prevent shorts and corrosion
(Outlander 500/650 and Renegade 500).

OUTLANDER 500/650 AND RENEGADE 500

1. 4 WD indicator switch
2. BLACKIYELLOW w ire for contact to 4WD
3. Actuator
4. Speed sensor

OUTLANOER 800 R
1. 4 WD indicator switch
2. BLACKIYELLOW wire for contact to 4WD
3. Actuator

4WD Indicator Switch Test

Measure switch resistance as foll ows.
SWITCH
SWITCH WIRE RESISTANCE
POSITION
BLACK/ Engine
2WD Infinite (OL)
YELLOW ground

If the resistance is out of specification, replace the

4WD indicator switch.

4WD Indicator Switch Installation

For installation, reverse the removal procedure .
Pay attention to the follow ing details.
Take ca re do not damage indicator switch threads
during installation.
Appl y carefully some LOCTITE 5910 (PIN 293 800
081) on threads of indicator switch .
vmi'2 009·01 7 15
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Section 04 ENGINE MANAGEMENT (V490N66 0N81 0)

Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES )

ADJU STMENT A ND REPAIR

PROCEDURES
GENERAL
Refer to the 2008 SHOP MANUAL (P/N 219 100
273) for topics not cove red in thi s section .

PROCEDURES
FUEL INJECTOR
Resistance Test
Disconnect the conne ctor " A" from the ECM and
the engi ne con nector.
Using a multi meter, chec k resistance valu e be-
tw een terminals as follows.
ENGINE ECM
RESISTANCE
INJECTOR CONNECTOR CONNECTOR
@ 20"C (6B"FI
PIN "A"
500/650 TYPICAL
FRONT A-15
3 13.8 - 15.2 (2 If read ings are out of specifications, replace injec-
REAR A-33 tor.
BOOR If reading s are good, repair/replace w iring goin g to
injector.
FRONT A-15
3 11.4-12.6 (2
REAR A-33 Fuel Injector Removal
Before removin g the injecto r, th e fuel ra il has to be
removed from the engine . Refer to FUEL RA IL for
the procedu re.
NOTE: The bottom O-ri ng of t he fu el inj ector is
different between th e SOOR engi ne and 500/650
engines.

1
If resistance value is incorrect, rem ove injector
con nector and check resista nce value between
injector pins as follows.

INJECTOR INJECTOR PIN

500/650
RESISTANCE @
20"C (SS"F)
--34

FRONT
1 2 13. 8- 15.2Q
REAR ~m r2QD9.Q22-001 _.

FUEL RAil ASS'Y

800R 7, Fuel rail
2. Fuel injector
FRONT 3. Injector top O-ring
1 2 11 .4 -1 2.6 (2 4. Injector bo ttom O-ring
REAR 5. Manifold a·ring

vmr2009.Q22 17
 www.midwestmanuals.com

Section 04 ENGINE MANAGEMENT (V490N660N81 0)

Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

The fuel injector can be ea sily pulled out of the fuel THROTTLE CABLE
rail.
Throttle Cable Adjustment
Fuel Injector Installation Throttle Cable Free-Play
For the installation, reve rse the remova l proce- Throttle cable routing must be correct.
dure . Pay attention to the following details.
1. Remove the throttle ca m cove r on throttle
Apply a thin fil m of eng ine oil to O-rings to ease body.
insertion in rail.
2. Activate throttle leve r a few ti mes and release.
Install new O-rings, if you reinsta ll a used injec-
tor th en in sert th e fuel injector in place w ith yo ur 3. Make sure throttle cam of throttle body rests
hand. Do not use any tool. aga inst the set screw w ithout any tension or
excessive free play on the cable.
Position the manifold O-ring as shown on injector.
3.1 If ca m rests against the set screw with
a 2 mm ( 078 in) cable free-pla y, go to
THROTTLE LEVER STOPPER SCREW
SETTING.
3.2 If cam does not rest against the set screw
or there is t ensio n on the cable, adjust ca-
ble free-playas follows

,,",1"2006-014-07 1.1

TYPICAL

Carefu lly in se rt inlector in manifold paying atten-

tion to th e manifold O-ri ng . Ge ntly push in evenly
all around w hil e inserting injector O-ring mu st be
com pletely inserted and not visible, before finish-
ing push in g injector.

I. Contact here
2. Free-play here

L![d'@il lmproper cable adjustment will

cause strain on the cable or cause damage to
the cable bracket or throttle lever.

A WARNING
Make sure throttle cam con tacts the set screw
when throttle lever is fully released at handle-
bar.

4. Pull the cable protector to expose ca ble ad-

juster.
5. Loosen the lock nut.
6. Turn cable ad juster in order to get a 2 mm
(078 in) cab le free-play at throttle cam .
Firmly push injector unti l it bottom s.
Reinstall fuel rail. See above .
18 vrnr2 009-022
 www.midwestmanuals.com

Section 04 ENGINE MANAGEMENT (V490N 660N81 0)

Subsection 03 (ADJUSTMENT AND REPAIR PROCEDURES)

7. Using BU.DS, verify throttle plate opening.

7.1 Select Setting tab . The display show s the
actual throttle opening in degrees .
. ~

Vchlde I

1. Lock nut
2. Cable adjuster
"mf20;.s.ol4C64~b

7. Keep the cable adjuster from turning and 7. Throttle openmg display
tighten lock nut Slide the cable protector over
adjuster. NOTE: Do not click on the Reset button .
8. Turn handlebar side to side and ensure there is 8. Fully depress th rottle lever (w ide open position)
still free-play in each position. and hold.
9. Install throttle cam cover. 9. Read throttle opening. It shou ld be w ithin the
following specification.
10. Go to THROTTLE LEVER STOPPER SCREW
SETTING. THROTTLE OPENING
Throttle Lev er Stopper Screw Setting 82' to 86'
1. Loosen the stopper screw lock nut
2. Fully depress throttle lever (wide open position)
and hold .
3. Loosen stopper screw until it ju st releases
throttle lever.

1. Lock nut
2. Stopper screw

4. Turn stopper screw clockwise until it contacts

throttle lever again.
5. From this point, tighten stopper screw 1/2 turn.
6. Keep stoppe r screw from turning and tighten
the lock nut.

vmr2009.Q22 19
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20
 www.midwestmanuals.com
Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

FUEL TANK AND FUEL PUMP

SERVICE TOOLS
Description Part Number Page
OETIKER PLIERS.. . ............... " ...... .. .. ................. .. 295 000 070 ...... ....... ... ............ . ..... 27
SMALL HOSE PINCH ER ....... .......... ............... . 295 000 076 ........... .... .. .. ............ ....... 24
ECM ADAPTER .................. ................... . . . . . ................ . 420277010.............. . . 3 3
VACUUM/PRESSURE PUMP ................. . 529021 800 .... .. ....... ...... ..... 24
PRESSURE GAUGE .......... . ................. . 529 035 709 . . ...... .. ..... ... . .... ........ 26
FLUKE 115 MULTIMETER .......................... .. 529 035 868 ..... ........ ... . ......... 32
T-F ITTING ... ................... ........ ... ...... ... . . 529 036 023 .. ... .. ...... ... .... ..... 26

SERVICE TOOLS - OTHER SUPPLIER

Description Part Number Page
FLUKE RIGID BACK PROBE ...... .. TP88 ... ............ . 32

SERVICE PRODUCTS
Description Part Number Page
FUEL PUMP NUT TOOL ..... ........... .... . 529035899 ........ 35

vmr2009~23 21
 www.midwestmanuals.com
Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

.,...-. - - - - - - - - - - -
,,'t--J--lf-<»>tbII Eng i n e
/
/

~ 29Nom
~ (21 Ibfoft)

\(:::=-u-«S3 Eng i ne

7 Nom
(62 Ibioin)

22 vmr2009'{)23
 www.midwestmanuals.com
Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

GENERAL A WARNING
A WARNING Do not allow fuel to spill on hot engine parts
or electrical connectors. The evaporating fuel
Fuel is flammable and explosive under cer- on the hot components or on the electrical
tain conditions. Ensure work area is well ven- connectors produce highly inflammable fuel
tilated. Do not smoke or allow open flames or vapors that can easily be ignited by the heat,
sparks in the vicinity. a spark, electrostatic discharge or stray cur-
rent resulting in a fire or an explosion.
A WARNING
Always disconnect battery prior to working Never use a hose pincher on injection system high
on the fuel system. Always disconnect bat- pressure hoses.
tery exactly in the specified order, BLACK (-) Replace any damaged or deteriorated fuel lines.
cable first.
When the repair is complete, ensure that all hoses
Whenever working on fuel system, always verify are connected and secured. The fuel pump is ac-
for water or dust infiltration in reservoir. tivated each time electrical power is turned on.
A pressure test must be carried out before turn-
During assembly/installation, use the torque val- ing the ignition key to ON and setting the engine
ues and service products as in the exploded run/stop switch to RUN .
views.
Clean threads before applying a threadlocker. Re- A WARNING
fer to SELF-LOCKING FASTENERS and LOCTITE Always carry out a fuel pump pressure test
APPLICATlON at the beginning of this manual for and/or a fuel tank leak test whenever a related
complete procedure. fuel system com ponent has been removed
during a maintenance procedure. A missed
A WARNING fuel leak could result in severe injury or
Torque wrench tightening specifications death.
must be strictly adhered to. Locking de-
vices (e.g.: locking tabs, elastic stop nuts, After performing a fuel pressure test, use the
self-locking fasteners, cotter pin, etc.) must valve on the fuel pressure gauge to relea se the
be replaced with new ones. pressure (if so equipped).

Hoses or cables removed or disconnected must SYSTEM DESCRIPTION

be installed and routed at the same place.
Fuel Tank Vent System
A CAUTION Locking ties removed during a The fuel tank is equipped with a vent system that
procedure must be replaced and installed at provides over pressure relief and negative pres-
the same location. sure relief of the fuel tank.
Air ca n enter the f uel tank at all times through
A WARNING the ve nt system INLET check valve. This prevents
Fuel lines remain under pressure at all times. negative press ure within the fuel tank w hich could
Always proceed with caution and use appro- cause fuel starvation.
priate safety equipment when working on
pressurized fuel system. Always wear safety
glasses.

Proceed with care when removi ng/installing pres-

sure test equipment or disconnecting fuel line
connections.
Slowly disconnect the fuel hose to min imize
spilling. Cover the fuel line connection w ith an
absorbent shop rag. Wipe off any fuel sp illage.

o,rmr2009-{)23 23
 www.midwestmanuals.com
Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

Remove seat.
All Models except Outlander MAX
Remove the seat reinforcement plate .

1. Vent infer check valve

The vent inlet check valve also prevents fuel from

flow ing out through the inlet of the vent system
If the pressure in the fuel tank bui lds up and ex-
ceeds 2.5 - 7.6 kPa (.36 - 1.1 PSI), the pressure vmr:2008· IJ5-001_~

relief valve opens and lets the excess pressure TYPICAL

1. Seat reinforcement plate
evacuate through the ven t system OUTLET 2. Exhaust hear shield
3. Retaining screws (5)

All Models
In sta ll a SMALL HOSE PINCHER IP/N 295 000 076)
on vent line (OUTLET side).

1. (nlet check valve blocks fuel

2. Ouaet pressure relief valve allows pressure to go our

INSPECTION
FUEL TANK LEAK TEST
1. Vem system outlet
A WARNING 2. Smaff hose pincher
3, Ven t pressure refief valve
Always carry out a fuel tank leak test when-
ever fuel tank shows signs of wear or dam- Using the VACUUMIPRESSURE PUMP IP/N 529 021
age which may cause a leak, or when the 800), pressurize fuel tank through vent line (INLET
fuel pump has been removed or replaced, or side).
if you suspect a leak. If damage is severe,
fuel tank should be replaced even if no leak
is present. Do not attempt to repair a plastic
fuel tank.

Refill fuel tank

24 vmr2009-023
 www.midwestmanuals.com
Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

Step 1: Block vent ourtet with finger

IImr200a-135·203_" Step 2: Remove hose pincher
VACUUM PUMP ON INLET SIDE
1. Fuel rank vent Alternately touch and release end of pressure re-
2. Vent inlet line
3. Vent check valve lief valve. You should feel pressurized air flowing
out indicating relief valve is working .
Pressurize fuel tank as follows.
TIME WITHOUT
PRESSURE
PRESSURE DROP
21 kPa (3 PSI) 3 minutes

If pressure drops, locate fuel leak(s) and repair or

replace leaking component(s).
To locate a leak, check for a fuel smell or leaking
fuel.
To ease locating leak(s), spray soapy water on all
hose connections and components; bubbles w ill
indicate the leak location(s).

Fuel Tank Check Valve and Pressure PRESSURE RELIEF TEST

1. Release vent Qutter and fee! for air flowing out
Relief Valve Test
While tank is still pressurized from the previous Using the pressure/vacuum pump, increase fuel
fuel tank leak test, carry out the following proce- tank pressure until the pressure relief va lve opens.
dure: NOTE: Pressure relief va lve should open w hen
Block the vent outlet as you remove the hose the fuel tank pressure exceeds 2.5 - 7.6 kPa
pincher. (.36 - 1.1 PSI) preventing fuel tank overpress ure .
This validates pressure relief valve operation.
Remove fuel tank cap.
NOTE: You should hear remaining air pressure
within fuel tank escape as fuel cap seal is loos-
ened .
Blow air in through ve nt inlet check valve.
NOTE: Air must flow freely through inlet check
valve and out fuel tank filler neck.

vn)l2009-023 25
 www.midwestmanuals.com
Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

A WARNING
The fuel hose may be under pressure, Cover
the fuel line connection with an absorbent
shop rag, Slowly disconnect the fuel hose
to release the pressure, Wipe off any fuel
spillage inside engine compartment.

En sure there is en ough gas in fuel tank.

Remove the seat and the RH side body panel, re-
fer to the BODYsection.
Wrap shop rags around the fuel hose end at the
injector. Unplug one injector only.
1, Blow air through vent inlet check valve
Ca refully disconnect the fu el pump outlet hoses
2. Airflow ou t of filler neck by pressing on the release tab of the quick discon-
nect f itting.
Rein stall removed parts.
Install fuel PRESSURE GAUGE (PIN 529035 709) and
T-FlnING (PIN 529 036 023) betw een discon nected
FUEL PUMP PRESSURE TEST hose and injector (in-line installation).
The pressure t est wi ll show the ava ilable pressure
at the fuel pump outlet. It val idates the pre ssu re
regulator, the fuel pump and tests for leaks in the
system .
NOTE: Refe r also to the FUEL SYSTEM DIA G-
NOSTIC FL OW CHART at the end of this section
to help diagnose a fuel system related problem. 529035709
Ensure there are no leaks from hoses and fittin gs.
Repair any leak.
Before proceeding w ith the pressure test ensure
the ba ttery is fu lly charged . Battery voltage must
be ove r 12 volts.
Disable fuel pump using B.U.D.S . Look in the Ac- PRESSURE GAUGE
tivation tab and select Disabled .

/
® Ot!lllIMd

T-FITTING

Using B.UD S., reactivate fuel pu m p by selecting

Enabled.
Release fuel press ure by running engine until it
runs out of gas.

26 vmr2009-0 23
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Section 05 FUEL SYSTEM

Subsection 01 (FUEL TANK AND FUEL PUMP)

PROCEDURES
FUEL HOSE AI\JD OETIKER
CLAMPS
1M P1.r.... I
'C~r.:F;) I Fuel Hose Replacement
'""07# Ro ~ I When replacing fuel hoses, be sure to use hoses
';1'u~".:.l.IIT~ I and clamps as available from BRP parts depart-
ment. This will ensure continued proper and safe
operation.
Turn ignition key ON. A WARNING
Set engine stop switch to RUN and observe fuel Use of fuel lines other than those recom-
pressure. mended by BRP may compromise fuel sys-
FUEL PRESSURE 350 kPa 151 PSI) tem integrity.

Turn ignition key OFF then back ON. Repeat the A WARNING
test. Whenever removing a hose in the fuel sys-
Remove tool and connect hose on injector. tem, always use new Oetiker clamps at as-
Disconnect fuel hose from the other injector and sembly. Then validate fuel system tightness
install the tool. by performing a fuel pressure test.
Repeat the pressure test.
Oetiker Clamp Replacement
Remove pressure gauge and T-fitting.
To secure or cut Oetiker clamps on fuel lines, use
Reconnect fuel hose on injector. OETIKER PLIERS (PIN 295 000 070).
A rapid pressure drop indicates leakage either
from the fuel rail or from the fuel pump check
valve.
Check fuel hoses and fittings for leaks. If it is not
leaking, replace fuel pump.
A slow pressure drop indicates leakage either
from the fuel injector or from the fuel pressure
regulator.
Check fuel injector for leaks. If it is not leaking,
replace fuel pump.
If there is no leakage, start engine and observe
fuel pressure. The fuel pressure should be the
F01B03A
same as above.
1. Cutting cfamp
If pressure is within limits, fuel pump and pres-
sure regulator are working adequately.
Release fuel pressure in the system using
B.U.D.S. Look in the Activation tab.

A WARNING "
Wipe off any fuel spillage. Fuel is flammable
and explosive under certain conditions. Al-
ways work in a well ventilated area.

Reinstall removed parts. F01B04A 1

1. Securing clamp
 www.midwestmanuals.com

Section 05 FUEL SYSTEM

Subsection 01 (FUEL TANK AND FUEL PUMP)

FOIBIlSA

1. Securing clamp in limited access

FLOW DIRECTION
7. Pressure relief valve
FUEL TANK
Fuel Tank Check Valve and Pressure Fuel Tank Draining
Relief Valve Installation
Alw ays install check valve with the black side con-
A WARNING
nected to vent line. Never perform this operation when the en-
gine andlor the exhaust system islare hot.
Never use a hose pincher on injection system
high pressure hoses.

Remove fuel tank cap and siphon gas into an ap-

proved fuel contai ner.

Fuel Tank Removal

Drain fuel tank . Refer to FUEL TANK DRAINING
above in this section.
Relea se fuel pressure by running engine until it
runs out of gas.
Disconnect battery, refer to CHARGING SYSTEM
section.
Remove seat. refer to the BODYsection .
IN LET CHECK VA LVE DIRECTION
1. Black side here
2. White side open to atmosphere All Models except Outlander MAX
Remove the seat reinforcement plate.
Always reinstall pressure relief valve according to
arrow on valve as shown.

28 vmr2009-{)23
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Section 05 FUEL SYSTEM

Subsection01 (FUEL TANK AND FUEL PUMP)

1. Pul/out vent outfet

TYPICAL 2. Fuel pump fitting
1. Sea t reinforcement plate
2. Exhaust heat shield All Models except Outlander MAX
3. Retaining screws (5)
Remove 2 fue l tank retaining screws on right side
All Models of the tank.
Remove side panels and rear fender assemb ly, re-
fer to BOD Y section.
Disconnect the fuel pump connector.

RH FUEL TANK MOUN TING SCREWS (2)

Outlander MAX Models

vmI1000-1J5-201 _f

7. Fuel pump connector Remove 3 rue I tank retaining screw s on right side
of th e tank.
Pull out vent system OUTLET f rom frame.
Disconnect fu el hose at fu el pum p fitting .

vmr2009.(l23 29
 www.midwestmanuals.com

Section 05 FUEL SYSTEM

Subsection 01 (FUEL TANK AND FUEL PUMP)

RH FUEL TA NK MOUNTING SCREWS (3) Pull fuel tank out from the RH side of vehicle.
All Models
Remove the upper and the lower fuel tank retain-
ing screws on the left sid e of the tan k.

Fuel Tank Protector Removal

Cut plastic rivet locking protector to tank .
LH FUEL TANK MOUNTING SCREWS (2)

Remove voltage regulator/rectifier protector.

Pul lout tank from protector.

vmt20oa·13~OCLa

Fuel Tank Inspection

Lift frame sufficiently to extend RH rear shock ab-
sorber and remove its upper moun ting screw. Inspect fuel tank for any damages or cracks which
may result in fuel leaks.
Move shock absorber rearw ards.
30 vmr2009-023
 www.midwestmanuals.com

Section 05 FUEL SYSTEM

Subsection 01 (FUEL TAN K AND FUEL PUMP)

Inspect tank and protector attachment points for

damages.
Inspect protector for damag es .
If cracks, gouges or other dama ges wh ich may
lead to a fuel leak, or damages to attach ment
points that could prevent the tank from be ing
secure are found, rep lace fuel tank.

Fuel Tank Protector Instal lation

For installation, use a NEW plastic rivet.

Fuel Tank Installation

The in stallation is th e reverse of th e remova l pro-
ced ure. However, pay attention to the foll owing.
Make sure to properly connect and route fuel tan k
SCREW INSTALLATION AND TORQU E SEQ UENCE
vent tube.
Use a NEW clam p on fuel pump hose. All Models
All Models except Outlander MAX Refu el tank and ensure there are no leaks by
pe rforming a FUEL TA NK LEAK TEST and a FUEL
Reinstall the seat re inforcement plate. PRESSURE TEST as described in this section.
Insta ll and torque f uel tank retaining screws to
7 Nom (62 lbf oin) as per follo w in g sequence. FUEL PUMP
Fuel Pump Quick Test
1. Set engine stop switch to RUN .
2. Turn ignition key to ON.
3. Li sten to fue l pump op eration.
4. Fu el pump should come ON for for a few sec-
onds, then stop.
5. If so, the fuel pump, ECM , and associated cir-
cuits are f unctioning normally. How ever, kee p
in mind this does not validate fuel pump pres-
sure.
6. Oth erwise, ca rry out the foll owin g step(s} until
the pump wo rks.
7. Check fue l pu mp fuse .
vmr200S· 13&-210.a

SCREW INSTALLATION AND TORQUE SEQUENCE

Outlander MAX Models

Reinstall th e heat shi eld.
Install and torqu e fu el tank retaining sc rews to
7 Nom (62lbf oin) as per following sequence.

7. Fuel pump fuse

8. Substitute fu el pu mp relay w ith a known work-

ing relay in f use box.

vmr2009.Q23 31
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Section 05 FUEL SYSTEM

Subsection 01 (FUEL TANK AND FUEL PUMP)

1. Fuel pump re lay

9. Check in B.U. O S. for applicable fault cod es.

Refer to COMMUNICATION TOOL S/B.U.o.5. 529035!1GLa
SOFTWARE section. FLUKE 115 MULT/METER
10. Ca rry out a fuel pump input voltage test.
Set ignition switch to OFF.

Fuel Pump Input Voltage Test

Remove sea t.
From the RH side of the veh icle, disconnect th e
fuel pu mp conn ector.
NOTE: It may be nece ssary to remove seat re-
inforceme nt plate andlor LH side panel to make FLUKE RIGID BACK PR OBE

room . Turn ignition key ON .

Set eng ine stop switch to RUN .
Read voltage as follows.
FUEL PUMP INPUT VOLTAGE TEST
TEST PROBES VOLTAGE READING
Fuel pump Fuel pump
con nector connector Battery voltage
Pin 3 Pin 4

Use the FLU KE 115 MULTIMETER (PIN 529 035868)

w ith the FLU KE RIG ID BACK PROBE (PIN TP88)
Set mu ltimeter to Vdc.

If battery vo ltage is read , carry out a fuel pump

wind ing re sistance test.

32 vmr200 9.Q 23
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Section 05 FUEL SYSTEM

Subsection 01 (FUEL TANK AND FUEL PUMP)

If battery voltage is not read carry out this voltage FUEL PUMP RELAY INPUT VOLTAGE TEST
test.
TEST PROBES READING
FUEL PUMP INPUT VOLTAGE TEST
Fuse box
TEST PROBES VOLTAGE READING contact 1 A
Battery ground Battery voltage
Fue l pump Battery Fuse box
connector Battery voltage contact 3 A
ground
Pin 3

CONTACT 1 A

If battery voltage is now read, check fuel pump

ground circuit. Refer to FUEL PUMP WINDING
RESISTANCE TEST
If battery voltage is still not read , check fuel pump
supp ly circuit. Refer to FUEL PUMP RELAY IN-
PUT VOLTAGE TEST

Fuel Pump Relay Input Voltage Test

Remove front compartment cover and fuse box
CONTACT 3A
cover.
Remove fuel pump relay. If battery voltage is not read, test wirin g for conti-
nuity between battery and fuse box.
If battery voltage is read, test w iring for continu-
ity between fuse box (conta ct 3B) and fuel pump
con nector (pin 3).
Repair or replace wiring as required.

Fuel Pump Relay Ground Control

Circuit
Remove RH inner fender panel , refer to the BODY
sectio n.
Disconnect ECM connector B.
1. Fuel pump relay
Install ECM ADAPTER (PIN 420 277 010) onto ECM
Tu rn ignition key ON. connector.
Set engine stop switch to RUN.
Measu re fuel pump rela y input vo ltage at fuse box
contacts.

vmr20 09-<l23 33
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Section 05 FUEL SYSTEM

Subsection01 (FUEL TANK AND FUEL PUMP)

420077010
If resistance test failed, disconnect fuel pump
Use a mu ltimeter and select (2. connector and measure winding again directly to
fuel pump connector.
Check continuity as follow s.
ECM FUEL PUMP RESISTANCE (2
CONNECTOR CONNECTOR @ 20°C (68°F)

Pin B-29 Pin 4 Close to 0 (2

If continuity is good, chec k ECM . Refer to ENGINE

MANAGEMENT SYSTEM secti on .
If continuity is not good, repair or replace w iring
and connectors between ECM and fuel pump con-
nector as requ ired .
Remove tool.
Install removed parts and connectors.

Fuel Pump Winding Resistance Test

Remove the fuel pump relay.
If test failed , check pump wiring and connector
and if good, replace fuel pump.
If test succeeded check wiring and connectors
from fuse box and to battery ground. Repair or
replace as necessary.

Fuel Pump Removal

Using B.U.D.S., disable fuel pump. Look in the
Activation tab and select Disable.

7. Fuel pump fela y

Set multimeter to n.
Measure w inding as follo ws.
FUEL PUMP WINDING RESISTANCE TEST
RESISTANCE (2
TEST PROBES
@ 20°C (68°F)
Fuse box Battery Approximately 2.5 (2
contact 3B ground vmr2009.IJ:t).004 _1

1. Select th e Activation tab

2. Click here co disable the fuel pump

34 "mr2009·023
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Section 05 FUEL SYSTEM

Subsection 01 (FUEL TANK AND FUEL PUMP)

Release fuel pressure by running engine until it

runs out of gas.
Remove seat.
Remove seat reinforcement plate (except
Outlander MAX).

Unscrew fuel pump retaining nut.

TYPICAL
1. Seat reinforcement plate
2 . Exhaus t heat shield
3. Retaining screws (x5)

Disconnect electric connector, vent line and fuel

hose from fuel pump.
Carefu lly pull out fuel pump.

A CAUTION While pulling out the fuel

pump, pay attention to fuel sensor float arm.
Float arm can get stuck and bend reducing fuel
sensor accuracy.

~m'Z008-135-201_~

1. Electric connector
2. Vent fine
3. Fuel hose

A CAUTION Replace fuel pump gasket

whenever fuel pump retaining nut is lo ose n.
Use the FUEL PUMP NUT TOOL (PIN 529035899).

Discard gasket.
Wipe off any fuel spillage.

vm r200S-023 35
 www.midwestmanuals.com
Section 05 FUEL SYSTEM
Subsection01 (FUEL TANK AND FUEL PUMP)

Fuel Pump Installation

For insta llation, reverse the removal process but
pay attention to the followin g.
, . ,

A CAUTION Never install a damaged pump

or a dropped pump.
Install a NEW gasket.
Pla ce gasket so that its flange wi ll be between
pump and tan k mounting surface.

A. Gasket parallel with tank surface (all aro und)

W hile maintaining pump sea ted, rotate pump to

align its mark with the mark on the fuel tank as
per the followi ng specification.

1. Gasket flange here

Pay attention to pump orientation as in following

illustration.

ANGLE PURPOSELY EXAGGERATED IN ILLUSTRATION FOR

CLARITY

W hile firmly holding pump against tank, engage

fuel pump nut threads. Sli ghtly tighten nut while
holding pump to prevent it from turning .

Firmly push against pum p to align its gasket par-

allel with tan k surface (all around).

36 vmr2009-023
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Section 05 FUEL SYSTEM

Subsection 01 (FUEL TAN K AND FUEL PUMP)

Ensure pump is still aligned as per specification.

TOROUE WRENCH PERPENDICULAR TO TOOL HANDLE

Torque nut w hil e ensur ing pump does not rotate

as nut is tightened. Reposition as necessary.
Secure fuel hose with a new cla mp.
Reinstall rema ining removed parts.
Using S.U.D.S ., enable the fuel pump. Look in the
Activation tab and select Ena ble .

ANGLE PURPOSELY EXAGGERATED IN ILLUSTRATION FOR

CLARITY

To apply the proper torque to the pump nut, use

a torque w rench and install it perpendicularly (90°1
to the tool handle. the Activation tab
Click here to enable the fuel pump
--
Refuel tank and ensure there are no leaks by
performing a FUEL TANK LEAK TESTand a FUEL
PRESSURE TESTas described in this sect ion.
Check fuel level sensor operation.

Fuel Pump Strainer Replacement

Remove FUEL PUMp, see procedure above in this
sectio n.
Unlock 2 tabs of plastic ring on opposite sides.

37
 www.midwestmanuals.com
Section 05 FUEL SYSTEM
Subsection 01 (FUEL TANK AND FUEL PUMP)

NOTE: A non serviceable filter is located in fuel

Remove rubber pad.
pump. If it is clogged, replace fuel pump.
Insert the new strainer on fuel pump makin g sure
to press it in tightly against pump face.
Press in a NEW push nut to secure strainer.
Reinstall rema ining remo ved parts.
J
FUEL LEVEL SENSOR
) The fuel level sensor is a float actuated variable re-
sistance type sensor that is part of the fuel pump.

Remove push nut securing strainer to fue l pump.

Be careful not to break the plastic pin.

FUEL PUMP
1. Fuel/eve! sensor

Fuel Level Sensor Resistance Test

Remove and disconnect multifunction gauge,
refer to the LIGHTS/GAUGE/ACCESSORIES sec-
tion.

Pull strainer off fuel pump.

38 vrn r2009·D23
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Section 05 FUEL SYSTEM

Subsection 01 (FUEL TANK AND FUEL PUMP)

Fuel Level Sensor Input Voltage Test

Set engine stop switch to RUN.
Set ignition switch to ON.
Disconnect fuel level sensor connector.

Step 1.' Press to release

Step 2: Pull connector off gauge

Use a multimeter and se lect «.

Measure the resistance of the sensor as follows.
FUEL LEVEL SENSOR RESISTANCE TEST
GAUGE RESISTANCE « Use a multimeter and select Vdc.
FUEL LEVEL @ 2QoC (68°F)
CONNECTOR Measure the input vo ltage as foll ows.
Full 5« ± 2 FUEL LEVEL SENSOR INPUT VOLTAGE TEST
Pins 4 and 21
Empty 1OQ « ±7 FUEL LEVEL
SENSOR BATTERY VOLTAGE
CONNECTOR
Negative
Pin 1 Battery voltage
terminal

If readings are out of specification check wiring If battery voltage is not read , test wi ring continuity
and co nnectors betwee n multifunction gauge and between sensor and multifunction gauge .
fuel level sen sor. If wiring is good, replace fuel If wiring was good, replace multifunction gauge.
level sensor. If continuity was not obtai ned, repair or replace
If readings are as per specification, test sensor in- wi rin g.
put voltage from multifunction gauge .
Recon nect the mu ltifunction gauge.
Fuel Level Sensor Replacement
Replace fu el pump.
vmr2009·023 39
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40
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Section 06 ELECTRICAL SYSTEM

Subsection03 (CHARGING SYSTEM)

CHARGING SYST EM
SERVICE TOOLS
Description Part Number Page
4-PIN MAGN ETO HARNE SS ADAPTER ........ ............ . 529 036 02 1 .......... ....................... .... 41

GENERAL
Refer to the 2008 SHOP MANUAL (PIN 2 19 100
273) for topics not covered in thi s section.

PROCEDURES
STATOR
Rem ove seat and RH side pan el.
Remove protecti ve plate as necessary.

Static Test: Continuity

1. Disconnect t he m agneto w iring harness con-
necto r. 1. Magn eto con ne ctor
2. Leave this tool connector unplugged

3. Set multi m eter to n.

4. Con nect mu ltimeter betw een YELLOW wires.
5. Read res istance.
RESISTANCE @
TERMINAL
20°C (69°F)
1 and 2
1 and 3 0. 15 - 0.30 n
2 and 3

2. Install the 4-PIN MAGNETO HARNE SS ADAPTER

(PIN 529 036 021) on magn eto connect or. Leave
t he ot her co nn ector unplugged.

V07Ci ()5A

TYPICAL

vrn r20 0g..o25 41

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Section 06 ELECTRICAL SYSTEM
Subs ection 03 (CHARGI N G SYSTEM)

6. If any readin g is out of specificati on. replace sta-

tor.
7. Replug co nnectors prope rly.

42 vrnr2 009-025
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Section 10 SUSPENSION
Subs ect ion 02 (REAR SUSPENSION )

REAR SUSPENSION
SERVICE TOOLS
Description Part Number Page
TRAILI NG ARM NUT SOC KET 52903 5 925 .... 45

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 271 (RED) 293800 005 . ... ... .. .. ... ....... .45

vmr2009'()311 43
 www.midwestmanuals.com
Section 10 SUSPENSION
Subsection 02 (REAR SUSPENSION)

53 Nom
--(39 IbHt)

44 vmr20()9.QJ4
 www.midwestmanuals.com

Section 10 SUSPENSION
Subsection 02 (REAR SUSPENSION )

GENERAL TRAILING ARM

Refer to the 2008 SHOP MANUA L (PI N 219 100 Trailing Arm Installation
273) for topics not covered in thi s section Insert drive shaft end into tra iling arm .
Insta ll the traili ng arm on fra me .
PROCEDURES
Insta ll th e lower shoc k absorber bo lt to support
th e tra iling arm. Do not torque yet.
TORSION BAR
Frame Side
Torsion Bar Installation
Apply LOCTITE 27 1 (R ED) (PIN 293 800 005) on
Insert the torsion bar into th e fram e.
th reads of fram e ext ensions.
Apply a line of LOCTITE 271 (RED) !PIN 293 800 005)
In sta ll th e tra iling arm nut and torque it to 190 Nom
on sp lin es of torsion bar and lever. (140 Iblolt) usin g th e TRAILING AR M NUT SOCK ET
(PIN 529 035 925).
Install th e circi ip retainin g the trailing arm nut.

1. Loctite 271

In sta ll both torsion bar levers with the arrows up-

w ard . Al ign lever tabs w ith t railing arm slots .

1. Circfip

Fin alize the torsion bar installation. Refer to TOR-

SION BAR in this section .
Torq ue the shoc k abso rber lower bolt to 53 Nom
(39Ibl oft)
Wheel Side
In stall whee l hu b, Belleville was her and castel-
lated nut.
Torque castellated nut to 205 Nom (151 Ibfoft) and
further tighten until its grooves align wit h the next
vmr2000 ·147.()1 I _a
cotter pin hole .
1. Torsion bar lever tab
2, Trailing arm SIOl In sta ll a NEW cotter pin then the w heel cap.
3. Arrow upward
NOTE: The longer end 01 cotter pin must be
Insta ll t he Ilat washer and a NEW elastic nut. folded over shaft end.
Tighten first the RH elastic nut of torsion bar lever
to 55 Nom (41 Ibfoft).
Tighten the LH elastic nut 01 torsion bar lever t o
120 Nom (89Ibf oft)
Reinstall both protective covers with NEW
cla mps.

vmr2009-Q34 45
 www.midwestmanuals.com
Section 10 SUSPENSION
Subsection 02 (REAR SUSPENSION)

V07 H1KA

In stall w heel.

46 vmr2009-034
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES )

FRONT AND REAR BRAKES

SERVICE TOOLS
Description Part Number Page
VACU UM/PR ESSUR E PUM P 529 02 1 800 ... ..... 55-56

SERVICE PRODUCTS
Description Part Number Page
DI ELE CTR IC GR EAS E .... 293550004 .... ..... .... ... 60, 63
XP-S SYNTHETI C GR EAS E ...... . . 293 550 010 . .. .. ... ... ........ 61 ,66
GTL MA BRAK E FLUi D .... 293600062 .. 54
LOCTITE 243 (BL UE) ... 293800060 . . ...... 66

Ym1 200S-035 47
 www.midwestmanuals.com
Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

OUTLANDER SERIES (FRONT AND REAR BRAKES)

T4

, • ' ~G Loctiter2_
43~:-;
~
•
/ r
T2
T12

T5 ~~

243 T1 · 48 N'm (35 IbHt) 0

T2 38 N'm (28 IbHt) T6 17 N'm (150 Ibfoin) T10 5.5 N'm (49 IbN n)
T3
mm T3
T4
34
28
N'm
N'm
(25
(21
IbHt)
IbHt)
T7
T8
10 N'm (89 IbHn )
8 N'm (71 IbHn)
T11
T12
5 N'm (44 IbNn)
2.5 N'm (22 IbHn)
T5 25 N'm (18 IbHt) T9 6 N·m (53 IbHn ) T13 1 N'm (9 Ibioinl

48
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Section 11 BRAKES
Su bsect ion 01 (FRON T A ND REA R BRAKES)

ALL RENEGADE MODELS EXCEPT CE (FRONT BRAKES)

1 'm
(9 I bfoin )

6 N'm
\
\
28 N' m
~)
\ (21 Ibfoft)
\

6 N'm
(53 Ibfoi n )
6 N' m
(3 1 Ibfoin )

I
"_
28 N' m
(2 1 Ibfoft)

25 N' m
(18Ibfoft ) , 38 N' m 6 N' m
/; (28 Ibfoft) (53Ibfoin )

) J., o
0
0
00 0
II- 0
28 N' m

0.
0
o 0 (21 Ibfoft)
a o
o
0 0

,/~'ir>
o 0 0 0
o 0 0

25 N' m
(18IbHt)
~ I ~Hk'"
/ I
I mm
en~17N.m
I
'-J
\£ (150Ibfoin ) () Loctite 243

vrn r2009-{)3 S 49
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

ALL RENEGADE MODELS EXCEPT CE (REAR BRAKE)

6 Nom
(53 Ibfoin) 28 Nom
(21 Ibf°ft)

\
\
,J
~ ,~

/'
\ XP,S
5 Nom ~
' synthetic
(44 IbNn) grease
~ \ (j

50 vmr2009-035
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

RENEGADE CE MODELS (FRONT BRAKES)

T1

T4

T5

T1 1 N'm (9 IbNn)
T2 5.5 N'm (49 IbNn)
T3 6 N'm (53 IbNn)
T4 8 N'm (71 Ibf';n)
T5 10 N'm (89 IbNn)
T6 17 N'm (150 Ibfoin)
n 25 N'm (18 Ibfoft)
T8 28 N'm (21 Ibf·ft)
T9 38 N'm (28 Ibf·ft)

vm r2009.o35 51
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

RENEGADE CE MODELS (REAR BRAKE)

T11

T7 T2

T10

T12
B ;:~
~x~-s
IB!I
T1 1 N'm (9 Ibfoin)
T2 2.5 N'm (22 Ibfoin) T8 17 N'm (150 Ibfoin) synthetic
T3 5 N'm (44 Ibfoin ) T9 18 N'm (159 Ibfoin) grease
T4 5.5 N'm (49 Ibfoin) T10 25 N·m (18 Ibfoft)
T5 6 N'm (53 Ibfoin) T11 28 N'm (2 1 Ibfoft)
T6 8 N'm (7 1 Ibfoin) T12 34 N'm (25 Ibfoft)
T7 10 N'm (89 Ibfoin) T13 48 N'm (35 Ibfoft)
vmr2Q09 ·Q:l!)-OO7 _1

52 vmr2009-03 5
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

GEN ERAL SYSTEM DESCRIPTION

During assembly/installation, use the torque val- The brake system cons ists of tw o circuits. Each
ues and service products as in the exploded system has its own master cylinder and reservoir.
view is). Both front and rear bra kes are disc type.
Clean threads before applying a thread loc ker. Re-
fer to SELF-LOCK/NG FASTENERS and LOCTITE A WARNING
APPLICATION at the beginning of this manual for Periodically check the brake hoses for dam-
complete procedure. ages or leaks. Repair any damage before op-
erating the vehicle.
A WARNING
Torque wrench tightening specifications Parking Brake
must strictly be adhered to .
Locking devices (e.g.: locking tabs, elastic The parking brake ope rates rear brakes. It is acti-
stop nuts, cotter pins, etc.) must be replaced vated by a locking mecha nism on LH brake lever.
with new ones. To engage mech anism: Squeeze brake lever and
maintain while moving lever lock. Brake lever is
Hoses or cables removed or disconnected must now compressed and applying rear brakes.
be installed and routed at the same place.
2 1
A CAUTION Locking ties removed during a
procedure must be replaced and installed at
the same location.

A WARNING
Never app ly anything to brake fittings, The
use of threads sealant or Teflon tape could
cause brake system failure. Severe injury or
death can occur.

A CAUTION Avoid spilling brake fluid on

plastic, rubber or painted parts. Protect these
parts w ith a rag when servicing brake system.

A CAUTION Wipe up any brake fluid

spillage. TYPICAL
1. LH brake lever
A CAUTION To av o id serious damage to the
2. Press lever to activate parking brake

brake system, use only DOT 4 brake fluid from NOTE: Locking lever can be adjusted in several
a sealed conta iner. Do not use brake flu id taken positions.
from old or already opened containers, nor mix
different fluids for t opp ing off. IM,lilll, Parking brake position can vary de-
pending on brake pads wear. Ensure when the
A CA UTION Sealing washers must be dis- parking brake is applied that the vehicle stays
securely in place.
carded and replaced with new ones every time
a Banjo fitting is loosen. To release mecha nism: Squeeze brake lever.
Lever lock should automatica lly return to its orig-
A CA UTION Before opening or working inal position. Brake lever should return to rest
near bleeders, reservoirs or fittings, clean the position .
part and its area to avoid system contamina-
tion.
Dispose brake fluid as per your loca l environmen-
tal regulation.

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

MAINTENANCE Brake Pedal Fluid Reservoir

Outlander Series
BRAKE FLUID
Recommended Brake Fluid
Alw ays use brake fluid meeting the specification
DOT 4 only such as GTLMA BRAKE FLUID (PIN 293
6000621 .

A CAUTION Use only DOT 4 brake fluid

from a sealed container. Do not use brake
fluid from an old or already opened container.
To avoid damage to the braking system, use
only the recommended fluid type.

Brake Fluid Level Verification

W ith vehicle on a leve l surface , check bra ke fluid
in reservoir for proper level. It should be above
MIN. mark.
Clean reservoir cover before removing.
Add fluid as required. Do not overfill .
NOTE: A low level may indicate leaks or w orn
brake pads. UNDER FRONT ACCESS PANEL

Brake Lever Flu id Reservoir Renegade Models

Turn steering in the straight-ahead position to en-
sure reservoir is level. Check the brake fluid level,
the reservoir is full when the fluid reaches the top
of w indow.

UNDER CONSOLE

Brake Fluid Draining

Clean and remove reservoir cover w ith its di-
aphragm.
Connect a clear hose to bleeder.
Loose n bleeder and pump brake lever(s) or brake
pedal until no more fluid flows out through the
clear hose.
Visually inspect lever boot condition. Check for
cracks. tears, etc. Replace if damaged. Brake Fluid Bleeding
(except Renegade CE Models)
General Recommendations
Fill reservoirs to recom mended level using recom-
mended brake fluid on ly.

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Check brake flu id reservoir level often. Do not al- Bleeding Procedure Using a Vacuum Pump
low the fluid level to drop below the low er mark Using a clear hose and the pump reservoir, install
during the bleeding process. the VACUUM/PR ESSU RE PUMP (PI N 529 021 800) to
For the front bra kes, bleed alternately the LH and bleeder.
RH calipers. Turn handlebar to full RH side when
bleeding right caliper and turn to the LH side for
the left caliper. This helps to bleed the air.
Preparation
Place vehicle on a level surface.
529 021 800
Loose n front wheel lug nuts.
Sec ure front of vehicle on jack stands.
Remove front w heels.

A CAUTION Never use any type of impact

wrench for lug nut removal and installation.
The use of impact wrench could damage the Place the pump in vacuum position.
wheel stud threads and lug nuts.
Pump vacuum pump then loosen bleeder.
Renegade Models Pump until no more air bub bles appea r in clea r
Remove clips retaining brake hoses on suspen- hose.
sio n arms (one on each side). Close bleeder.
Rem ove caliper mounting bolts from both front Operate brake lever or brake pedal. If it still feel s
calipers. spongy, bleed system again .
Repeat the procedures until air bubbles do not ap-
A CAUTION Do not let caliper hang by the pear in hose and lever or pedal is stiff.
hose and do not stretch or twist the hose.
Top up reservo irs to the upper level w ith DOT 4
Install each caliper horizontally on the top of its brake fluid.
brake disc.
Install diaphragms and covers on reservo irs.
Secure caliper with a lock ing tie.
Check brakes operation before ridi ng the vehicle.
All Mode/s
Manual Bleeding Procedure
Unscrew the bleeder on the top of rear master
cylin der until brake fluid comes out then close it. Install a clear hose to bleeder.
Place the other end of hose in a small co ntainer
partially filled with clean brake fluid .
Open bleeder. Fil l reservoirs and pump brake
lever or brake pedal until fluid freely flow s out of
the hose .
Pump up system pressu re with brake lever or
brake pedal until a res istan ce is felt .
Maintain pressure on leve r or pedal w hile opening
the bleeder.
NOTE: When bleeder is opened, brake fluid w ill
flow out from the caliper and brake lever or the
1. Bleeder brake pedal will move accordingly.
Retighten the bleeder, then release brake lever or
On each caliper, unscrew the bleeder until the
brake pedal gradually.
brake fluid com es out then close it.
Repeat the procedure until no more air bubbles
Bleed system as per one of the foll owing proce-
appear in hose and lever or pedal is stiff.
dures.
Top up reservoirs to the appropriate level.
Install diaphragm and covers on reservoirs.
vmr2009-035 55
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Check brakes operation carefully before riding the Using a clear hose and the pump reservoir, install
veh icle . the VACUUM/PRESSURE PUMP (P/N 529021 800) to
LH front caliper bleeder.
Brake Fluid Bleeding
(Renegade CE Models)
General Recommendations
Fill reservoirs to recommended level using recom-
mended brake fluid only.
529021 800
Check brake fluid reservoir level often. Do not al-
low the flu id level to drop below the lower mark
during the bleeding process.
For the front brakes , bleed alternately the LH and
RH calipers. Turn handlebar to full RH side when
bleeding right caliper and turn to the LH side for
the left caliper. This helps to bleed the air.
Place the pump in vacuum position.
Preparation Pump vacuum pump then loose n bleeder.
Place vehicle on a level surface. Pump until no more air bubbles appear in clear
Loosen front w heel lug nuts. hose.
Secure front of vehicle on jack stands. Close bleeder.
Remove front wheels. Re peat the same procedure following the proper
bleeding sequence for the other bleeders.
A CAUTION Never use any type of impact Top up reservoir to the upper level with DOT 4
wrench for lug nut removal and installation. brake fluid.
The use of impact wrench could damage the
wheel stud threads and lug nuts. Install diaphragm and cover on RH hand reservoir.
Remove clips retaining brake hoses on suspen- Check brakes operation before riding the ve hicle.
sion arms (one on each side). Manual Bleeding Procedure
Remove caliper mounting bolts from both front The brake system is bled in the following se-
calip ers quen ce:
- Front ca lipers using the RH brake lever
A CAUTION Do not let caliper hang by the
- LH splitter using the LH brake lever
hose and do not stretch or twist the hose .
- RH splitter and rear caliper using the brake
Install each ca liper horizontally on the top of its pedal.
brake disc.
In stall a clear hose to bleeder.
Secure ca liper with a locking tie.
Place the other end of hose in a small container
On each caliper and both splitters. unscrew the partially filled with clean brake fluid.
bleeder until the brake fluid comes out then close
it. Pump brake leve r three or four times and hold
lever while open ing the bleeder.
Top up reservoirs if required.
NOTE : W hen bleeder is opened, brake fluid will
Bleed system as per one of the following proce- flow out from the caliper and the lever will m ove
dures. accordingly.
Bleeding Procedure Using a Vacuum Pump Retighten the bleeder, then release brake lever or
The bra ke system is bled in the following se- brake pedal gradually.
quence: Repeat the procedure until no more air bubbles
- Front calipers appear in hose and lever and pedal are firm.
- LH splitter Top up reservoirs to the appropriate level.
- RH splitter and rear caliper. Install diaphragm and covers on reservoirs.
Check brakes operation carefully before riding the
vehicle.
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRA KES )

PROCEDURES OUTLANDER SERIES

BRAKE LIGHT
REAR BRAKE LIGHT SWITCH SWITCH POS ITI ON
PIN RESISTA NCE

Rea r Brake Ligh t Switch In spection Firmly pushed 1 2 0.2 fl max.

First ensure bra ke light is good . Released 1 2 Infinite (O l )
Ch eck brake light switch for dirt or corro sion.
Make sure it is operat ing properly. RENEGADE MODELS

Dep ress brake pedal and check for brake light to BRA KE LI GHT
PIN RES ISTANCE
turn on. Repeat w ith t he brake lever(s). SWITCH POSITION
Firmly pushed 1 3 0.2 fl max.
Rear Brake Light Switc h Test
Released 1 3 Infi nite (OLI
Outlander Series
Remove t he LH footrest. If switch is defective, rep lace with a new one.
If the switch tests good, verify wire contin uity be-
Renegade Models (except CE)
twee n harness connector and ECM.
Remove the master cylinder cover.
EC M HARN ESS
CONNECTOR CONNECTOR RESI STA NCE
PIN WIRES
8-23 REDIORANGE Close to 0 fl

Rear Brake Light Switch Removal

All Models except Renegade CE
Th e rear brake light switch is located on the rear
master cylinder and it cannot be ad ju sted.

1. Mester cylinder cover

Renegade CE
Remove the LH inner fender.
All Models
Disconnect switch connector.

1. Brake light switch

Renegade CE
The rear brake ligh t switch is located on the LH
splitter and cannot be adj usted
All Models
Disconnect switch co nnector.
OU TLANDER MODEL SHOWN
Drain brake system.
1. Switch connector Unscrew brake light switch from master cylind er
Check switch operation as follows. or sp litte r. Catch spilled f luid with a rag.
Discard sea ling washers.

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Rear Brake Light Switch Installation Unscrew bra ke light swi tch from brake lever then
For installation, reverse the removal procedure. remove it.
Install two NEW sea ling washers . Front Brake Light Switch Installation
For installation, reverse the remova l procedure.
FRONT BRAKE LIGHT SWITCH
Tighten switch screw to 1 Nom (9Ibf oin).
Renegade Models
PARKING BRAKE MECHANISM
Front Brake Light Switch Inspection
First, ensure bulb is not burnt. Parking Brake Mechanism Removal
Check brake light switch for dirt or corrosion. NOTE: The parking brake mechanism is located
Make sure it is operating properly. on the LH brake handle.
Depress fr ont brake lever and check for brake light Unscrew nut under LH bra ke leve r.
to turn on. Re move screw , spring and brake lever lock.

Front Brake Light Switch Test 3

Disconnect switch connectors.

UNDERN EATH RH BRAKE LEVE R

1. Swirch connectors
2. Brake light switch
V07K07A 4 2
Check switch operation as follows. 1. Brake lever lock
2. Spring
BRAKE LIGHT 3. Screw
PIN RESISTANCE
SWITCH POSITION 4. Nut

Firmly pushed Switch 0.2 n max. Parking Brake Mechanism Installation

Released pins Infinite lOLl For installation, reverse t he removal procedure.
If switch is defective, replace with a new one. See the follow ing illustration to install the spring
properly.
If the switch test good, verify wire continuity be-
tween brake light switch and ECM .
ECM
BRAKE LIGHT
CONNEC1OR RESISTANCE
SWITCH PIN
PIN
B-23 RED/ORANGE Close to 0 n

Front Brake Light Switch Removal

The front brake light switc h is located underneath
the RH brake lever and it cannot be adjusted.
Disconnect switch conn ectors.

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

FRONT MASTER CYLINDER

Front Master Cylinder Removal
Remove master cylinder cover and its diaphragm
then drain brake fluid until front master cylinder
reservoir is empty.
Remove banjo fitting and sealing washers retain-
ing brake hose to front master cylinder. Discard
the sea ling washers.

BRAKE LEVER
Brake Lever Removal
Remove the parking brake mechanism (LH brake
handle only).
Unscrew the brake lever nut.
vmr2008-011·011. "
Remove the screw and the brake lever.
TYPICAL - RH MASTER CYLINDER SHOWN
1. From master cylinder
2. Banjo fitting
3. Sealing washers

When removing RH master cylinder, unplug brake

"F=='----- 1 light switch connectors.
Remove screws from master cylinder holder and
remove master cylinder from handlebar.

V07K09A

1. Brake lever
2. Screw
3. Nut
TYPICAL - RH MASTER CYLINDER SHOWN
7. Holder screws
Brake Lever Inspection
Check brake lever for bending, cracks or other Front Master Cylinder Disassembly
damages. Replace if necessary. Remove brake lever.
Brake Lever Installation Remove piston boot, snap ring, piston and spring .
For installation, reverse the removal procedure. Front Master Cylinder Inspection and
Lubrication
Discard any remaining fluid inside reservoir.
Clean reservoir, piston and master cylinder thor-
oughly with clean brake fluid.
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Check:
- Boot for crack
- Spring for damage
- Pi ston cup for wear, deterioration or damages
- Master cylinder and piston for scoring,
scratches or other damages.
Change part(s) if necessary.
Check if t he end ca p O-ring is brittle, hard or dam-
aged.
NOTE: If master cylinder housing is damaged or
leaking, replace as an assembly.

Front Master Cylinder Assembly

Coat piston and piston cup s with clean brake fluid.
In stall spring onto piston.
Connect brake hose to ma ster cylinder w ith a
Install piston into ma ster cyli nder. Banjo fitting and NEW sealing w ashe rs.
Install the snap ring into groove in the master Bleed brake system.
cylinder
Check for lea ks and ma ke sure the brakes ope rate
Install boot into master cylinder and the groove in normally before driving.
piston.
Apply DIELECTR IC GREASE (PIN 293 550 004) to the REAR MASTER CYLINDER
brake lever contacting surface of the piston .
Rear Master Cylinder Removal
Install brake lever and loc king mechanism.
Drain brake fluid .
Appl y DIELECTRIC GREASE (PIN 293 550 004) on
lever pivot bolt. Outlander Series
Remove LH and RH footrests .
Front Master Cylinder Installation
For the installation , reve rse the removal proce- Renegade Models
dure, pay attention to the followin g details. Remove the master cylinde r cover.
Place the brake lever assembly on the handlebar All Models
Position cylinder holding bracket w ith the UP mark Unplug brake switch connecto r (except Renegade
upward. CEI
Install screws and tighten loosely. NOTE: At this time , check hoses and fittin gs for
W ith the handlebar in straight ahead position, damages or leaks.
position cylinder re servoir parallel to the ground. Disconnect reservoir flexible hose and plug the
Tighten upper screw first. end to avoid brake fluid spillage .
Unscrew brake light switch from master cylinder
(except Ren egade CEI Discard sealing w ashers.

60 vmr20 09·035
 www.midwestmanuals.com
Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Rear Master Cylinder Inspection and

Lubrication
Discard an y remain ing fluid inside reservoir.
Clean reservoir, piston and master cylinder thor-
oughly w ith clean brake fluid.
Check :
- Boot for crack
- Spring for damage
- Pi ston cup for wear, deterioration or damages
- Master cylinder and piston for scoring ,
scratches or other damages.
1. Brake switch
2. Reservoir hose Change part(s) if necessa ry
3. Rear hose
Check the push rod lock for excessive wear, re-
Unscrew front hose from master cylinder. place if nece ssary.
Unhook push rod from brake pedal. Check if the end cap O-ring is brittle, hard or dam-
Remove bolts retaining master cylinder to the aged .
frame. NOTE: If maste r cylinder housing is damaged or
leaking, replace as an assembly.

Rear Master Cylinder Assembly

Apply XP-S SYNTHETIC GREASE (PIN 293 550010)
on both ends of push rod.
Install the push rod, the snap ring and the boot.
If push rod yoke has been removed, reinstall it
then adjust push rod length, see the following il-
lustration.

1. From hose
2. Push rod lock
3. Master cylinder bolts

Rear Master Cylinder Disassembly

Remove the end cap, the spring and the piston.

V07KOIA

V07KOHA 3 2 1 A. 44 1: 1 mm (1.732 ± .039 in)

1. End cap
2. Spring Coat piston and piston cups with clean brake fluid.
3. Piston
The spring is conical. Install the smaller end on
Remove the boot, the snap ring and the push rod. piston.
Insert piston in the master cylinder.

vmr2009-035 61
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

V07KOJA

Install the end cap . Do not forget the O-ring.

FRONT CALIPER - OUTLANDER SERIES
Rear Master Cylinder Installation ,. Retaining screw

Insta ll master cylinder to frame .

Hook push rod on brake peda l.
Connect front hose on master cylinder.
Connect reservoir flexible hose.
Install the rear hose and the bra ke light switch
with two NEW sealing w ashers (except Rene-
gade CE)
Connect brake light switch connector (except
Renegade CEI
Fill up reservoir w ith clean brake fluid
Bleed brake system.
Check for leaks and make sure the brakes operate FRONT CA LIPER - RENEGADE MOOELS
normally before driving.

CALIPER
Caliper Removal
Loose n wheel lug nuts.
Raise vehic le and support it securely.
Remove appropriate wheel.
Remove the caliper screws then the caliper. If the
caliper is not being removed from the vehicle as
during brake pad replacement, simply hang the
caliper with a piece of w ire to ta ke the weig ht off
the brake hose.

A CAUTION Do not let caliper hangs by the REAR CALIPER - ALL MODELS
,. Remove banjo fitting and sealing washers
hose and do not stretch or twist the hose. 2. Unscrew bolts

If the caliper is being removed for replacement, Catch spilled fluid with a rag . Attach the brake
drain bra ke system before removing the Banjo fit- hose in a pos ition to prevent the f luid from flow-
ting and its sea ling washers . Remove the caliper ing out.
from the ve hicle .
Discard all sealing washers.

Caliper Disassembly
Remove brake pads, see further in this section.
62
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Remove slide caliper support and pad spring Check for leaks and make sure the bra kes operate
Place rag over piston. normally before driving.
Place caliper body wi th piston down and apply
small squirts of air pressure to the fluid inlet to BRAKE PADS
remove pisto n. Brake Pads Removal
Raise vehicle and support it securely.
Remove appropriate whee l.
Loose n pad pins .

Rem~epi sronwal. 3

A CAUTION Be careful not to damage pis-

ton sliding surface.
Clean piston grooves, caliper cylinder and piston
with clean brake fluid.
Clean slide pins with bra ke cleaner and a rag.

Caliper Inspection
If boots are deteriorated or hard, replace the
caliper.
Check caliper cylinder for scratches, rust or other
damages. If so, replace caliper.
Check piston for sc ratches, rust or other dam-
ages. If so, replace caliper.

Caliper Assembly V07KOMA 2

Coat piston seal with clean brake fluid and install , . Pad pins
2. Caliper
it into piston grooves in caliper. 3. Pad
Coat piston w ith clean brake fluid and install into Remove caliper from its supp ort or from knuckle.
cylinder w ith the closing toward caliper body
Unscrew pad pins then remove pads. Discard pad
Apply DIELECTRIC GR EAS E (PIN 293 550 004) into pins.
sliding bores and install slide pins .
NOTE: Ma ke sure that rubber boots are correctly A CAUTION Do not let the caliper hang by
installed in slide pins grooves. the hose and do not stretch or twist the hose.
Install pad spring, caliper bracket and pads.
Brake Pads Inspection
Caliper Installation
For the installation, reverse the removal proce- A CAUTION Do not clean brake pads in
dure, pay attention to the following details. petroleum based solvent. Use brake system
cleaner only. Soiled brake pads must be re-
Use NEW sealing washers wh en installing banjo placed with new ones.
fitting retaining brake hose to caliper.
Measure brake pad lining thickness.
Install ca liper in its origi nal position.
Brake pads must be replaced when lining is 1 mm
Torque screws in accordance with the follow ing (1 (32 in) thick or less, or look the hollow places on
table. both sides on the pad lining.
MODELS TORQUE There are four hollow places on one set of brake
OUTLANDER SERIES 34 Nom (25Ibf oft) pads When the pad wear reach es one of the hol-
low places, the pad must be changed even if the
RENEGADE MODELS 24 Nom (18lbfoftl pad w ear does not reach another hollow place.
Bleed the brake system.
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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

NOTE: Be careful not to damage pads and make

~1
su re pads are correctly in serted in their location.
Aft er the job is completed, firml y depress the
brake lever a few tim es to bring the pads in co n-

V02KOFA
W tact w ith the disc.
Check for leaks and make sure the brakes ope rate
normally before driving. Th e pads must rest flat
1. Hollow place on the disk.

BRAKE PAD MINIMUM BRAKE DISC

1 mm (1/32 in!
THICKNESS
Brake Disc Inspection
A WARNING Brake discs can be inspected without removing
Avoid getting oil or grease on brake pads . th em from the vehicle.
Contaminated brake pads can affect stopping Raise vehicle and support it securely. Remove
capacities. w heels and visu ally in spect di sc surfaces for
scratches or grooves. Make su re to check both
A CAUTION Brake pads must always be re- sides of di sc.
placed in pairs. Measure thickness of the disc.
Brake Pads Installation DISC MINIMUM THICKNESS
Clea n the visible portion of piston with clean brake FRONT 3.5 mm (. 138 in!
fluid.
REAR 4.3 mm (.169 in!
Push cal iper pi stons inward before installing brake
pad s Replace disc if not within specifications .
NOTE: Use a C-clamp or another suitable tool. To
avoid damaging the piston, use an old pad t o pu sh A CAUTION Brake discs should never be
it into th e ca lipe r. machined.
Make surR that pad spring is in pos ition . Turn the disc by hand and che ck w arpage.
MAXIMUM DISC WARPAGE
FRONT
0. 2 mm (.0 1 in)
REAR

Brake Disc Removal

Front Brake Disc
Outlander Series
Apply parking brake and raise the front of the ve-
hicle .
Remove the appropriate wheel.
\!02K06A 2 Remove w heel hub. Refer to FRONT DRIVE
1. Pad spring
2. Piston On Outlander 650 and 800 series , remove the
shock absorber
Install new brake pad s.
Separate knuckle from low er sus pensi on arm.
Install NEW pad pins by pushi ng in the pad s
Remove drive shaft from kn uckle.
against pad spring to align pad slots in the pads
and ca liper body. Attach uppe r suspension arm or strut out of way.
Install brake calipe r so the disc is positioned be- Unscrew brake disc screws .
tween pads. Keep the Bellevi lle w ashers

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Release parking brake and remove calipe r. Su s-

pend caliper out of the way.

A CAUTION Do not let the caliper hang by

the hose and do not stretch or twist the hose.
Remove bra ke disc. Pay attention not to cut the
CV boot.
Renegade Models
1. Differential protector
Remove appropriate w heel.
Remove the differential bolts.
Remove calipe r as de scribed previous ly. Do not
disconnect brake hose fr om ca liper. Loosen hitch plate bolts.
After removing the caliper. suspend it out of the Move the differential backward .
way. Disconnect prope ller shaft from differential.
Unscrew brake disc screws. Heat up brake disc
A CAUTION Do not let the caliper hang by around screws to facilitate removal. Discard brake
the hose and do not stretch or twist the hose. disc screws.
Remove whee l hub w ith brake disc. Refer to
FRONT DRIVE Brake Disc Installation
Heat up brake disc around screw to break the Front Brake Disc
threadlocker. Remove and discard bra ke disc
screws . Renegade Models
The installation is the reverse of the removal pro-
cedure.
Outlander Series

1>,
The installation is the reverse of rem ova l proce-
dure. Howeve r. pay attention to the following de-
tails.
Do not forget Belleville w ashers when installing

• brake disc screws. Place the concave side of

was hers towards brake disc.

vm ,2007·058-00 5_,

1. Brake disc screws

2. Brake disc
Tighten brake di sc screws to 38 Nom (28Ibf oft) in
Rear Brake Disc a criss-cross sequence.
Remove rear w heels. Rear Brake Disc
Remove the caliper and suspend it out of the way.
All Models
A CAUTION Do not let the caliper hang by Install brake disc on propeller shaft and tighten
the hose and do not stretch or twist the hose. NEW screws to 34 Nom (25Ibf oft) in a criss-cross
sequence.
Unscrew and remove the rea r propeller shaft
screw from differential.
Remove the differential protector.
BRAKE PEDAL
Brake Pedal Removal
Remove RH footwell.
Detach the return spring from the brake pedal.
Open the master cyl inder push rod hook.

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Remove all brake hoses from the splitter and dis-

card sealing washe rs.

A CAUTION When hoses are disconnected,

cleanliness must be observed. Clean all parts
before disassembly.
To remove the LH splitter, unplug the brake light
switch connector.
Unscrew splitter retaining screw s. Do not remove
screw s yet.
Place your hand under the splitter to catch both
shims . Shims are located betw een splitter and
3
frame.
V07KONA 2
Pull the splitter to remove it.
7. Return s pring
2. Push rod hook W ipe up any brake fluid spillages .
3. Brake pedal

Remove bolt retaining the brake pedal to frame . Brake Circuit Splitters Installation
The installation is the reverse of the removal pro-
cedure . However, pay attention to the following.
Install shims behind splitters.
Apply LOCTITE 243 (BLUEI (PIN 293 800 0601 on
thread s of splitter screw s.
Install splitters and tighten screws to 10 Nom
(89 Ibf o in).
Using NEW sealing w ashers, connect brake
hoses. Use the next illustrations to position
hoses correctly.

1. Brake pedal bolt

2. Brake pedal

Brake Pedal Inspection

Check brake pedal for cracks or distortion .
Check if O-rings are brittle, hard or otherwise dam-
aged.
Replace any defective parts.

Brake Pedal Installation

For installation, reverse the removal procedure . vmr2009-03S-00A -,

RH SPLITTER
Apply XP-S SYNTHETIC GREASE (PI N 293 550010) 1. Towa rd front calipers
on both O-rings and into brake pedal. 2. From AH lever
3. From LH spfitter

BRAKE CIRCUIT SPLITTERS

(RENEGADE CE MODELS)
Brake Circuit Splitters Removal
Remove LH or RH inner fender. Refer to BODY
section.
Drain brake fluid . Refer to BRA KE FLUID DRA IN-
ING at the beginning of this section .

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Section 11 BRAKES
Subsection 01 (FRONT AND REAR BRAKES)

Brake Hoses Installation

Install the new hose.
Make sure the piece w ill not rub against any other
part
When there is a banjo fitting se curing the hose to
the caliper or to the master cylinde r, alw ays re-
place the sealing w ashers with new ones.

LH SPLITTER
1. From LH lever
2. From RH splitter
3. From rear master cylinder
4. Toward rear caliper
5. Brake light sw itch

Tighten all Banjo fittings to 28 Nom (21 Ibfoft).

Refill and bleed the system. Refer to BRAKE
FLUID at the beginning of this section .
Connect the brake light switch.
Install all other removed parts.

BRAKE HOSES
Brake Hoses Inspection
Brake hoses should be inspected frequently for V07KOPA 1
leaks and damages. FRONT MASTER CYLINDER SHOWN
1. Banjo fitting
Check if the hoses are crushed or damaged. Any 2. Sealing washers
deformation can restrict the proper flow of fluid
and cause braking problems. Install any retaining clips or brackets .
Check hoses for cracking or scrapes . This damage Refill and bleed the system.
can cause hose failure under pressure.
When hoses are removed or disconnected, clean-
liness must be observed. Clean all joints and con-
nections before disassembly. New hoses should
be cleaned w ith brake fluid before installation to
remove any contamination .
Replace any defective parts.

Brake Hoses Removal

NOTE: Before removing any hoses, drain brake
system.
Remove all necessary parts to reach the hoses.
Thoroughly clean the area around the joints that
will be disconnected.
Place a drain pan under the joint that will be dis-
connected .
Disconnect any retaining clips or brackets holding
the hose and remove the defective part(s).

vmr2009'()35 67
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68
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Section 12 BODY/FRAME
Subsection 01 (BODY)

BODY
OUTLANDER (500 AND 650)
Body Parts (Front View)

4.5 N' m
(40 Ibfoin )

2.5 N'm
(22 Ibfoin )

20 N· m .-==::g;tflJ::DJ.~
(15Ibfoft)

20 N'm
(15 Ibfoft)

2. 5 N'm
(22 Ibfoin )

"""'""- 2.5 N· m
8 N'm (22 Ibf'in )
(71 Ibfoin )
 www.midwestmanuals.com

Section 12 BODY/FRAME
Subsection 01 (BODY)

Body Parts (Rear View)

4.5 N'm
(40 Ibf'in)
. - -1- - / 1

~ 2.5N·m
(22 Ibf'in)

4.5N·m
(40 Ibf'in )
--
~- - ~ 4.5 N'm
(40Ibfoin)

24 N'm
(18Ibfoft)

70 vmr2009-036
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Section 12 BODY/FRAME
Subsection 01 (BODY)

Body Parts (Side View)

OUTLANDER MAX
OUTLANDER MAX XT

". I
i
OUTLANDER
OUTLANDER XT

:_l----::/,- 5.5 Nom

(49Ibfoin)

5.5 Nom
(49 Ibfoin) -=---,

vmr2009.Q36 71
 www.midwestmanuals.com
Section 12 BODY/FRAME
Subsection 01 (BODY)

Seat

OUTLANDER
OUTLANDER XT

!._ 6.5 N'm

, I' (58Ibfoin)
,I

OUTLANDER MAX
OUTLANDER MAX X T

-~4.5N.m
~ (40 Ibf'in)
I
9
9§ 10N'm
~~ (89 Ibfoin)
§» '" 6.5 N'm
(58Ibfoin)

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 www.midwestmanuals.com
Section 12 BODY/FRAME
Subsection 01 (BODY)

XT Package

11 N'm
r(97 Ibfoin)
./ 25 N'm
(18Ibfoft)
11 N'm
(97 Ibfoin)

'Loct~t~~
243 Yel~--'v'"
25 N'm 25 N'm

~
(18 Ibfoft) (18 Ibfoft)

-
'l-':::"'-_
.
~ 2.5 N'm
(22Ibfoin)
::-~-~ 16N'm \
(142 Ibfoin )
25 N'm
(18 Ibfott)

2.5 N'm
(22 Ibfoin)

~. 8 N'm
".---:7(71 Ibfoin)

( ~ 11 N'm
'" (97Ibf~

,
2.5 N'm
4.5 N'm
(40 Ibfoin)
(22 Ibf'in)

vmr2009-036 73
 www.midwestmanuals.com
Section 12 BODV/FRAME
Subsection 01 (BODY)

OUTLANDER (800R)
Body Parts (Front View)

2.5 N'm
(2 0 Ibfoin )
4.5 N'm_;
(40lbfoinl

20 N'm
(15IbHtl""""'l~~~

20 N' m
(15Ibfoft)

~
2'5N.m ~~~
(22Ibf';n) . 80 N'm
.~ • ./ . - (71 Ibfoinl

~
I '. .. /. '
. 2.5 N'm
• (22 Ibf';n)

vml2009 ·036.002 _a

74 vm r2009-Q36
 www.midwestmanuals.com
Section 12 BODY/FRAME
Subsection 01 (BODY)

Body Parts (Rear View)

~ 2,5 N-m
+- (22Ibfoin )

L 4,5N-m
(40 Ibfoin )

25 N-m 1
(18 Ibfoft)~ 25 N-m
~(18 Ibfoftl

"m f2009~36 75
 www.midwestmanuals.com
Section 12 BODY/FRAME
Subsection 01 (BODY)

Body Parts (Side vy'e w)

OUTLANDER MAX
OUTLANDER MAX XT

OUTLANDER
OUTLANDER XT

!~---?-- 5.5 N'm

(49Ibfoin)

5.5 N'm .......--:

(49Ibfoin )

76 vmr2009-036
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Section 12 BODY/FRAME
Subsectio n 01 (BODY)

Seat

OUTLANDER
OUTLANDER XT

! ._ 6.5 N-m
I' (58 Ibf.in )
.I

OUTLANDER MAX
OU TLANDER MAX XT

-~4. 5N-m
~ (40IbHn )
I
e
e~
. n ~ 10N -m
(89 IbH n )
t(;l §;> '" 6.5N-m
(58Ibf.i n )

vm r2009{)36 77
 www.midwestmanuals.com
Sectio n 12
Subsection 01BODYJFRAME
(BODY)

XT Package

11 N'm

4I ~
r{S7lbfoin)

(
s1Ib
N'm
foi n ) i .~r...,5'.-<!f.J..1>i
' 2 5 IN'm
(18 bfoft)
__ 11N·m
(97 Ibfoin)

(9 lbfoin~
1 N'm .1\
\ I

25 N'm 8 N' m
(18 lbfoft)
(7 1 I ~foin )<:.

{Y ~. ~
~
11 N' m
(97 Ibfoin )
16N' m II J -
~
~.~.. 8N ' m
(71Ibf' in )

~
( o·
2.5 N'm
(22 Ibfoi n )

25 N' m
(18 I bfoft )~:::.-_..<Ii'() i~N~
i
Loctite 243

_
____________________________ ~~40· 51IN.m
(40 Ibfoin )

78 IImr2009-036
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Section 12 BODY/FRAME
Subsection 01 (BODY)

RENEGADE MODELS
Body Parts (Front View)

25 N'm
25 N' m (18Ibf·ft)
Loctite (18I bf·ft)
243 Ii

1.5 N'm
(13Ibfoin)
t
I
~ (131.5N·m
2 N· m '----AI
(22 IbNn)
Ibfoin )
1.5 N'm
(13Ibfoin)
2.5 N'm
(22 Ibloin)
I

.J
/
2.5 'm
(22 Ibfoi n ) fl 4.5 N'm
1 (40 Ibfoin )

1.5 N'm
4.5 N' m (13IbNn )
(40 Ibfoin)
.--.~~
\~ ./ '. 1!.. 5 N'm
2.5 N'm 1.5 N' m i (44Ibfoin )
f
.A
(22 Ibfoi n ) ty"",.-= (13 Ibloi n ) '"
2 5 N'm 2.5 N'~
(22 Ibfoin ) (22 Ibf' rn )

vmr20 09-{)3 6 79
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Section 12 BODV/FRAME
Subsection 01 (BODY)

Body Parts (Rear ~'ew)

European Commun ity Models

r- -- - - -- -- - - - ----- - - - - - - - - - - - - l

20 Nom
(15IbHt)

4.5 Nom
(40 Ibfoin )---++ 4.5 Nom
i '
2.5 Nom
(22 IbNn ) '1
L
1~ 25Nom
(40 Ibfoi n )

4,5 Nom (18IbHt)

(40Ibfoi n )
25 Nom
(18 Ibfoft )

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Section 12 BODY/FRAME
SubsectionOl (BODY)

Body Parts (Side View)

RH side LH side

~
. ~

~
I .-h'~
I
I

5.5 N'm
(49 Ibloin)

5.5 N'm
(49 Ibl'in)

vmI2009-036 81
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Section 12 BODY/FRAME
Subsection 01 (BODY)

Seat

6.5 N'm
~-(58 Ibloin )

82 vmr200 9'{) 36
 www.midwestmanuals.com

Section 12 BODY/FRA ME
Subse ction 01 (BODY)

GEN ERAL
Refer to th e 2008 SHOP MANUAL (PIN 219 100
273) fo r topics not covered in this section.

PROCEDURES
CENTRAL PANEL
Central Panel Removal
Outlander Series

Renegade Models

1. Central panel

Re move seat(s) .
Come off the plastic studs from t he grommet s.

1. Central panel

Remove seat.
Lift the front part of the centra l panel.

Pull central pane l to separate its tabs from front

fender.

, . Lift here

Come off the plastic st uds from the grom mets.

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Section 12 BODY/FRAME
Subsection 01 (BODY)

Remove scre ws that attach the heavy duty

bumper to the rack .

Remove centra l panel.

Central Panel Installation

Remove the heavy duty bumper.
The installation is the revers e of the removal pro-
cedure. Rear Bumper

HEAVY DUTY BUMPER

Outlander XT Package

Bumper Removal
Front Bumper

vm,2009<13&.O'2

TYPICAL - OUTLANOER MAX BOOR XT SHOWN

Unscrew bolts retaining the rear heavy duty

bumper to the rear bu mper.
Remove screws that attac h the heavy duty
bumper to the rack.
vm r'2009..036-011

TYPICAL - OUTLANDER MAX BOOR XT SHOWN

Remove bo lts retaining the heavy duty bumper to

the front bumper.

Bumper Installation
The installa tion is the reverse of the removal pro-
cedure.

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Section 12 BODY/FRAME
Subsection 01 (BODY)

FRONT BUMPER/FRONT SKID

PLATE/FRONT FASCIA
Removal
Outlander Series

1. Front bumper screws

Remove front bumper w ith fron t skid plate an d

front fascia assembly.
Disassemble all parts if necessa ry.
Renegade Models
TYPICA L - OU TLAN DER MAX BOOR SHOWN Unscrew bolts securing the front bumper to the
On XT models, remove hook at the end of w inch bumper bracket.
cab le and the front heavy duty bumper.
Remove front fender.
Unplug headlamps connectors .
On CE models, unplug director indicators con nec-
tors.
Unscrew bolts that atta ch front bumper to fender
support.

1. Upper bumper bolts

2. Front bumper
3. Bumper bra cket

Unscrew bolts retaining the bottom of front

bumper to frame.

Unsc rew bolts retaining the bottom of bu mper to

frame.

"maOO7 .(1S9-() l l~.

1. Lower bumper bolt

2. LH tower suspension arm
3. Front bumper

Remove front bumper.

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Section 12 BODY/FRAME
Subsection 01 (BODY)

Installation
The installation is the re ve rse of re mova l proce-
dure.
Outlander Series
Install a washer under each plastic rivet located at
the both ends of fa sc ia.

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Section 13 TECHNICAL SPECIFICATIONS

Sub section 01 (OUTLANDER)

OUTLANDER
OUTLANDERTM OUTLANDERTM OUTLANDERTM
MODEL
500 650 BOOR
EN GINE
ROTAX® V490 ROTAX® V660 RO TAX® V81 0
Engi ne type
4·stroke, Single Over Head Camshaft (SOHe), liquid cooled
Number of cylinders 2
Number of valves 8 valve s (mechanical adjustment)
Bore mm (in) 82.03 (323) 91 (358)
Stroke mm (i n) 47.3 (186) 615 (2.42)
Displacement cm' (in') 500 (3051 ) 650 (39 67) 800 (4882)
Compression ratio 10.7:1 10.3: 1 10.3: 1
Decompressor type NA
Maxi mum HP RPM RPM 7250
Type Wet sump. Rep laceable oil filter
Oil filter BRP Rotax paper type, replaceable
Engine oil
Minimu m 350 kPa (51 PSI) at 6000 RPM
Lubrication pressure
Capacity (oil change
2 L (211 quart s)
wi th filter)
Engine oil
SAE 5W30 API cl assification SM, SL or SJ
Recommended
see OIL VISCOSITY CHART in LUBRICATION SYSTEM
Intake valve opening 3' BlDC 5' BlOC 5' BlOC
Intake valve closing 34' A8DC 45' ABOC 45' ABDC
Exhaust valve opening 39' BB DC 50' BBDC 55' BBDC
Exhaust valve closing 2' ATOC 0' AlOC 5' ATDC
Chain tensioner plunger protrusion Service limit mm (in) 20.0 (7874)
Intake mm (in) 0.06 to 0.14 (.0024 to .0055)
Valve clearance
Exhaust mm (in) 0.1 1 to 0.19 (0043 to 0075)
New mm (in) 4.966 to 4.980 (1955 to .1 960)
Intake
Service limit mm (in) 4.930 (1941)
Valve stem diameter
New mm (in) 4956 to 4.970 (.1951 to 1957)
Exhaust
Service limit mm (in) 4.930 (1941 )
Intake and New mm (in) 0.005 (0002)
Valve out of rou nd
exhaust Service limit mm (in) 0.06 (0024)
New mm (in) 4.998 to 5 018 ( 1968 to 1976)
Valve guide diameter
Service limit mm (in) 5.050 ( 1988)
New mm (in) 40.81 (1607)
Valve spring free length
Service limit mm (in) 39.00 (1535)
New mm (in) 1.05 to 1.35 (04 1 to 053)
Intake
Service limit mm (in) 18 ( 070)
Valve seat contact width
New mm (in) 1.25 to 1.55 (049 to 061)
Exhaust
Service limit mm (in) 2 ( 078)

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Section 13 TECHNICAL SPECIFICATIONS
Subse ction 01 (OUTLANDER)

OUTLANDERTM OUTLANDERTM OUTLANDERTM

MODEl
500 650 800R
ENGINE (cont'd)
New mm (in) 12.036 to 12.050 (.4739 to .4744)
Rocker arm bore diameter
Service limit mm (in) 12060 (.4748)
New mm (in) 12000 to 12.018 (,4724 to A731)
Rocker arm shaft diameter
Service limit mm (in) 11.990 (.4720)
81.950 to 81.966 90.950 to 90.966
New mm (in)
Piston measurem ent (3.2264 to 3.2270) (3.5807 to 3.5813)
Service limit mm (in) 81.850 (32224) 90.850 (3 577)
New mm (in) 0.057 ( 0022) 0.027 (0011 )
Piston/cylinder clearance
Service limit mm (in) 0.1 30 (,0051) 0.100 (,0040)
1" Upper compression ring, rectangular
Piston ring type 2" Lower compression ring, tapered fa ce
3"' Oil scraper ring
Rectangular 0.20 to 0.40 (.008 to .016)
Tapered face New mm (in) 0.20 to OAO (,008 to 016)
Ring end gap
Oil scraper ring 0.20 to 070 (,008 to .028)
All Service limit mm (in) 15 (,059)
Rectangular 0.03 to 0.070 (.0012 to 0028)
Tapered face New mm (in) 0.02 to 0.060 (.0008 to .0024)
Oi I scraper ring 0.01 to 0.01 B (0004 to .0007)
Ring/piston groove cl earance
Rectangular 0.15 (,0059)
Tapered face Service limit mm (in) 0.15 (.0059)
Oil scraper ring 0.25 (,0098)
82.023 to 82 037 90.993 to 91.007
Cyl inder bore New mm (in)
(3.2292 to 32298) (3.5823 to 3.5829)
Maximum
mm (in) 0038 (,00 15)
Cylinder taper New
Service limit mm (in) 0090 (.0035)
Maximum
mm (in) 0.015 (.0006)
Cylinder out of round New
Service limit mm (in) O.OZO (,0008)
Timing chain New mm (in) 34.959 to 34.975 (13763 to 13770)
Camshaft main bearing side Service limit mm (in) 34.950 (13760)
iourna l New mm (in) 21.959 to 21.980 ('8645 to .8654)
Spark plug side
Service limit mm (in) 21 .950 (.8642)
Timing chain New mm (in) 35.000 to 35.025 (137S0 to 1. 3789)
Camshaft main bearing side Service limit mm (in) 35040 (13795)
journal bore
Spark plug side
New mm (in) nooo to 22.021 (,8661 to 8670)
Wear limit mm (in) ZZ.040 (.8677)
31.830 to 32030 32. 11 to 3Z 3 1 32 950 - 33.150
New mm (in)
Intake valve (1.2531 to 12610) (1.2642 to 1.2721 ) (1.2972- 13051)
Service limit mm (in) 31.810 (1.2524) 32.09 (1 .2634) 32.870 (1.2941)
Camshaft lobe
31730 to 31.930 31.94 to 3Z.14 32.950 - 33. 150
New mm (in)
Exhaust va lve (1.2492 to 12571) (1.2575 to 12654) (1 .2972- 13051)
Service limit mm (in ) 31710 (1.2484) 31 .92 (12567) 32 930 (1.2965)

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Section 13 TECHNICAL SPECIFICATIONS

Sub sect ion 01 (OUTLANDER)

OUTLANDERTM OUTLANDERTM! OUTLANDERTM

MODEL
500 650 . 800R
,ENGI NE (conl'd )
Crankshaft ma in journal diamete r MAG/PTa New mm (in) 42.024 to 42.040 (16545 to 1. 655 1)
side Service limit mm (in) 42 .000 (1.6535)
Crankshaft radial play MAG/PTO side Service limit mm (in ) 0.07 (0031)
Crankshaft main jou rn al diameter PTa support New mm (in) 34.024 to 34.040 (13395 to 13402)
bearing Service lim it mm (in) 34.01 0 (13390)
Crankshaft rad ial play PTO support bea ring Service limit mm (in) 0. 10 (0039)
35.064 to 35.0BO 40.009 to 40.025
New mm (in)
Crankshaft pin diameter (13805 to 13811) (1.5752 to 15758)
Service lirnit mm (in) 35050 (13800) 39.990 (1 5744)
Crankshaft deflecti on MAG/PTO side New mm (in) 0.050 ( 002)
Crankcase plain bearing MAG/PTa side Service limit mm (in) 42.100 (1 6575)
PTa cover plain bearing Service limit mm (in) 34. 120 (1 .3433)
Connecting rod big end diameter Service limit mm (in) 35.150 (13839) 40.100 (1.579)
Connecting rod big end radial play Service limit mm (in) 0.09 (0035)
New rnrn (in) 0.200 to 0.500 (008 to .020)
Connecting rod big end axial play
Service limit mm (in) 0.600 (024)
18.010 to 18.020 20.01 0 to 20.020
New mm (in)
Connecting rod small end diameter (7091 to .7095) (.7878 to .7882)
Service limit mm (in) 18.060 (7110) 20.060 (.7898)
17 .996 to 18.000 19.996 to 20.000
New mm (in)
Piston pin diameter (.70B5 to .70B7) (.7872 to .7874)
Service limit mrn (inl 17.980 (7079) 19.980 (7866)
Connecting rod/piston pin clearance
Service limit mm (in) 0.080 (0035)
(radial play)
GEARBOX
Type Dual range (HI-LO) with park, neutral and reverse
Capacity 400 ml (14 U.S. OZ)
Gearbox oil
Recomrnended XP-S chaincase oil
New mm (in) 0.10 to 0.20 (.0039 to 0079)
Output sha ft backlash
Service limit mm (in) 0.25 (009B)
New mrn (in ) 0.02 to 0.15 (OOOB to 0059)
Bevel gear axial play
Service limit mm (in) 0.1 9 (0075)
New mm (in) 5.25 to 5.35 ( 207 to 2 11)
Shifting sleeve groove width
Service limit mm (in) 5.50 (217)
New rnm (in) 4.95 to 5.05 (195 to 199)
Sh iftin g fork claw thickness
Service lirnit mm (in) 4.BO ( 189)
Shift fork claw thickness New mm (in) 4.80 to 4.90 ( 189 to 193)
(for high gear shifting) Service li mit mm (in) 4.70 ( 185)
Shift fo rk cl aw thickness New mm (in ) 5.10 to 5.20 (201 to 205)
(for low/reverse gear shifti ng) Service lirnit mm (in) 500 (197)
New mm (in) 6.920 to 6.970 (272 to .274)
Shift fork pin diameter
Service limit rnm (in) 6.B50 (270)

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Section 13 TECH NICAL SPECIFICATIONS

Subs ection 01 (OUTLANDER)

MODEL
OUTLANDERTM I OUTlANDERTM I OUTLANDERTM
500 650 BOOR
ENGI NE (conl' d)
Gap of shi ft fork engagement groove New mm lin) 5.00 to 5.10 ( 197 to 201)
Ihigh gear shifting) Service limit mm (in) 5.20 (205)
Gap of shi ft fork engagement groove New mm lin) 5.30 to 5AO (.209 to 213)
(Iow/reverse gea r shihing) Service limit mm (in) 5.50 (2 17)
New mm lin ) 29.000 to 29013 (114 17 to 11422)
Diameter free pinions
Service limit mm (in) 29.015 (11 422)
New mm lin) 24.979 to 25.000 1.983 to .984)
Intermediate gear shaft
Service limit mm (in) 24.977 (983)
Right side 17.990 [708)
Free pinion
Countershaft Service limit mm (in) 24.970 (.983)
bearing
CVT side 24.970 (.983)
Free pinion
Bevel gear shah Servi ce limit mm (in) 24.984 (984)
bearinq
COOLING SYSTEM
Ethyl glycol/wa ter mix 150% coolant, 50% water).
Type Use premixed coolant sold by BRP (PI N 219 700 362) or
Coolant coolant specifically designed for aluminum engines
Capacity L (Quarts) 2.9 (306)
Thermostat Open ing temperature °C (OF) 65 (149)
kPa
Rad iator cap opening pressure 11 0 (16)
IPSI) -
ELECTRI CAL SYSTEM
Magneto generator ou tput 400 W @ 6000 RPM
Ignition system type 101 !Inductive Discharge Ignition)
Ignition timing Not adjustable
Quantity 2
Spark plug Make and type NGK DCPR8E
Gap mm (in) 0.6 to 07 (024 to 027)

Engine RPM limiter setting

Forward RPM 8000 I 8200
Reverse RPM 3200
Type Maintenance free
Voltage 12 volts
Battery
Nominal rating Aoh 18
Power starter output 1& 07
Headlamp W 2 x 35
Taillight W 8/27
Director indicator IEuropean Community models} W 10
Indicator lights LEOS, 07 V approximately leach}

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Section 13 TE CHNICAL SPECIFICATIONS

Subse ction 01 (OUTLANDER)

MODEl
OUTLANDERTM
500 I
OUTlANDERTM
650
I OUTlANDERTM
aOOR
ELECTRICAL SYSTEM (conl'd)
Accessories A 20
Fan A 20
Main A 30
Ignition coils A 5

Fuses Fuel injectors A 5

Solenoids/speedometer/speed
A 7.5
sensor/ tail lamp
Fuel pump A 7.5
Engine control module (ECM ) A 5
Main accessories A 30
FUEL SYSTEM ,

Electronic Fuel Injection (EFI), DeLorto 46 mm throttle

Fuel delivery Type
body, 1 injector per cylinder
Type Bosch

Fuel pump Model Electrical (in fuel tank)

kPa
Operating pressure 350 (51)
(PSI)
Idle speed RPM ± 50 1250 Inot adjustable)
Type Regular unleaded gasoline
Inside North
(R+Ml/2 87 or higher
Fuel America
Octane rating Outside
North RO N 92 or higher
America
Fuel tank capacity L IUS gal) 20 153)
Remaining fuel in fuel tank wh en display light
L IU.s gal) ± 51132)
turns ON
DRIVE TRAI N
Front drive Shaft driven/Auto -lock diffe rential (shea r pump)
Front drive ratio 3.6:1
Rear drive Shaft driven/ locked different ial
Rear drive ratio 3.6:1
Front 500 ml (17 US. oz)
Ca pacity
Differential oil Rear 250 ml 18.5 U.S. oz)
BRP differen tial oil (P/ N 293 600 043) or
Recommended
synthetic oil 75W90 lAP I GL5)
CV joint grease CV joint grease (P/N 293 550 019)
Propeller shaft grease XP-S synthetic grease /P/ N 293 550 010)

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Section 13 TECHNICAL SPECIFICATIONS

Subsection 01 (OUTLANDER)

MODEL ,
OUTlANDERTM
500
DUTlANDERTM
650
I OUTLANDERTM
BOOR
,

TRAN SMISSIO N
Type CVT (Continuously Variable Transmission)
Engagement RPM ± 100 RPM 1800
CVT
Drive belt width Service limit mm (in) 3000 (1 181)
New mm (in) 13.70 to 13.80 (539 to .543)
Governor cup ro ll er outer diameter
Service limit mm (in) 13.20 1519J
New rnrn (in) 8.05 to 8.15 (.317 to .321)
Governor cup roll er inner diameter
Service limit mm (in) 9.00 ( 354)
New rnm (in) 6. 078 to 6. 100 1239 to 240)
Centrifuga l lever pivot bolt diameter
Service limit mm (in) 6.000 (236)
Centrifugal lever bore diameter Service limit mm (in) 6.200 (.244)
Drive pulley sliding half centrifugal lever pivot New mrn (in) 6. 113 to 6.171 (241 to .243)
bolt bore diameter Service limit mm (in) 6.300 (248)
New rnm (in) 55.000 to 55.040 (2 165 to 2 167)
Drive pulley sliding half large bushing
Service limit mm (in) 55.200 (2 173)
New mm (in) 32.000 to 32 040 (1.260 to 1.261)
Drive pulley sliding half small bushing
Service limit mm (in ) 32.200 (1.268)
New mm (in) 30.060 to 30.100 (1.183 to 11 85)
Driven pulley sliding half bushing
Service limit mm (in) 30.200 (11 89)
New mm (in) 30060 to 30100 (1 183 to 11 85)
Driven pu lley sliding fixed bush ing
Service limit mm (in) 30200 (1.189)
Torque gear on driven pu lley Service limit mm (in ) 7.500 (295)
STEERING
1-UP Models 2.16 m (7 ft)
Turning ra dius
2-UP Models 2.4 m (7 It 10 in)
Total toe (vehicle on ground) mm (in) o ± 4 (0 ! .157)
0
Camber angle 0
Tie-rod maximum length unengaged threads mm (in) 17.5 ± 5 (11 /1 6 ± 3/16)
SUSPENSION
FRONT
Suspension type Mac Pherson Double suspension arm
Suspension travel mm (in) 178 (7) 203 (8)
Dty 2
Shock absorber
Typ e Oil
Standard mm (in) 372 (14-5/8) 349 (13-3/4)
XT mm (in) 387 (15-1/4) 359 (14-1/8)
Spring free length MAX mm (in) 372 (1 4-21 /32) 358 (14-3/32)
MAX XT mm (in) 387 (15-15/64) 369 (14-17/32)
LTD mm (in) - I 369 (14- 17/ 32)

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Section 13 TECHNICAL SPECIFICAT IONS

Subsection01 (OUTLANDER)

MODEL
OUTLANDERTM OUTLANDERTM I OUTLANDERTM
500 650 800R
SUSPENS ION (conl'd)
Standard Si Iver/Silver/Silver SilverlYe Ilow/Silver
XT White/Blue/Gold Si Iver/Gold/Silver
Spring color code MAX Si Ive r/SilverlSi Iver White/ Silver/White
MAX XT Red/Gold/Red Gold/ Silver/Gold
LTD - I Gold/Silver/G old
Front preload adjustment NA 5 settings
REAR
Suspension type TIl'" independent
Suspension travel mm(in) 229 (9)
Qty 2
Shock absorber
Type Oil
Standard
mm (i n) 354 (13-1 5/16)
and XT
Spring free length MAX and
mm (in) 364 (14-2 1/64)
MAX XT
LTD mm (in) - I 364 (14-21/64)
Standard Silver/White/Gold
XT GOld/Blue/Gold Silver/White/ Go ld
Spring color code
MAX and MAX XT Si Iver/S iIver/Gold
LTD - I Si lver/Silver/Gold
Rear preload adjustment 5 settings
BRAKES
Qty 2
Front brake
Type Hyd rau lic, discs
Qty 1
Rear brake
Type Hydraulic, disc
Capacity 180 ml (6. 1 U.S. Ol )
Brake fluid
Type DOT 4
Parking brake Hyd rau lic 10ck-4 wheels
Caliper Floating
Organic
Front
Brake pad material CE models: Metallic
Rear Metall ic
Minimum brake pad thickness mm (in) 1 (04)
Front mm (in) 3.5 (.138)
Minimum brake disc thickness
Rear mm (in) 4.3 (17)
Maximum brake disc warpage mm (in) 0.2 (01)

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Section 13 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER)

OUTLANDERTM OUTLANDERTM OUTlANDERTM

MODEL
500 650 BOOR
TIRES AND WHEELS
TIRES
kPa Maximum: 34.5 (5) Maximum: 48 (7)
Front
(PSI) Minimum: 31 (45) Minimum: 31 (4.5)
l-UP Models
kPa Maximum : 34.5 (5) Maximum: 48 (7)
Rear
(PSI) Minimum: 31 (4.5) Minimum : 31 (4.5)
Pressure
kPa Maximum: 34.5 (5) Maximum: 48 (7)
Front
(PSI) Minimum: 31 (45) Minimum: 31 (4.5)
2-UP Models
kPa Maximum: 34.5 (5) Maximum: 48 (7)
Rear
(PSI) Minim um: 31 (45) Minimum: 345 (5)
Minimum tire thread depth mm (in) 3 (0 .118)
Front 25 x 8 x 12 26 x 8 x 12
Size
Rear 25 x 10 x 12 26x l0x12
WHEELS
Front 12 x 6
Size
Rear 12 x 7.5
DIMENS IO N
l -UP
m (in) 2.18 (86)
Models
Overall length
2-UP
m (in) 2.39 (94)
Models
Overall width m [in) 1.17 146)
Overall heig ht m (in) 1.14 (45)
l-UP
m [in) 130 (51)
Models
Whe el base
2-UP
m lin) 1.50 (59)
Models
Front mm lin) 965 138)
Whee l track
Rear mm lin) 914 (36)
GlOund clea ra nce mm lin) 279 (11) 305 112)
WEIGH I AND LOADING CAPAC ITY
l -UP
kg lib) 293 1645) 299 (660) 301 (663)
Models
Dry weight
2-UP
kg lib) 312 (688) 322 (710) 323 (713)
Models
51 /49
Weight distribution Front/rear % 500 XT and MAX: 48/ 52
Rear storage box (Included with rear rack weight) kg (Ib) 10 (22)
Front kg (Ib) 45 (100)
Ra ck 90 (200)
Rear kg (Ib)
lincluding rear storage box and tongue weight)
l-UP
kg lib) 235 (517)
Total ve hicle load allowed lincluding driver, all Models
other loads and added accessories) 2-UP
kg (Ib) 272 (600)
Models

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Section 13 TECHNICAL SPECI FICATIONS

Sub secti on 01 (OUTLANDER )

MODEL
OUTLANDERTM OUTLANDERTM I OUTLANDERTM
500 650 SOOR
WEI GHT AND LO ADI NG CA PACITY Icont'd)
l-UP
kg li b) 553 11220) 584 11287)
Models
Gross vehicle weight rating
2-UP
kg lib) 558 11228) 649 11430)
Models
590 11300)
Towing capacity kg lib)
CE mod el s: 1351298)
23 150)
Tongue capacity (included with rea r rack weight) kg lib)
CE models: 13 129)

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Section 13 TECHNICAL SPECIFICATIONS

Subsection 02 (RENEGADE)

RENEGAD E
RENEGADpM RENEGADE'M RENEGADpM
MODEL
500 SOOR SOOR X
ENGINE
ROTAX® V490 ROTAX® V810
Engine type
4-stroke. Single Over Head Camshaft ISO HC). liquid cooled
Number of cylinders 2
Number of valves 8 valves (mechanical ad justment)
Bore mm lin) 82031323) 91 135S)
Stroke mm lin) 47.3 1186) 61. 5 1242)
Displacement cm' (in') 500 (3051) 800 14882)
Compression ratio 1071 10.3 1
Decompressor type N.A.
Maximum HP RPM RPM 7250
Type Wet sump. Replaceable oil filter
Oil filter BRP Rotax paper type. replaceable
Engine oil
Minimum 350 kPa 151 PSI) at 6000 RPM
lubrication pressure
Capacity (oil change
2 l (2.11 quarts)
with filter)
Engine oil
SAE 5W30 API classification SM. SL or SJ
Recommended
see Oil VISCOSITY CHART in lUBRICATION SYSTEM
Intake va lve opening 3° BTDC 5" BTDC
Intake valve closing 34° ABDC 45° ABDC
Exhaust valve opening 39° BBDC 55" BBDC
Exhaust valve closing 2° ATDC 5° ATDC
Chain tensioner plunger protrusion Service limit mm (in) 20.0 17 874)
Intake mm lin) 0.06 to 0.14 (0024 to 0055)
Va lve clea rance
Exhaust mm (in) 0.11 to 0.19 (0043 to 0075)
New mm (in) 4966 to 4.980 (1955 to 1960)
Intake
Service limit mm lin) 4.930 (1941)
Valve stem diameter
New mm (in) 4.956 to 4.970 ( 1951 to 1957)
Exhaust
Service limit mm (in) 4.930 ( 1941)
Intake and New mm (in) 0.005 10002)
Valve out of round
exhaust Service limit mm (in) 0.06 10024)
New mm (in) 5.006 to 5018 (1971 to 1976)
Va lve guide diameter
Service limit mm lin) 5050 (1988)
New mm (in) 40.81 (1607)
Valve spring free length
Service limit mm (in) 39.00 (1535)
New mm lin) 1.05 to 1.35 1041 to 053)
Intake
Service limit mm (in) 1.8 ( 070)
Valve seat contact width
New mm (in) 1.25 to 1.55 [.049 to .061)
Exhaust
Service limit mm (in) 2 (078)

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Section 13 TECHNICAL SPECIFICATIONS

Subs ection 02 (RENEGADE)

RENEGADETM RENEGADETM RENEGADpM

MODEL
500 BOOR I BOOR X
ENG INE Icont'd)
New mm lin) 12.036 to 12.050 1.4739 to 4744)
Rocker arm bore diameter
Service limit mm lin) 12060 14748)
New mm lin) 12.000 to 1201814724 to 4 731)
Rocker arm shaft diameter
Service limit mm lin) 11.990 (4720)
81.950 to 81.966 90.950 to 90966
New mm lin)
Piston measurement 132264 to 32270) 135807 to 3.5813)
Service lim it mm lin) 81.850 132224) 90.850 13.577 )
New mm lin) 0.057 (0022) 0.027 (0011)
Piston/cylinder clea rance
Service limit mm lin) 0.130 (0051) 0.100 (0040)
1~t Upper com pression ring, rectangular
Piston ring type 0
2' Lower compression ring, tapered face
3" Oil scraper ring
Rectangular 0.20 to 040 1008 to 016)
Taper-face New mm (in) 0.20 to 0.40 1008 to 016)
Ring end gap
Oil scraper ri ng 0.20 to 0.70 1008 to .028)
All Service limit mm lin) 1.5 (059)
Rectangular 003 to 0.070 (0012 to .0028)
Taper-face New mm (in) 0.02 to 0.060 1.0008 to 0024)
Oi l scraper ring 0.01 to 0. 018 10004 to .0007)
Ring/piston groove cl earance
Rectangu lar 0.15 (0059)
Taper·face Service limit mm (in ) 0.15 (0059)
Oil scraper ring 0.25 10098)
Cyl inder bore New
82.023 to 82.037 90.993 to 91.007
mm lin)
132292 to 3.2298) 135823 to 35829)
Maximum
mm lin) 0038 (0015)
Cylinder taper New
Service limit mm lin) 0.090 (0035)
Maximum
mm lin I 0.015 (0006)
Cyli nder out of round New
Service limit mm (in) 0.020 10008)
li ming chain New mm lin) 34.959 to 34.975 113763 to 137701
Camshaft main bearing side Service limit mm lin) 34.950 113760)
journ al New mm (in) 21.959 to 21.980 18645 to 8654)
Spark plug side
Se rvice limit mm lin) 21 .950 1.8642)
Timi ng cha in New mm lin) 35.000 to 35.025 113780 to 13789)
Camshaft main bearing side Service lim it mm lin) 35.040 11.3795)
journal bore
Spark plug side
New mm lin) nooo to n021(.8661 to .B670)
Wea r limit mm lin) 22.040 (8677)
31.830 to 32 030 32.950 . 33 150
New mm lin)
Intake va lve 11.2531 to 1.261 0) (1.2972- 13051)
Service limit mm (in ) 31810 112524) 32.870 11.2941)
Cams haft lobe
31.730 to 31.930 32950 - 33.150
New mm lin)
Exhaust valve 11.2492 to 12571) 11.2972- 13051)
Service lim it mm linl 31. 710 112484) 32.930 11 2965)

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Section 13 TECHNICAL SPECIFICATIONS

Subse ction 02 (R ENEGADE )

RENEGAD ETM RENEGADE'M RENE GADE'M

MODEL
500 800R I 800R X
ENGINE Icont'd)
Crankshalt main journal diameter MAG/PTO New mm (in) 42024 to 42040 116545 to 1 6551)
side Service limit mm (in) 42.000 (16535)
Crankshalt radial play MAG/PTO side Service limit mm lin) 007 (0031)
Crankshalt main jou rnal diameter PTO support New mm (in) 34.024 to 34.040 (1.3395 to 13402)
bea ri ng Service limit mm lin) 34.010 11.3390)
Crankshaft radial play PTO support bearing Service limit mm lin) 0.10 (0039)
35.064 to 35.080 40.009 to 40.025
New mm lin)
Crankshaft pin diameter (1.3805 to 13811) (15752 to 15758)
Service limit mm (in) 35.050 (13800) 39.990 (15744)
Crankshaft deflection MAG/Pro side New mm (in) 0.050 (002)
Crankcase plain bearing MAG/PTO side Service limit mm (in) 42.100116575)
PTO cover plain bearing Service limit mm (in) 34.120 (1.3433)
Connecling rod big end diameter Service limit mm lin) 35.150 (1.3839) 40.10011579)
Connecting rod big end radia l play Service limit mm lin) 0.09 (0035)
New mm (in) 0.200 to 0.500 1008 to 020)
Connecting rod big end axia l play
Service limit mm (in) 0.600 (024)
18.010 to 18.020 20.010 to 20.020
New mm (in)
Connecting rod small end diameter (.7091 to .7095) (.7878 to .7882)
Service limit mm (in) 18.060 (711 0) 20.060 (7898)
17.996 to 18.000 19.996 to 20.000
New mm lin)
Piston pin diameter (.7085 to .7087) (7872 to .7874)
Service limit mm (in) 17.980 (7079) 19.980 (.7866)
Connecting rod/ piston pin clearance
Service limit mm lin) 0.080 (0035)
(radial play)
GEARBOX
Type Dual range (HI·LO) with park. neutral and reverse
Capacity 400 ml (14 U.S. oz)
Gearbox oil
Recommended XP·S chaincase oil
New mm (in) 0.10 to 0.20 10039 to 0079)
Output shaft backlash
Service limit mm (in) 0.25 (0098)
New mm (in) 0.02 to 0.1 5 10008 to 0059)
Bevel gear axial play
Service limit mm lin) 0.19 (0075)
New mm lin) 5.25 to 5.35 1207 to 211)
Shifting sleeve groove width
Service limit mm (in) 5.50 (.217)
New mm (in) 4.95 to 5.05 1195 to 199)
Shilting fork claw thickn ess
Service limit mm (in) 4.80 (189)
Shift fork claw thickness New mm (in) 4.80 to 4.90 1189 to 193)
(for high gear shifting) Service limit mm lin) 4.70 (185)
Shift fork claw thickness New mm (in) 5.10 to 5.20 (.201 to 205)
(lor low/reverse gear shifti ng) Service limit mm (in) 5.00 ( 197)
New mm (in) 6.920 to 6.970 1272 to 274)
Shift l ork pin diameter
Service limit mm (in) 6.850 ( 270)

VITI r2009-036 99
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Section 13 TECHNICAL SPECIFICATIONS
Subsection 02 (RENEGADE)

RENEGADE'M RENEGADETM RENEGADETM

MODEL
500 I BOOR I BOOR X
ENGINE (cont'd)
Gap of shift fork engagement groove New mm (in) 5.00 to 5.10 (.197 to .201)
(high gear shifting) Service limit mm (in) 5.20 (205)
Gap of shift fork engagement groove New mm (in) 5.30 to 540 (209 to 213)
(low/reverse gear shifti ng) Service limit mm (in) 5.50 (217)
New mm (in) 29.000 to 29.013 (1.14 17 to 1.1422)
Diameter free pinions
Service limit mm (in) 29.015 (1.1 422)
New mm {in} 24.979 to 25.000 {.983 to .984}
Interm ediate gear shaft
Service limit mm (in) 24.977 (983)
Right side 17.990 (708)
Free pinion
Countershaft Service limit mm (in) 24.970 {.983}
bearing
CVT side 24 .970 {.983}
Free pinion
8evel gear shaft Service limit mm (in) 24.984 (.984)
bearing
COOLING SYSTEM
Ethyl glycol/water mix {50% coolant. 50% water}.
Type Use premixed coolant sold by BRP (PIN 219700362) or
Coolant coolant specifica lly designed for aluminum engines
Capacity L (quarts) 2.9 (306)
Thermostat Opening temperature °C (OF) 65 (149)
kPa
Radiator cap opening pressure 110 {16}
{PSI}
ELECTRICAL SYSTEM
Magneto generator output 400 W @ 6000 RPM
Ignition system type IDI (Inductive Discharge Ignition)
Ignition timing Not adjustable
Quantity 2
Spark plug Make and type NGK DCPR8E
Gap mm (in) 0.6 to 07 (024 to .027)

Engine RPM limiter setting

Forward RPM 8000 I B200
Reverse RPM 3200
Type Maintenance free
Voltage 12 volts
Battery
Nominal rating A-h 18
Power starter output KW 07
Headlamp W 2 x 35
Taillight W 8/27
Director indicator (European Community models) W 10
Indicator lights LEOS, 0.7 V approximately {each}

100 vmr2009-036
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Section 13 TECHNICAL SPECIFICATIONS

Subsection 02 (RENEGADE)

RENEGADETM RENEGADpM RENEGADpM

MODEL
500 I BOOR I BOOR X
ELECTRICAL SYSTEM (cont'd)
Accessories A 20
Fan A 20
Main A 30
Ignition coils A 5

Fuses Fuel injectors A 5

Sale noids/speedomete r/speed
A 7.5
sensor/tail lamp
Fuel pump A 7.5
Engine control module (ECM) A 5
Main accessories A 30
FUEL SYSTEM
Electronic Fuel Injection (EFII. Dell'Orto 46 mm throttle
Fuel delivery Type
body, 1 injector per cylinder
Type Bosch
Fuel pump Model Electrical (in fuel tank)
kPa
Operating pressure 350 (51)
(PSI)
Idle speed RPM ± 50 1250 (not adjustable)
Type Regular unleaded gasoline
Inside North
[R+M)(2 87 or higher
Fuel America
Octane rating Outside
North RON 92 or higher
America
Fuel tank capacity L (US gal) 20 (53)
Remaining fuel in fuel tank when display light
L [US ga l) ± 5 (132)
turn s ON
DRIVE TRAIN
Front drive Shaft driven/Auto-lock differential (shear pump)
Front drive ratio 36:1
Re ar drive Shaft driven/locked diHerential
Rear drive ratio 361
Front 500 ml 11 7 US. Ol)
Capacity
DiHerential oil Rear 250 ml (85 U.S. oz)
BRP differential oi l (P/ N 293 600 043) or
Recommended
synthetic oil 75W90 IAPI GL5)
CV joint grease CV joint grease (P/ N 293 550 019)
Propeller shaft grease XP-S synthetic grea se (P/N 293 550 010)

vm r20 09{)36 101

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Section 13 TECHNICAL SPECIFICATIONS

Subsection 02 (RENEGADE)

RENEGADE'M RENEGADE'M RENEGADE'M

MODEl
500 I 800R 800R X
TRANSMISSION
Type CVT IContinuously Variable Transmission)
Engagement RPM ± 100 RPM 1800 I 1600
CVT
Drive belt width Service limit mm lin) 30.00 [1.181)
New mm lin) 13.70 to 13.80 (.539 to 543)
Governor cup roller outer diameter
Service limit mm lin) 13.20 (.519)
New mm [in) 8.05 to 8.15 (.317 to .32 1)
Governor cup roller inner diameter
Service limit mm lin) 9.00 1.354)
New mm lin) 6.078 to 6.100 (.239 to 240)
Centrifugal lever pivot bolt diameter
Service limit mm lin) 6.000 [236)
Centrifugal lever bore diameter Service limit mm lin) 6.200 [244)
Drive pulley sliding half centrifugal lever pivot New mm lin) 6. 11 3 to 6.171 1241 to 243)
bolt bore diameter Service limit mm lin) 6.300 1248)
New mm lin) 55.000 to 55.040 12.165 to 2 167)
Drive pulley sliding half large bushing
Service limit mm lin) 55.200 12.173)
New mm lin) 32000 to 32.040 11260 to 1 26 1)
Drive pulley sliding half small bushing
Service limit mm lin) 32.200 11.268)
New mm lin) 30060 to 30.100 [1.183 to 1.185)
Driven pulley sliding half bushing
Service limit mm lin) 30.200 11.189)
New mm lin) 30.060 to 30.100 11.183 to 1.185)
Driven pulley sliding fixed bushing
Service limit mm [in) 30.200 11.1 89)
Torque gear on driven pulley Service limit mm [in) 7.500 [ 295)
STEERING
Turni ng radius 2.16 m [7 ft)
Total toe Ivehicle on ground) mm lin) 0±410±157)
Camber angle 0°
Tie-rod maximum length unengaged mm lin) 17.5 ± 5 111 / 16 • 3/ 16)
SUSPENSION
FRONT
Suspension type Double suspension arm
Suspension travel mm lin) 216185)
Dty 2
Shock absorber
Type Oil I Gas
Spri ng free length mm lin) 319 [12-9/16) 329 [12-61/64)
Spring color code Silver/Wh ite/Gree n Si Iver/ Green/S ilver
Front preload adjustment 5 setting s

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Section 13 TECHNICAL SPECIFICATIONS

Subsection 02 (RENEGADE)

RENEGAOpM RENEGADpM RENEGADpM

MODEL
500 aOOR aOOR x
SUSPENSION Icont'd)
REAR
Suspension type TTlTM independent
Suspension travel mm (in) 229 19)
Dty 2
Shock absorber
Type Oil Gas
Spring free length mm lin) 381 115) 348 113-45/64) 384115-1/8)
Spring color code White/Silver/Gold Silver/Red/Silver Silver/Blue/Si Iver
Rear preload adjustment 5 settings
BRAKES
Dty 2
Front brake
Type Hydraulic, discs
Dty 1
Rear brake
Type Hydraulic, disc
Capacity 250 ml 185 U.S. oz)
Brake fluid
Type DOT 4
Parking brake Hydraulic lock/2 rear wh eels
Caliper Floating
Front Metall ic
Brake pad material
Rear Metall ic
Minimum brake pad thickness mm lin) 1 (.04)
Front mm lin) 3.5 (.138)
Minimum brake disc thickness
Rear mm lin) 4.3 (17)
Maximum brake disc warpage mm lin) 0.2 (.01)
TIRES AND WHEELS
TIRES
Maximum: 48 kPa 17 PSI)
Front
Minimum: 34.5 kPa 15 PSI)
Pressure
Maximum: 48 kPa (7 PSI)
Rear
Minimum: 38 kPa (55 PSI)
Minimum tire thread depth mm linl 3 (0118)
front 25 x 8 x 12
Size
Rear 25 x lOx 12
WHEELS
front 12 x 6
Size
Rear 12 x 7.5

vm12009-036 103
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Section 13 TECHNICAL SPECIFICATIONS
Subsection 02 (RENEGADE)

RENEGADpM RENEGADpM RENEGADETM

MODEL
500 I BOOR I BOOR X
DIMENSIO N
Overall length m (in) 2. 18 (86)
Overall width m (in) 1.17 (46)
Overall height m (in) 1.14 (45)
Whee l base m (in) 1.30 (51)
Front mm (in) 965 (38)
Whee l track
Rear mm (in) 914 (36)
Ground clearance mm (in) 279 (11)
WEIGH T AND LO ADI NG CAPACI TY
Dry weight kg (lb) 275 (607)
Weight distribution IFronVrear % 51/ 49
Rear storage box kg (Ib) 3.7 (1)
Rack Rear kg (Ibl 16 (35)
Total vehicle load allowed
(including driver, all other loads and kg (Ibl 141 (310)
added accessori es)
Gross veh icle weight rating kg (Ib) 476 (10501
590 (1300)
Towing capacity kg (Ib)
CE mod els: 135(298)
23 (50)
Tongue capacity (included with rear rack weight) kg (lb)
CE models: 13 (29)

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NOTES
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2010
DPS /ACS TM
TM

Technical Manual

219 100 388 CA

DPS/ACS TECHNICAL MANUAL / ENGLISH

MANUEL TECHNIQUE DPS/ACS / ANGLAIS

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. 2 1 9 1 0 0 3 8 8
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2010
DPS/ACS
Technical Manual
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TABLE OF CONTENTS

SAFETY NOTICE . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. II

INTRODUCTION .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . III
COLOR CODE LEGEND . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . III

01 TECHNICAL MANUAL
01 – DYNAMIC POWER STEERING (DPS) . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 3
GENERAL .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 5
SYSTEM DESCRIPTION (FEATURES). .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 5
SYSTEM DESCRIPTION (COMPONENTS) .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 6
ADJUSTMENT . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 7
TORQUE OFFSET RESET . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 7
DPS ASSIST MODE . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 7
TROUBLESHOOTING . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 8
PROCEDURES. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 9
DPS UNIT . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 9
PITMAN ARM . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 22
02 – AIR CONTROLLED SUSPENSION (ACS) . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 23
GENERAL .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 25
SYSTEM DESCRIPTION (FEATURES). .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 25
SYSTEM DESCRIPTION (COMPONENTS) .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 27
TROUBLESHOOTING . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 30
DIAGNOSTIC TIPS .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 30
TROUBLESHOOTING GUIDELINES . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 30
TROUBLESHOOTING WITH B.U.D.S. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 31
PROCEDURES. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 31
ACS SOLENOID VALVE . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 31
ACS MANIFOLD . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 33
ACS MODULE .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 35
ACS COMPRESSOR RELAY (R5) . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 37
ACS COMPRESSOR . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 37
ACS AIR FILTER. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 42
PRESSURE TRANSDUCER (ACS AUXILIARY LINE) . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 43
ACS HOSES . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 44
SHOCK ABSORBERS . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 45

I
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SAFETY NOTICE

SAFETY NOTICE
This manual has been prepared as a guide to cor- 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 supplementary information
mechanical technicians who are already familiar needed to fully complete an instruction.
with all service procedures relating to BRP prod-
ucts. Mechanical technicians should attend train- Although the mere reading of such information
ing courses given by B.R.P.T.I. does not eliminate the hazard, your understand-
ing of the information will promote its correct
Please note that the instructions will apply only use. Always use common shop safety practice.
if proper hand tools and special service tools are
used. BRP disclaims liability for all damages and/or in-
juries resulting from the improper use of the con-
It is understood that this manual may be trans- tents. We strongly recommend that any services
lated into another language. In the event of any be carried out and/or verified by a highly skilled
discrepancy, the English version shall prevail. professional mechanic. It is understood that cer-
The content depicts parts and/or procedures appli- tain modifications may render use of the vehicle
cable to the particular product at time of writing. illegal under existing federal, provincial and state
Service and Warranty Bulletins may be published regulations.
to update the content of this manual. Make sure
to read and understand these. It does not include
dealer modifications, whether authorized or not by
BRP, after manufacturing the product.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or ex-
act replicas of the parts.
The use of BRP parts is most strongly recom-
mended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.
The engines and the corresponding components
identified in this document should not be utilized
on product(s) other than those for which it was
designed.

WARNING
Unless otherwise specified, engine should be
turned OFF and cold for all maintenance and
repair procedures.

This manual emphasizes particular information de-

noted by the wording and symbols:

WARNING
Indicates a potential hazard, if not avoided,
could result in serious injury or death.

CAUTION Indicates a hazard situation

which, if not avoided, could result in minor or
moderate injury.
II vmr2010-002
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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
XT Yellow, Red, Camo 2UAA, 2UAB, 2UAC, 2UAD, 2UAE
XT-P Black 5JAB
500 MAX XT Yellow, Red, Camo 2XAA, 2XAB, 2XAC, 2XAD, 2XAE
MAX XT-P Black 5KAC
MAX LTD Steel grey 5NAA
XT Yellow, Red, Camo 2PAA, 2PAB, 2PAC, 2PAD, 2PAE, 2PAF
XT-P Black 5GAB
650
MAX XT Yellow, Red, Camo 2SAA, 2SAB, 2SAC, 2SAD, 2SAE, 2SAF
MAX XT-P Black 5HAC
XT Yellow, Red, Camo 2JAA, 2JAB, 2JAC, 2JAE, 2JAF
XT-P Black 5EAB, 5EAE
800R MAX XT Yellow, Red, Camo 2LAA, 2LAB, 2LAC, 2LAD, 2LAF
MAX XT-P Black 5FAC, 5FAF, 5FAJ
MAX LTD Red, Steel grey 2MAA, 2MAB, 2MAC, 2MAD

RENEGADE™
ENGINE MODEL COLOR MODEL NUMBER
800R X xc Black 4DAA, 4DAB, 4DAC

The information and component/system descriptions contained in this manual are correct at time of writ-
ing. BRP however, maintains a policy of continuous improvement of its products without imposing upon
itself any obligation to install them on products previously manufactured.
Due to late changes, there may be some differences between the manufactured product and the de-
scription and/or specifications in this document.
BRP reserves the right at any time to discontinue or change specifications, designs, features, models or
equipment without incurring obligation.

COLOR CODE LEGEND

COLOR CODE
BE = BEIGE OR = ORANGE
BK = BLACK PK = PK
BU = BLUE RD = RED
BR = BROWN VI = VIOLET
GN = GREEN WH = WHITE
GR = GRAY YL = YELLOW

vmr2010-002 III
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IV vmr2010-002
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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

1
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2
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Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

DYNAMIC POWER STEERING (DPS)

SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ....................................... 9, 11

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON® TELESCOPING GAUGE SET....................................... LST 52616 ........................................... 20

SERVICE PRODUCTS
Description Part Number Page
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 19

vmr2010-003 3
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Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

XPS synthetic
grease (400 g) XPS synthetic If torqued
grease (400 g) by elastic nuts
24.5 N•m
(18 lbf•ft)
NEW
38 N•m
(28 lbf•ft)
If torqued
by screw head NEW

NEW NEW 24.5 N•m

(18 lbf•ft)

NEW

24.5 N•m
(18 lbf•ft) NEW

NEW

72 N•m
(53 lbf•ft)

vmr2010-003-001_a

4 vmr2010-003
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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
WARNING the load on the electrical system.
Torque wrench tightening specifications When the electrical system is under high load
must be strictly adhered to. (battery not at full charge, operating the vehicle
Locking devices (e.g.: locking tabs, elastic for prolonged periods of time at slow speed and
stop nuts, cotter pins, etc.) must be replaced. low RPM which, requires higher power steering
assist), the battery power reserve will gradually
Hoses, cables or locking ties removed during a decrease. This further increases the load on the
procedure must be reinstalled as per factory stan- charging system and the electrical system volt-
dards. age will drop. As system voltage drops, so does
power steering assist.
SYSTEM DESCRIPTION NOTE: It is important to maintain the battery at
a full state of charge to ensure proper DPS op-
(FEATURES) eration. The magneto output is increased to 650
The Dynamic Power Steering (DPS) provides watts minimize battery drain and system voltage
a computer controlled, variable power assist, drop.
achieved by an electric motor to optimize the
amount of steering input required by the rider. DPS Assist Mode
The DPS system normally provides two rider se-
lectable modes of operation.
DPS MAX provides maximum steering assist for
technical low speed riding in rough or muddy ter-
rain, or for touring.
DPS MIN provides less steering assist for in-
creased feedback and aggressive trail riding.
A third mode of operation is available as an acces-
sory to adjust the steering assist level for opera-
tion with an approved BRP track kit.
vmr2010-003-014_a How to View DPS Assist Mode Selection
1. Dynamic power steering unit (DPS)
1. To view the active DPS ASSIST mode, press
The DPS system uses the following parameters to and release the OVERRIDE/DPS button on the
determine how much steering assist it provides: LH multifunction switch assembly.
– Engine RPM
– Battery/electrical system voltage
– Vehicle speed
– DPS shaft torque sensor input.
The amount of steering assist provided is depen-
dent on the handlebar effort (steering torque),
electrical power available, and vehicle speed.
The greater the handlebar effort (torque), the
greater the assist will be.
The slower the vehicle speed, the greater the as-
sist will be.
If the electrical system is activated but the engine
is not running, there is no power assist provided.
vmo2010-004-006_a
When the handlebar is in the straight ahead posi-
1. OVERRIDE/DPS button
tion, there is no steering assist.

vmr2010-003 5
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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. The
direction in which the motor turns is changed by
reversing the polarity of the circuit current.
The DPS motor does not "spin", but rather turns in
very small increments based on the amount, du-
ration, and direction of DC power delivered by the
DPS module.
vmo2010-004-004_a

1. DPS mode indication DPS Unit Protection

How to Change DPS Assist Mode To protect the DPS electronic components, the
steering assist behavior will change as follows.
To change DPS ASSIST mode, press and hold
the OVERRIDE/DPS button for approximately CONDITION DPS BEHAVIOR
4 seconds, the DPS system will toggle to the When motor internal
other available mode. The newly activated DPS temperature reaches a certain
mode will be briefly displayed in the multifunction temperature (DPS continuously Steering assist
gauge. estimates it) will gradually
decrease.
NOTE: The DPS mode cannot be changed if DPS internal board temperature
the vehicle is in reverse, of if the ACS mode is is above 85°C (185°F)
displayed in the multifunction gauge on vehicles
DPS internal board temperature Steering assist is
equipped with an Air Controlled Suspension.
is above 100°C (212°F) stopped.

SYSTEM DESCRIPTION When the DPS unit temperature is back within

(COMPONENTS) normal operating range:
– Turn the ignition key OFF.
DPS Unit
– Wait 30 seconds.
The DPS unit is a self contained unit that includes – Turn the ignition key ON.
the steering gear, the DPS module, the DPS mo-
tor, and the torque sensor. Steering assist should resume normal operation.

6 vmr2010-003
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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
– Wheel bearing
– Ball joint
– Front suspension arm
(lower/upper)
– Steering alignment

1. Ensure proper STEERING ALIGNMENT, refer

to appropriate Shop Manual subsection.
2. Connect vehicle to the latest B.U.D.S. soft-
ware.
rmr2008-019-017
3. In B.U.D.S., select Read Data.
The steering column is connected to the shaft on 4. Choose the Setting tab.
the DPS unit. A small area of the DPS shaft is
magnetized. Inside the DPS unit, a torque sensor 5. At the bottom LH corner of the Setting page,
surrounds the magnetized area of the DPS shaft. choose the DPS tab.
When the handlebar is turned, torque is applied to NOTICE Ensure handlebar is free and cen-
the shaft which tends to twist the shaft slightly, tered within ±10 degrees of center position.
deforming the magnetic field in the shaft. The There MUST NOT be any effort applied to the
sensor detects the torque by measuring the devi- steering column.
ation of the magnetic field.
6. Press Reset Torque Offset button.
The torque sensor is very sensitive and can de-
tect very small changes in the magnetic field.
The harder the handlebar is turned, the greater
the magnetic deviation, the greater the power
steering assist.

ADJUSTMENT
TORQUE OFFSET RESET
When replacing the following parts or adjusting
steering alignment, the sensor torque offset must
be reset to zero) for proper system operation.
vmr2010-003-002_a

DPS TORQUE OFFSET RESET

1. Setting page tab
2. DPS tab
3. Reset Torque Offset button

DPS ASSIST MODE

1. To view the active DPS ASSIST mode, press
and release the OVERRIDE/DPS button on the
LH multifunction switch assembly.

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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. No power to DPS unit.
- Carry out a DPS UNIT FUSE TEST as detailed in
this subsection. Replace as required.
- Carry out a DPS UNIT INPUT VOLTAGE TEST
(POWER SIDE) as detailed in this subsection.
Repair or replace wiring/connectors as required.
vmo2010-004-006_a - Carry out a DPS UNIT INPUT VOLTAGE TEST
1. OVERRIDE/DPS button (CONTROL SIDE) as detailed in this subsection.
Repair or replace wiring/connectors as required.
The active DPS mode will be displayed in the
lower portion of multifunction gauge. 3. No ground to DPS unit.
- Carry out a DPS UNIT GROUND CIRCUIT TEST
as detailed in this subsection. Repair or replace
wiring/connectors as required.
4. No engine RPM signal from ECM.
- If engine RPM can be displayed in the multifunc-
tion gauge when the engine is running, carry out a
DPS UNIT COMMUNICATION LINK (CAN) CON-
TINUITY TEST as detailed in this subsection. Re-
pair or replace wiring/connector as required.
- If engine RPM cannot be displayed in the multi-
function gauge, use B.U.D.S. to check for appli-
cable fault codes. Carry out service actions.

LOW POWER STEERING ASSIST

1. Low battery voltage.
- Check battery terminals. Clean, repair, replace or
tighten as required.
- Test battery voltage. Recharge or replace battery
as required.
- Carry out a DPS UNIT INPUT VOLTAGE TEST
(POWER SIDE) as detailed in this subsection. En-
vmo2010-004-004_a
sure power connector pins (DPS2-A and DPS2-B)
1. DPS mode indication are clean, corrosion free, tight, and make good
contact. Repair or replace wiring/connectors as
2. To change DPS ASSIST mode, press and hold required.
the OVERRIDE/DPS button for approximately - Carry out a DPS UNIT GROUND CIRCUIT TEST as
4 seconds, the DPS system will toggle to the detailed in this subsection. Ensure ground post
other available mode. The newly activated DPS connections and DPS connector pins are clean,
mode will be briefly displayed in the multifunc- corrosion free, tight, and make good contact. Re-
tion gauge. pair or replace wiring/connectors as required.
NOTE: The DPS mode of operation cannot be - Carry out a DPS SYSTEM LOAD TEST as detailed
in this subsection.
changed if the vehicle is in reverse, of if the ACS
mode is displayed in the multifunction gauge. 2. Low input voltage to DPS unit.
- Carry out a DPS UNIT INPUT VOLTAGE TEST
(POWER SIDE) as detailed in this subsection. En-
sure power connector pins (DPS2-A and DPS2-B)
are clean, corrosion free, tight, and make good
contact. Repair or replace wiring/connectors as
required.

8 vmr2010-003
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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.

ASYMMETRICAL POWER STEERING

ASSIST (SIDE TO SIDE)
1. Torque sensor not reset to zero.
- Ensure steering alignment is within specification
and carry out the TORQUE OFFSET RESET pro-
cedure detailed in this subsection.
vmo2010-004-202_a

DPS WILL NOT CHANGE MODES OF TYPICAL - OUTLANDER 800R LTD ILLUSTRATED
OPERATION 1. Rear fuse box (PF2)

1. Faulty OVERRIDE/DPS switch. 1. To remove fuse box cover, simultaneously

- Set transmission to reverse with engine running. squeeze tabs inwards on each end of fuse box
- Press the OVERRIDE/DPS button. cover as you pull on the cover.
- Look for the OVERRIDE message to appear in the
multifunction gauge. If it comes on, button and
wiring to gauge are good.
- If OVERRIDE message does not appear in gauge,
test drive vehicle to determine if OVERRIDE func-
tion can be activated. If the function can not be
activated, test the OVERRIDE/DPS switch and
wiring. If the function is activated, test wiring
from switch to multifunction gauge.

PROCEDURES
DPS UNIT
DPS Unit Power Fuse Test
A 40 A DPS fuse located in the rear fuse box (PF2-
vmr2010-003-004_a
F3) next to the voltage regulator/rectifier unit pro-
1. Squeeze and pull these tabs to remove cover
vides power for the DPS motor.
2. Using a FLUKE 115 MULTIMETER (P/N 529 035
868) set to selection, remove and test the
DPS fuse.

529035868

vmr2010-003 9
 www.midwestmanuals.com
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-
lowing DPS UNIT INPUT VOLTAGE TEST (CON-
TROL SIDE).
NOTE: This test may also be carried out by con-
necting a 12 Vdc test light between each DPS
PWR connector pins (A and B), and the battery (-)
negative terminal. The test light must come on
bright.

DPS Unit Input Voltage Test (Control

vmr2010-003-005_a Side)
1. 40 amp DPS fuse (PF2-F3)
1. Disconnect DPS CTRL (control) connector and
3. Replace fuse as required. turn ignition switch ON.
2. Set the ignition switch to ON.
DPS Unit Input Voltage Test (Power
3. Set the engine RUN/STOP switch to RUN.
Side)
4. Test for 12 Vdc power to the DPS module at
1. Disconnect the DPS PWR (power) connector.
DPS1-A as per following table.
MULTIMETER PROBE
VOLTAGE
POSITIONS
DPS control connector (pin A)
and battery ground

Battery voltage

rmr2008-028-093_a

vmr2010-003-013_d If NO voltage is measured, check wires and con-

1. DPS PWR connector (motor power) nector pins from DPS unit to the Relays/Speedo
fuse in front fuse box (PF1-F4). Replace or repair
2. Test for 12 Vdc DPS motor power at DPS2-A defective parts and reset fault codes.
and DPS2-B as per following table.
If battery voltage is measured, carry out the fol-
MULTIMETER PROBE POSITIONS VOLTAGE lowing DPS UNIT GROUND CIRCUIT TEST.
DPS power NOTE: This test may also be carried out by con-
connector pin A necting a 12 Vdc test light between the DPS con-
Battery ground trol connector (pin A), and the battery (-) negative
DPS power
connector pin B terminal. The test light must come on bright.
Battery DPS Unit Ground Circuit Test
voltage
1. Disconnect the DPS ground connector (GDN).

rmr2008-028-091_a

10 vmr2010-003
 www.midwestmanuals.com
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
vmr2010-003-013_c
Below 1
DPS control connector (pin D)
1. DPS ground connector (GDN)
and diagnostic connector (pin 2)
2. Test for continuity between DPS3-A and
DPS3-B to battery ground.
MULTIMETER PROBE
READING
POSITIONS
DPS GDN
connector pin A Continuity
Battery ground
DPS GDN (close to 0 ) rmr2008-028-094_b
connector pin B
If resistance measured is out of specification,
If there is NO continuity or a high resistance is check wires and connector pins. Carry out re-
measured, check wires and connector pins from pairs as required and reset fault codes using
DPS unit to chassis ground post. Replace or re- B.U.D.S software.
pair defective parts and reset fault codes. If resistance measured is good, replace the DPS
If there is good continuity, carry out the following unit and reset fault codes using B.U.D.S software.
DPS UNIT COMMUNICATION LINK (CAN) CON-
TINUITY TEST. DPS System Load Test
NOTE: This test may also be carried out by con- If the charging system cannot sustain normal volt-
necting a 12 Vdc test light between each GDN age when the DPS is operating, DPS ASSIST may
connector pin and the battery (+) positive termi- be greatly reduced or nonexistent. Carry out the
nal. The test light must come on bright. following steps.
1. Connect the red lead of a FLUKE 115 MULTIME-
DPS Unit Communication Link (CAN) TER (P/N 529 035 868) set to Vdc to the rear fuse
Continuity Test box battery terminal.
NOTE: DPS unit must receive an RPM signal to 2. Connect the black multimeter lead to the bat-
provide power steering assist. tery ground.
Disconnect the DPS control connector and the di-
agnostic connector.
Test continuity of CAN Bus Wires at DPS1-C and
DPS1-D.

vmr2010-003 11
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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. MIN function selected
5. Start the engine.
9. Turn the handlebar momentarily against the
6. Note the voltage on the multimeter with the en-
steering frame stops to each side.
gine running (charging system voltage).
NOTE: Do not hold steering against frame stops
7. Press the RANGE button repeatedly to select
for and extended period of time.
Manual Range 6 0.
10. Read the MIN charging system voltage
recorded while the handlebar was turned
against each stop.
DPS SYSTEM LOAD TEST
STEERING VOLTAGE
PROBE POSITIONS
POSITION READING
Battery Rear fuse LH stop
At least
(-) box battery
RH stop 12 Vdc
terminal terminal

NOTE: Turning the handlebar momentarily

against the frame stops generates maximum
DPS load (maximum current draw on electrical
system). Electrical system must sustain at least
12 Vdc for proper DPS operation.

mmr2009-023-027_a

VDC SELECTED TO MANUAL RANGE 6 0

8. Press the MIN MAX button on the multimeter

to engage the MIN function.

12 vmr2010-003
 www.midwestmanuals.com
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.
The DPS Current ammeter should increase pro-
portionately to the torque applied, and decrease
with the torque as steering assist is provided.

vmr2010-003-007

If the electrical system cannot sustain at least

12 Vdc, check the following:
– Battery
– Battery connections
– DPS unit power and ground connections
– Charging system vmr2010-003-009_a

TYPICAL - LH TURN
– Frame and engine ground studs. 1. Torque sensor indication (negative)
2. DPS current indication (positive)
If the previously listed items, carry out the follow-
ing DPS UNIT CURRENT TEST.

DPS Unit Current Test

1. Connect vehicle to the latest B.U.D.S. soft-
ware.
2. Click on the Read Data button.
3. Choose the Monitoring page tab.
4. At the bottom of the Monitoring page, choose
the DPS tab.

vmr2010-003-010_a

TYPICAL - RH TURN
1. Torque sensor indication (positive)
2. DPS current indication (negative)

NOTE: Increase and decrease in torque and cur-

rent readings is very brief as steering assist is
quickly provided. Current draw should remain
within green scale but may momentarily peak to
60 amps, then drop off close to 0 amps as torque
applied is nulled out by steering assist. A residual
torque of 2 N•m (18 lbf•in) with a corresponding
current draw is acceptable.
vmr2010-003-008_a
If current draw tends to remain high, carry out the
Step 1: Press Data button following:
Step 2: Select Monitoring page tab – Steering alignment check.
Step 3: Select DPS tab

vmr2010-003 13
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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.
– Replace DPS unit.

DPS Unit Removal

1. Remove the following items:
– Seat
– Center panel
– LH and RH side panels vmr2010-003-012_a

– LH and RH inner fender panels. 1. Gear clamp to loosen

2. Lift up on the dash board (gauge support) and
6. Remove the screws securing the engine air fil-
disconnect the following:
ter housing.
– Gauge
7. Move the shift lever and guide plate slightly to
– Ignition switch
the right.
– 12 Vdc power outlet.
8. Lift up on the air filter housing to release it from
3. Remove dash board from vehicle. the throttle body and move the filter housing
4. Remove the screw securing the shift lever towards the RH side of the vehicle.
guide plate to the engine air filter housing. NOTE: Moving the air filter housing to the right
provides access required for CVT air inlet duct re-
moval.
9. Remove the CVT air inlet duct assembly.

vmr2006-014-055_d

TYPICAL vmr2010-003-011_a
1. Shift lever guide plate
2. Guide plate screws (forward screw not visible) 1. CVT air inlet duct

NOTE: It is not necessary to disconnect the shift 10. Remove the ECM from it's support bracket.
lever. 11. Disconnect the 3 electrical connectors from
5. Loosen the gear clamp securing the air filter the DPS unit.
housing duct to the throttle body.

14 vmr2010-003
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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
access the steering column pinch bolt.
1. Elastic nuts to remove and discard
2. Frame support
3. Steering column half bushings

15. Remove the 2 hexagonal screws from the

ECM support.

vmr2010-003-016_a

1. Cut this locking tie

2. Steering column bellows

13. Remove the steering column pinch bolt and

retaining nut. Discard the retaining nut. vmr2010-003-021_a

1. Hexagonal screws to remove

2. ECM support

16. Remove and save the shim(s) from between

the rear half bushing and the steering support
on the frame.

vmr2010-003-017_a

1. Steering column pinch bolt

vmr2010-003 15
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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
17. Pull up on the steering column to disengage it at this time. They will come off easily when the
from the DPS unit and move it to the side. DPS unit is lifted from its frame support.

vmr2010-003-020_a
vmr2010-003-023
Step 1: Pull up on steering column TIE ROD ENDS (HARDWARE REMOVED)
Step 2: Disengage column from DPS unit
19. Remove the 4 hexagonal flanged screws se-
18. Remove the hardware that secures both tie-
curing DPS unit to frame.
rod ends to the pitman arm (steering lever).
Discard cotter pins. NOTE: Discard the 4 conical spring washers on
the DPS retaining screws. Do not remove the 2
small hexagonal forming screws from the DPS
unit unless it is being replaced.

16 vmr2010-003
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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-
20. Pull up on DPS unit to align the 2 small hexag- ing bracket by engaging the two hexagonal
onal forming screws with the extraction holes forming screws in the slots provided in the
in the DPS mounting bracket, then remove the bracket.
DPS unit from the bracket.

vmr2010-003-027_a

1. DPS mounting bracket

vmr2010-003-025_a
2. Engage hexagonal forming screw on DPS unit here
TYPICAL - RIGHT SIDE ILLUSTRATED
1. Hexagonal forming screws (1 each side) 3. Engage the 2 tie rod ends in the pitman arm
2. Extraction holes
3. DPS unit as you lower the DPS unit on it's mounting
bracket.
NOTE: As you pull the DPS unit from the frame
support, the 2 tie rod ends should release from NOTE: Ensure both tie rod ends has a hardened
the pitman arm. Be careful not to loose the hard- steel washer on it.
ened steel washers on the tie rod ends.

DPS Unit Installation

NOTICE The following procedure MUST be
followed as specified. Failure to do so may re-
sult in steering column/DPS misalignment and
poor DPS operation due to an induced erro-
neous torque on the DPS shaft.
1. If installing a new DPS unit, install the two M5
hexagonal forming screws on the mounting
flange of the DPS unit.

vmr2010-003 17
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Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

vmr2010-003-029_a

vmr2010-003-023_a
1. O-ring seals on steering column
1. Pitman arm
2. Tie rod ends inserted in pitman arm 6. Index steering column splines with DPS unit
3. Hardened steel washer on tie rod end splines.
4. Engage NEW M8 hexagonal flanged screws NOTE: The DPS shaft splines have a key which
through the DPS frame support and into the must be aligned with the keyway in the steering
DPS unit. column end.
NOTE: Ensure each retaining screw has a NEW
conical spring washer between the screw head
and the DPS frame support. Do not tighten the
retaining screws more than half thread length at
this time.

vmr2010-003-031

STEERING COLUMN INDEXED TO DPS SHAFT SPLINES

7. Fully insert steering column end onto DPS shaft

splines. If necessary, place a rag on steering
cover and gently tap on it with a plastic ham-
vmr2010-003-028_a
mer.
TYPICAL - RH SIDE ILLUSTRATED
Step 1: Engage NEW DPS mounting screws (2 each side) NOTICE The following steps MUST be fol-
Step 2: Install NEW conical washers
lowed as specified. Failure to do so may result
5. Remove the two half bushings from the steer- in steering column/DPS misalignment and
ing column and ensure the two O-ring seals are poor DPS operation due to an induced erro-
installed on the shaft and in good condition. Re- neous torque on the DPS shaft.
place as required.
8. Install steering column pinch bolt and a NEW
elastic nut. Torque nut to 24 N•m (18 lbf•ft).

18 vmr2010-003
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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. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
NOTE: Ensure the locking tie is on the tube part of to the inside of both steering column half bush-
the steering column, not on the forged end. Bel- ings.
lows should cover end of ring flange on DPS unit
but not cover the drainage hole at the bottom of
the ring flange. Do not install a locking tie on the
DPS end of the bellows. Lower portion of bellows
MUST remain floating over the DPS housing.

vmr2010-003-034

10. Loosely secure the steering column to its

frame support by installing the following parts
vmr2010-003-016_a
to provide side to side alignment of steering
1. Locking tie location
2. Steering column bellows column.
– Half bushings (x2)
– Metal sleeves between bushings (x2)
– O-ring seals (x2)
– M8 hexagonal screws (x2)
– M8 elastic nuts (x2).
NOTE: Do not install shims and do not torque the
fasteners at this time. Hand tighten only. Steering
column must not be drawn in towards the column
support.

vmr2010-003 19
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Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))

vmr2010-003-035_a vmr2010-003-036

1. These nuts installed hand tight at this time STEERING COLUMN SHIM MEASUREMENT

11. Torque DPS unit mounting screws to NOTE: Ensure the forward end of the tool is in the
24.5 N•m (18 lbf•ft). center of the steering column, and the rearward
end does not protrude through the notch in the
support.
13. Measure the telescoping gauge using a
Vernier caliper (or a micrometer) and com-
pare the measured distance to the following
table to establish the required shim thickness

vmr2010-003-028_b

TYPICAL - RH SIDE ILLUSTRATED

1. Torque DPS mounting screws (x4)

12. Using an 8 mm (5/16 ft) telescoping gauge as

found in the SNAP-ON® TELESCOPING GAUGE
SET (P/N LST 52616), measure the distance be- vmr2010-003-037
tween the steering column shaft and the face
of the column frame support. Measurement STEERING COLUMN SHIM REQUIREMENT
is taken above rear half bushing. TOTAL SHIM
MEASURED DISTANCE
THICKNESS REQUIRED
8.63 mm (.34 in) None
9.63 mm (.379 in) 1 mm (.039 in)
10.65 mm (.419 in) 2 mm (.079 in)
11.66 mm (.459 in) 3 mm (.118 in)
12.65 mm (.498 in) 4 mm (.157 in)

NOTE: Shims come in 1 mm (.039 in) and 2 mm

(.079 in) thicknesses. Total shim thickness must
not exceed 4 mm (.157 in).

20 vmr2010-003
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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
– Re-measure the distance between steering (18 lbf•ft).
column and support. Ensure the forward end 16. Install hardware on LH and RH tie rods on pit-
of the tool is in the center of the steering col- man arm. Follow parts assembly sequence as
umn, and the rearward end does not protrude in following illustration.
through the notch in the support.
17. Torque tie rod end retaining nuts to 72 N•m
– Check steering column support and frame to (53 lbf•ft).
ensure they are not bent, twisted or damaged
in any way.
– Check machined flat mounting surface on new
DPS.
– Compare old and new DPS units.
– Ensure the 4 DPS mounting screws and
the steering column pinch bolt are properly
torqued.
14. Insert appropriate shim(s) between the rear
half bushing and the steering column support.

vmr2010-003-022_b

1. Hardened steel washers (one each side of pitman arm)

2. Tie rod end retaining nut (torque applied)
3. NEW cotter pin installed

18. Turn handlebar fully to each side and check for

proper contact between pitman arm and pit-
man arm frame stops (both sides).

vmr2010-003-038_a

1. Insert required shim(s) here

15. As you hold each elastic nut with a wrench,

torque the hexagonal SCREWS retaining the
steering column to 38 N•m (28 lbf•ft).

vmr2010-003-039_a

TYPICAL - LH ILLUSTRATED
1. Pitman arm
2. Contact point with frame stop

NOTE: Contact between pitman arm and pitman

arm stops must be checked with vehicle weight
on wheels.
19. Perform a STEERING ALIGNMENT as de-
vmr2010-003-021_b scribed in the applicable Shop Manual sub-
Step 1: Hold elastic nuts with wrench (not illustrated) section.
Step 2: Apply specified torque to hexagonal screws

vmr2010-003 21
 www.midwestmanuals.com
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:
– Multifunction gauge PITMAN ARM
– Ignition switch If the pitman arm requires replacement, the DPS
– 12 Vdc accessories outlet. unit MUST be replaced.
22. If installing a replacement DPS unit, refer to
DPS REPLACEMENT in this subsection. WARNING
23. Perform the torque offset reset. Refer to DO NOT attempt to replace or repair the pit-
TORQUE OFFSET RESET in this subsection. man arm. Do not use a torch or arc welder on
the pitman arm. Failure to comply will result
24. Install all other removed parts in the reverse in DPS unit malfunction.
order of removal.
25. Carry out a test ride of the ATV to ensure
proper operation of the DPS unit.

DPS Unit Replacement

New DPS units do not come with the required
software programmed into the unit. A DPS unit
fault will be generated when the vehicle is pow-
ered up. The check engine light will come on and
a DPS FAULT message will appear in the multi-
function gauge.
When DPS unit installation is complete, carry out
the following steps.
1. Connect the ATV to the latest B.U.D.S. soft-
ware.
2. Select the Read Data button.
3. In the Module menu, choose the DPS sub-
menu and install the latest DPS software
Update file as applicable to the type ATV (Out-
lander or Renegade).

vmr2010-003-040

DPS SOFTWARE UPDATE

4. Once the correct DPS software file is installed,

go to the Faults page and clear the fault codes.
5. Carry out the TORQUE OFFSET RESET proce-
dure as described in this subsection.

22 vmr2010-003
 www.midwestmanuals.com
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

AIR CONTROLLED SUSPENSION (ACS)

SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............. 32, 35, 37–38, 43–44
OETIKER PLIERS........................................................................... 295 000 070 ........................................... 44
SPRING REMOVER ....................................................................... 529 036 007 ........................................... 46

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 592 (PIPE SEALANT) ..................................................... 293 800 018 ......................... 33–34, 41, 47

vmr2010-004 23
 www.midwestmanuals.com
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

53 N•m
(39 lbf•ft)

53 N•m
(39 lbf•ft)

ACS hose
ACS solenoid
release valve
Loctite
592 NEW
(pipe
sealant) NEW

53 N•m
(39 lbf•ft)

ACS
module

ACS
compressor

vmr2010-004-033_a

24 vmr2010-004
 www.midwestmanuals.com
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

GENERAL ACS SUSPENSION SETTINGS

During assembly/installation, use torque values RIDING RECOMMENDED
SETTING PRESSURE
and service products as in the exploded views. COMFORT LOAD
ACS 1 0.5 bar (8 PSI) Softest
WARNING Operator only
ACS 2 1 bar (15 PSI) Soft
Torque wrench tightening specifications
must be strictly adhered to. ACS 3 2 bar (30 PSI) Semi-soft Transporting a
Locking devices (e.g.: locking tabs, cotter passenger OR
ACS 4 4 bar (55 PSI) Semi-firm a cargo
pins, etc.) must replaced with new ones.
ACS 5 5 bar (70 PSI) Firm Transporting a
Hoses, cables or locking ties removed during a passenger AND
procedure must be reinstalled as per factory stan- ACS 6 6 bar (85 PSI) Firmest a cargo
dards. Hoses must be properly inserted.
Be careful while manipulating nylon hoses, they Changing ACS Setting
must not be kinked. To change the ACS setting proceed as follows:
– Press selector button several times until
CAUTION Always wear safety goggles AIR_SUSP is displayed.
when working with pressurized air system.
– Press and release ACS button until the re-
quested setting is displayed.
CAUTION The ACS suspension system
may be under high pressure (up to 6 bar
(85 PSI)). Release air pressure prior to work-
ing on the system. Refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING.

SYSTEM DESCRIPTION
(FEATURES)
The ACS suspension automatically keeps air pres-
sure constant with changing rider weights or loads
applied. The system can be adjusted on the fly to
suit rider's preferences.
The multifunction gauge indicates suspension set-
ting as follows. vmo2010-004-005_a

1. Selector button
2. AIR_SUSP displayed

vmo2010-004-005_d

1. Requested setting (set point)

2. Actual setting (pressure transducer reading)
vmo2010-004-006_a
Refer to the following table to know the ACS pres- TYPICAL
sure related to multifunction gauge setting. 1. ACS button

vmr2010-004 25
 www.midwestmanuals.com
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.

ACS Setting Acknowledgement

If ACS suspension was set to ACS 5 or ACS 6 be-
fore shutting down the vehicle, the multifunction
gauge will scroll an acknowledgement message
at startup. vmo2010-004-201_a

To acknowledge the ACS suspension setting, 1. Auxiliary line adaptor to inflate tire
press and release ACS button while message
appears. To ensure that the use of the auxiliary line will
not change the pressure setting inside shock
absorber, the system has been divided in two
zones using check valves. With this layout, both
pressure zones are independent to eliminate any
air pressure variation.
NOTE: The auxiliary line output pressure will vary
according to the ACS suspension setting. The
ACS 1 adjustment will provide less pressure than
the ACS 6 adjustment.
NOTICE Never inflate tires above the recom-
mended pressure.
ACS SYSTEM
PRESSURE
vmo2010-004-006_a
ZONE LINK WITH TRANSDUCER
TYPICAL
LOCATION
1. ACS button
High-pressure Shock Inside ACS
NOTE: If the message is not acknowledged, the zone absorbers module
suspension will automatically return to setting In line between
ACS 3. Low-pressure solenoid release
Auxiliary line
NOTE: If the selector button in the multifunction zone valve and
compressor
gauge is pressed while the acknowledgement
message appears, the suspension will directly
return to setting ACS 3. Releasing Air Pressure in System for
NOTE: If the vehicle transmission is set to RE- Servicing
VERSE position at startup, the override message It is recommended to release air pressure in the
will be displayed instead of acknowledgement system before servicing any components.
message. 1. Remove seats.
Using the Auxiliary Line to Inflate Tires 2. Remove RH side panel.
The ACS system is equipped with an auxiliary line 3. Unscrew pneumatic valve cap.
specially designed to inflate tires. The air pressure
in this auxiliary line is controlled by a second pres-
sure transducer connected to the ACS module.

26 vmr2010-004
 www.midwestmanuals.com
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
screwdriver. ACS Compressor Relay (R5)
Compressor relay is located in the front fuse box,
under front service compartment panel. Note that
the relay is not at the same position on a 500 LTD
and on a 800R LTD models. Refer to the following
table.
RELAY (R5) FRONT FUSE BOX PIN
TERMINAL 500 LTD 800R LTD
86 6D 11B
85 7C 12A
30 7D 12B
87 6C 11A
vmr2010-004-002

5. Wait until the system is completely empty of Outlander 500 LTD

air.
NOTE: Make sure to wait enough time in order to
let the system expel the air. (no more pressurized
air sound from the valve).
6. Reinstall pneumatic valve cap.

SYSTEM DESCRIPTION
(COMPONENTS)
Fuse and Relay
ACS Fuse (F14) vmr2010-004-107_a

1. ACS fuse (F14) is located in the front fuse box. OUTLANDER 500 LTD MODEL
1. ACS compressor relay (R5)
FRONT FUSES BOX
NO DESCRIPTION RATING
F14 ACS 20 A

vmr2010-004 27
 www.midwestmanuals.com
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)

28 vmr2010-004
 www.midwestmanuals.com
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
Compressor To pressurize the system
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
system
Pressure transducer (Low-pressure zone) To monitor the air pressure of the auxiliary line
Pressure transducer (High-pressure zone) To monitor the air pressure of the shock absorbers
Check valve (compressor) To protect the compressor
To eliminate air pressure variation between low and high
Check valve (between both zones)
pressure zone
Auxiliary line To inflate tire
Cluster To monitor the air pressure setting

Low pressure High pressure

Pneumatic zone zone

Electric
Auxiliary
output

Release
valve

Check-valve Check-valve Shock 1

Filter Compressor Manifold

Pressure Shock 2
transducer
Pressure
transducer

Electronic
Cluster module

vdd2010-001-601_en

vmr2010-004 29
 www.midwestmanuals.com
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 Refer to ACS MODULE to see the complete test-
The error code AIR FAULT can appear on the mul- ing procedures.
tifunction gauge for different reasons that are not
necessarily related to a failure of the ACS system. Suspension Setting Can Be Reached to
If the error code appears on the multifunction Decrease Pressure Only
gauge, it indicates a disparity between the re- 1. Check relay (R5).
quested and the actual suspension settings. The 2. Check ACS compressor operation.
system should react to correct this situation and
the error code will disappear. 3. Check ACS compressor input voltage.
If the error code remains active for a long period, Refer to ACS COMPRESSOR to see the complete
it may indicates a major leak in the system. In this testing procedures.
case, the module will automatically shut down the
compressor to prevent it from overheating. The
Suspension Setting Can Be Reached
shut down procedure of the compressor will stay To Increase Pressure Only
active until the next restart of the vehicle (key OFF, 1. Check ACS solenoid valve operation.
key ON). 2. Check ACS solenoid valve input voltage.
If there is a major leak in the system, check the Refer to ACS SOLENOID VALVE to see the com-
system for leakage, refer to ACS SYSTEM LEAK plete testing procedures.
TEST (TROUBLESHOOTING WITH B.U.D.S.) sub-
section. No Pressure Output from the Auxiliary
Error Code Displayed and Suspension Setting Line
Can Not Be Adjusted 1. Ensure that ACS suspension setting is adjusted
If there is no leak, it is probably an electrical prob- to ACS 6 to provide the maximum air pressure
lem. In this case, an electrical failure of the com- in the auxiliary line.
pressor or the solenoid valve will result the impos- 2. Check pressure transducer for air leakage.
sibility to change the actual suspension setting. 3. Check signal continuity of the auxiliary line pres-
After multiple attempts to change suspension sure transducer.
setting, the module will activate error code AIR 4. Check input voltage of the auxiliary line pres-
FAULT. Refer to TROUBLESHOOTING GUIDE- sure transducer.
LINES for further troubleshooting procedure.
5. Check ground of the auxiliary line pressure
transducer.
TROUBLESHOOTING
GUIDELINES 6. Check compressor operation.

Requested Setting Display Does Not Multifunction Gauge Display Flickers

Change in Gauge OFF and Back ON
1. Check the override/ACS button as detailed in 1. Check diode (D7) of the solenoid valve.
OVERRIDE SWITCH in the LIGHTS GAUGE NOTE: The diode (D7) is located on the main har-
AND ACCESSORIES subsection of the appro- ness near the ACS sub-harness junction. Refer to
priate Shop Manual. the appropriate WIRING DIAGRAM for location.
Suspension Setting Can Not Be
Changed
1. Check the override/ACS button as detailed in
OVERRIDE SWITCH in the LIGHTS GAUGE
AND ACCESSORIES subsection of the appro-
priate Shop Manual.

30 vmr2010-004
 www.midwestmanuals.com
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

TROUBLESHOOTING WITH
B.U.D.S.
ACS System Leak Test
1. Connect vehicle to B.U.D.S. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
2. Select Activation page.
3. Select ACS folder.
4. Press Test START button to proceed.

vmr2010-004-401_a

1. Auxiliary line check valve

ACS Air Pressure Monitoring

To monitor air pressure in the system during trou-
bleshooting operation, proceed as follows:
1. Connect vehicle to B.U.D.S. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
2. Select Monitoring page.
3. Select ACS folder.
vmr2010-004-201_a

Step 1: Activation page

Step 2: ACS folder
Step 3: Leak Test START button

After pressing Test START button, the com-

pressor will pressurize the air system at 6.5 bar
(90 PSI) for approximately 2 minutes and B.U.D.S.
will monitor the system for any leakage. The
result will be indicated in the TEST STATUS box.
If a leak is detected, pressurize the system again
and inspect hoses and fittings with soapy water
to locate the faulty component.
If no leak is detected from hoses or fittings, in- vmr2010-004-301_a

spect the compressor check valve and the auxil- Step 1: Monitoring page
Step 2: ACS folder
iary line check valve with soapy water.
PROCEDURES
ACS SOLENOID VALVE
ACS Solenoid Valve Operation Test
1. Connect vehicle to B.U.D.S. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
2. Select Activation page.
3. Select ACS folder.
4. Press Relief Valve button to proceed.
vmr2010-004-202_b

1. Compressor check valve

vmr2010-004 31
 www.midwestmanuals.com
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. Verify that air exits from side port to confirm

proper solenoid operation.
vmr2010-004-101_a

1. Actual setting (pressure transducer reading)

NOTE: Make sure to wait enough time in order to

let the system adjust the air pressure.
6. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
7. Back probe solenoid connector (without discon-
necting).

vmr2010-004-202_a

1. Side port

ACS Solenoid Valve Input Voltage Test

1. Remove seats and RH side panel.
2. Place ignition switch to ON position.
3. Press selector button several times until
AIR_SUSP is displayed.
vmr2010-004-102

8. Set suspension mode to ACS 1 using the ACS

button.
9. Measure voltage between solenoid connector
terminals as per the following table.
TEST PROBES VOLTAGE
Pin 2 (YL/GN) Battery voltage
Pin 1 (BK) (± 12 Vdc)

ACS Solenoid Valve Removal

vmo2010-004-005_a
1. Release air pressure, refer to RELEASING AIR
1. Selector button
PRESSURE IN SYSTEM FOR SERVICING in this
2. AIR_SUSP displayed subsection.
32 vmr2010-004
 www.midwestmanuals.com
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. Module hose
holding support. 3. Shocks hose

4. To disconnect hoses, proceed as follows:

4.1 Push fitting ring toward manifold.
4.2 Hold ring in place.
4.3 Pull air hose.

vmr2010-004-004_a

1. Solenoid valve

ACS Solenoid Valve Installation

The installation procedure is the reverse of re-
moval procedure, however pay attention to the vmr2010-004-008_a
following. 1. Fitting
2. Fitting ring
Apply LOCTITE 592 (PIPE SEALANT) (P/N 293 800
018) on solenoid valve male threads. 5. From underneath support, remove manifold re-
taining screws.
ACS MANIFOLD
ACS Manifold Removal
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove solenoid valve. Refer to ACS SOLE-
NOID VALVE REMOVAL.
3. Disconnect the following hoses from manifold
air fittings.
– Manifold air inlet hose (from compressor)
vmr2010-004 33
 www.midwestmanuals.com
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. Manifold air inlet fitting (from compressor)
2. Auxiliary line check valve
3. Pneumatic valve
4. Shocks fitting
5. Module fitting
vmr2010-004-007_a

1. Manifold air inlet fitting (from compressor) Ensure that air hoses are properly inserted into fit-
2. Auxiliary line check valve
3. Pneumatic valve tings, refer to the following illustrations.
4. Shocks fitting
5. Module fitting

ACS Manifold Installation

The installation procedure is the reverse of re-
moval procedure, however pay attention to the
following.
If fitting is the one previously removed (old one),
apply LOCTITE 592 (PIPE SEALANT) (P/N 293 800 018)
on all male threads. vmo2010-011-102_a

PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED

If fitting is a new one, do not apply sealant, it 1. Fitting
should be already applied on male threads. 2. Mark
A. Must be inserted into fitting
On pneumatic valve, check valve, and solenoid
valve, apply LOCTITE 592 (PIPE SEALANT) (P/N 293
800 018) on all male threads.
Install check valve with arrows pointing toward
manifold.

vmo2010-011-103

HOSE PROPERLY INSERTED INTO FITTING

34 vmr2010-004
 www.midwestmanuals.com
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.
Refer to LIGHTS, GAUGE AND ACCESSORIES
subsection of the appropriate Shop Manual.
3. Disconnect ACS module connector.

vmr2010-004-011_a

1. Module connector

3. Set the FLUKE 115 MULTIMETER (P/N 529 035

868) to Vdc.
4. Place ignition switch to ON position.
5. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 12 (OR/GN) Battery voltage
Battery negative (-) post (± 12 Vdc)
vmr2010-004-011_a

1. Module connector
ACS Module Ground Test
4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to . 1. Remove seats and RH side panel.
5. Measure resistance as per the following tables. 2. Disconnect module connector.

TEST PROBES RESISTANCE

Gauge pin 18 (BK/BE)
Close to 0
Module pin 5 (BE/GN)

TEST PROBES RESISTANCE

Gauge pin 19 (BE/GN)
Close to 0
Module pin 6 (WH/BE)

ACS Module Input Voltage Test

1. Remove seats and RH side panel.
vmr2010-004-011_a
2. Disconnect module connector. 1. Module connector

3. Set the FLUKE 115 MULTIMETER (P/N 529 035

868) to Vdc.
4. Place ignition switch to ON position.
5. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 7 (BK) Battery voltage
Battery positive (+) post (± 12 Vdc)

vmr2010-004 35
 www.midwestmanuals.com
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

ACS Module Removal

1. Release air pressure, refer to RELEASING AIR
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.
2.2 Hold ring in place.
2.3 Pull air hose.

vmr2010-004-012_a

1. Module retaining bolt

5. Remove module from vehicle.

ACS Module Installation

The installation procedure is the reverse of re-
moval procedure, however pay attention to the
following.
If a new ACS module is installed, check diode (D7)
of the solenoid valve to ensure that it is not de-
fective as it can damage the ACS module. The
vmr2010-004-010_a
diode (D7) is located on the main harness near the
1. Module hose
ACS sub-harness junction. Refer to the appropri-
NOTICE Do not attempt to disconnect hose ate WIRING DIAGRAM for diode location.
from module. Ensure that air hoses are properly inserted into fit-
tings, refer to the following illustrations.
3. Disconnect module connector.

vmo2010-011-102_a

PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED

1. Fitting
2. Mark
A. Must be inserted into fitting

vmr2010-004-011_a

1. Module connector

4. Remove module retaining bolts and nuts.

vmo2010-011-103

HOSE PROPERLY INSERTED INTO FITTING

36 vmr2010-004
 www.midwestmanuals.com
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

ACS COMPRESSOR RELAY (R5) Outlander 800R LTD

ACS Relay Continuity Test TEST PROBES VOLTAGE
1. Remove relay (R5), refer to FUSE AND RELAY Fuse box pin 12B (BE/PK)
Battery voltage
at the beginning of this section. (± 12 Vdc)
Battery negative (-) post
2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to . If voltage is not as specified, check wiring, con-
3. Measure resistance as per the following table. nector and terminal condition.
TEST PROBES RESISTANCE
ACS Relay Ground Wire Continuity
Terminal 30 Test
Open (OL)
Terminal 87 1. Remove relay (R5), refer to FUSE AND RELAY
at the beginning of this section.
4. Apply 12 volts on terminals 86 and 85. 2. Disconnect module connector.
5. Measure resistance again as per the following
table.
TEST PROBES RESISTANCE
Terminal 30
Close to 0
Terminal 87

If results are not as per the above tables, replace

relay.

ACS Relay Input Voltage Test

1. Remove relay (R5), refer to FUSE AND RELAY
at the beginning of this section.
vmr2010-004-011_a
2. Set the FLUKE 115 MULTIMETER (P/N 529 035 1. Module connector
868) to Vdc.
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
3. Place ignition switch to ON position.
868) to .
4. Measure voltage as per the following tables.
4. Measure resistance as per the following table.
Outlander 500 LTD
Outlander 500 LTD
TEST PROBES VOLTAGE
TEST PROBES RESISTANCE
Fuse box pin 6D (OR/GN)
Battery voltage Module pin 8 (OR/PK)
Battery negative (-) post (± 12 Vdc) Close to 0
Fuse box pin 7C (OR/PK)

Outlander 800R LTD

Outlander 800R LTD
TEST PROBES VOLTAGE
TEST PROBES RESISTANCE
Fuse box pin 12A
(OR/GN) Module pin 8 (OR/PK)
Battery voltage
(± 12 Vdc) Fuse box pin 11B Close to 0
Battery negative (-) post (OR/PK)

Outlander 500 LTD ACS COMPRESSOR

TEST PROBES VOLTAGE ACS Compressor Operation Test
Fuse box pin 7D (BE/PK) 1. Connect vehicle to B.U.D.S. Refer to COMMU-
Battery voltage
Battery negative (-) post (± 12 Vdc) NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.

vmr2010-004 37
 www.midwestmanuals.com
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

1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
3. Disconnect compressor connector.

vmr2010-004-201_c

Step 1: Activation page

Step 2: ACS folder
Step 3: Compressor operation test button

5. Verify if compressor works properly.

ACS Compressor Power Wire

Continuity Test (from Relay)
1. Remove relay, refer to FUSE AND RELAY at the
beginning of this section.
2. Disconnect compressor connector.
vmr2010-004-103_a

1. Compressor connector

4. Place ignition switch to ON position.

5. Probe compressor connector.
6. Press selector button several times until
AIR_SUSP is displayed.

vmr2010-004-103_a

1. Compressor connector

3. Set the FLUKE 115 MULTIMETER (P/N 529 035

868) to .
4. Measure resistance as per the following table.
Outlander 500 LTD
TEST PROBES RESISTANCE vmo2010-004-005_a

Compressor pin C (BE/VI) 1. Selector button

2. AIR_SUSP displayed
Close to 0
Fuse box pin 6C (BE/VI) 7. Set suspension mode to ACS 2 using the ACS
button.

38 vmr2010-004
 www.midwestmanuals.com
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-
tor terminals as per the following table. 8. Disconnect compressor connector.
TEST PROBES VOLTAGE
Pin C (BE/VI) Battery voltage
Pin A (BK) (± 12 Vdc)

ACS Compressor Removal

1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove LH side panel.
3. Remove storage tray.

vmr2010-004-015_a

1. Compressor connector

9. Disconnect the following hoses from compres-

sor air fittings.
– Compressor air inlet hose
– Compressor air outlet hose
– Auxiliary line hose.

vmr2010-004-013_a

1. Storage tray

4. Remove solenoid valve. Refer to ACS SOLE-

NOID VALVE REMOVAL.
5. Remove manifold. Refer to ACS MANIFOLD
REMOVAL.
6. Remove module. Refer to ACS MODULE RE-
MOVAL.
7. Remove connector of auxiliary line pressure vmr2010-004-016_a

transducer from support. 1. Compressor air inlet hose

2. Compressor air outlet hose
3. Auxiliary line hose

vmr2010-004 39
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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. Front retaining screws

13. Remove compressor from vehicle by pulling it

upwards.

vmr2010-004-017_a

1. RH side retaining bolt

vmr2010-004-020

14. Detach compressor connector from front sup-

port.
15. Remove mounting nuts from compressor
vmr2010-004-018_a front support.
1. LH side retaining bolt
16. Remove front support from compressor.
12. Remove compressor front retaining screws.

40 vmr2010-004
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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
3. Front support Ensure that check valve is installed with arrows
pointing toward T-fitting.
NOTICE Do not remove rear support from
compressor.
17. Remove the following fittings from compres-
sor.
– Compressor air inlet fitting
– Compressor T-fitting
– Compressor check valve.

vmr2010-004-024_a

Ensure that air hoses are properly inserted into fit-

tings, refer to the following illustrations.

vmr2010-004-023_a

1. Compressor air inlet fitting

2. Compressor T-fitting
3. Compressor check valve

ACS Compressor Installation

vmo2010-011-102_a
The installation procedure is the reverse of re- PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED
moval procedure, however pay attention to the 1. Fitting
following. 2. Mark
A. Must be inserted into fitting
If fitting or valve is the one previously removed
(old one), apply LOCTITE 592 (PIPE SEALANT)
(P/N 293 800 018) on all male threads.
If fitting or valve is a new one, do not apply
sealant, it should be already applied on male
threads.
Install T-fitting with an angle of 45° as shown on vmo2010-011-103

following illustration. HOSE PROPERLY INSERTED INTO FITTING

vmr2010-004 41
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Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

ACS AIR FILTER 5. Locate ACS compressor air filter.

ACS Air Filter Removal 6. Unscrew ACS compressor air filter from air box.
1. Remove seat.
2. Remove central panel.

vmo2010-004-009_a

1. ACS compressor air filter

vmo2006-007-026_a

1. Central panel
7. Push tabs then open cover.
2. Tabs to pull

3. Lift dashboard upwards.

vmo2010-004-010_a

1. tabs

8. Remove prefilter (foam) and filter (disc).

vmr2008-068-002_a

TYPICAL
1. Central panel
2. Dashboard

4. Release clamps and remove air filter box cover.

vmo2010-004-011_a

1. Prefilter (foam)
2. Filter (disc)

The installation is the reverse of removal proce-

dure.

ACS Air Filter Cleaning

Remove ACS compressor air filter, refer to AIR
FILTER REMOVAL.
Prefilter (Foam) Cleaning
1. Pour cleaning solution (P/N 219 700 341) or an
vmo2006-007-027_a
equivalent into a bucket.
1. Release clamps
2. Put the prefilter in to soak for a few minutes.
42 vmr2010-004
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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) to .
4. Let the prefilter dry completely. 5. Measure resistance as per the following table.
Filter (Disc) Cleaning TEST PROBES RESISTANCE
1. Blow low pressure compressed air on filter to Pressure transducer
clean it. pin 2 (PK/BR) Close to 0
NOTICE Do not wash the filter (disc) with any Module pin 3 (PK/BR)
cleaning solution.
Refer to the following illustration for the pressure
Housing Cleaning transducer connector pinout.
1. Blow low pressure compressed air in housing
to clean it.

PRESSURE TRANSDUCER (ACS

AUXILIARY LINE)
Pressure Transducer Signal Circuit
Continuity Test vmr2010-004-108

1. Remove seats and RH side panel. Pressure Transducer Input Voltage Test
2. Disconnect module connector. 1. Remove seats and RH side panel.
2. Disconnect pressure transducer connector.

vmr2010-004-011_a

1. Module connector

3. Disconnect pressure transducer connector. vmr2010-004-104_a

1. Pressure transducer connector

3. Set the FLUKE 115 MULTIMETER (P/N 529 035

868) to Vdc.
4. Place ignition switch to ON position.
5. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 3 (PK/OR) Battery voltage
Battery negative (-) post (± 12 Vdc)

Refer to the following illustration for the pressure

transducer connector pinout.
vmr2010-004-104_a

1. Pressure transducer connector

vmr2010-004 43
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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. Oetiker clamp

5. Install a new pressure transducer on hose.

6. Install a new Oetiker clamp using OETIKER PLI-
ERS (P/N 295 000 070).
7. Connect pressure transducer connector.
8. Ensure that there is no air leaks from pressure
transducer hose. Refer to ACS SYSTEM LEAK
TEST (WITH B.U.D.S.).
vmr2010-004-104_a

1. Pressure transducer connector ACS HOSES

3. Set the FLUKE 115 MULTIMETER (P/N 529 035 ACS Hose and Fitting Replacement
868) to Vdc. 1. Release air pressure, refer to RELEASING AIR
4. Place ignition switch to ON position. PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
5. Measure voltage as per the following table.
2. Locate hose or fitting to be replaced.
TEST PROBES VOLTAGE
3. Remove it from vehicle.
Pin 1 (BK/GY) Battery voltage 4. Install the new hose or fitting.
Battery positive (+) post (± 12 Vdc)
5. Perform a ACS SYSTEM LEAK TEST (WITH
B.U.D.S.).
Refer to the following illustration for the pressure
transducer connector pinout. Auxiliary Line Adapter Replacement
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Disconnect auxiliary line hose from adapter as
follows:
2.1 Push fitting ring toward adapter.
vmr2010-004-108
2.2 Hold ring in place.
Pressure Transducer Replacement 2.3 Pull air hose.
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Disconnect pressure transducer connector.
3. Remove Oetiker clamp.
44 vmr2010-004
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Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

vmo2010-011-103

HOSE PROPERLY INSERTED INTO FITTING

SHOCK ABSORBERS
Shock Absorber Removal
vmr2010-004-031_a
1. Lift rear of vehicle until rear shock absorbers are
1. Auxiliary line adapter
fully extended.
2. Fitting ring 2. Install jack stands or blocks under the frame to
3. Drill retaining rivets. support the vehicle.
3. Unscrew air hose from shock absorber as fol-
lows:
3.1 Install an appropriate wrench on shock fit-
ting to hold it in place.
3.2 Unscrew air hose fitting using another
wrench.

vmr2010-004-032_a

1. Retaining rivets

4. Install new adapter.

5. Secure adapter support using rivets.
6. Connect auxiliary line hose into adapter.
vmr2010-004-027_a
Ensure that air hoses are properly inserted into fit- 1. Shock absorber fitting
tings, refer to the following illustrations. 2. Air hose fitting

NOTICE To avoid damaging the shock fitting

threads, install a wrench on the shock fitting to
hold it in place while unscrewing the air hose
fitting.
4. Remove the shock absorber lower bolt and nut.

vmo2010-011-102_a

PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED

1. Fitting
2. Mark
A. Must be inserted into fitting

vmr2010-004 45
 www.midwestmanuals.com
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.

1
vmr2010-004-028_a

1. Shock absorber lower bolt

5. Remove the shock absorber upper bolt and nut.

A14F0BA

TYPICAL
1. Clamp here

NOTICE Do not clamp directly on shock

body.
Inspect shock absorber as following:
1. Examine the shock absorber for leaks.
2. Extend and compress the shock absorber shaft
several times over its entire stroke.
vmr2010-004-029_a
3. Check that the shock absorber shaft moves
1. Shock absorber upper bolt
smoothly and with uniform resistance with its
rod upward.
6. Remove shock absorber from vehicle. Any of the following conditions will denote a de-
fective shock absorber:
Shock Absorber Disassembly
– A skip or a hang back when reversing stroke at
NOTICE Be careful while manipulating or mid travel.
installing the shock absorber in the spring – Seizing or binding condition except at extreme
remover tool. The shock absorber body must end of either stroke.
not be scratched or damaged to avoid air leak- – A gurgling noise, after completing one full com-
age. pression and extension stroke.
1. Use the SPRING REMOVER (P/N 529 036 007). Replace shock absorber if any faults are present.

Shock Absorber Assembly and

Installation
Assembly and installation are the reverse of dis-
assembly and removal procedures, however pay
529036007
attention to the following.
Assemble shock absorber as per the following il-
2. Place the tool in a vise. lustrations.
3. Position the shock absorber in the tool and in-
stall the spring compressor pins.
4. Tighten the spring remover screw until the
spring is sufficiently compressed to remove
spring locking devices.

46 vmr2010-004
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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.
Torque upper and lower shock absorber bolts to
53 N•m (39 lbf•ft).
If the same shock absorber is reused, apply LOC-
TITE 592 (PIPE SEALANT) (P/N 293 800 018) on air
hose sleeve male threads.
While holding shock fitting with a wrench, tighten
air hose fitting to 19 N•m (168 lbf•in).

vmr2010-004 47
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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. To
avoid damaging the shock fitting threads, in-
stall a wrench on the shock fitting to hold it in
place while screwing the air hose fitting.

48 vmr2010-004
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NOTES
 www.midwestmanuals.com

NOTES