2017 Can-Am Outlander 450 570 Service Manual

SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to cor- NOTE: Indicates supplementary information re-
rectly service and repair the Can-Am™ Outlander™ quired to fully complete an instruction.
and Renegade™ ATV . Although the mere reading of such information
This edition was primarily published to be used does not eliminate the hazard, your understanding
by mechanics and technicians who are already of the information will promote its correct use.
familiar with all service procedures relating to Always observe common shop safety practice.
BRP products. Technicians should attend training
courses given by BRPTI. Unless otherwise noted, the engine must be
stopped and the key must be removed prior to
Please note that the instructions in this manual performing any services.
will apply only if proper hand tools and special ser-
vice tools are used. Torque wrench tightening specifications must be
strictly adhered to. Use the torque values and ser-
The contents of this manual depicts parts and vice products as in the exploded views or in the
procedures applicable to the particular product at procedures when noted.
the time of writing. Service and warranty bulletins
may be published to update the content of this Locking devices when removed must be replaced
manual. Dealer modifications that were carried (e.g.: locking tabs, elastic stop nuts, self-locking
out after manufacturing of the product, whether fasteners, cotter pins, etc.).
or not authorized by BRP, are not included. Hoses, cables and locking ties removed during a
In addition, the sole purpose of the illustrations procedure must be reinstalled as per factory stan-
throughout the manual, is to assist identification dards.
of the general configuration of the parts. They are When ordering parts always refer to the specific
not to be interpreted as technical drawings or ex- model PARTS CATALOGS.
act replicas of the parts. We strongly recommend that any services be car-
The use of BRP parts is most strongly recom- ried out and/or verified by a highly skilled profes-
mended when considering replacement of any sional mechanic.
component. Dealer and/or distributor assistance It is understood that this manual may be trans-
should be sought in case of doubt. lated into another language. In the event of any
The engines and the corresponding components discrepancy, the English version shall prevail.
identified in this document should not be utilized BRP disclaims liability for all damages and/or in-
on product(s) other than those mentioned in this juries resulting from the improper use of the con-
document. tents of this publication.
It is understood that certain modifications may
render use of the ATV illegal under existing fed-
eral, provincial and state regulations.
This manual emphasizes particular information de-
noted by the following wording and symbols:
WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.
CAUTION Indicates a hazardous situation

which, if not avoided, could result in minor or
moderate injury.
NOTICE Indicates an instruction which, if not
followed, could result in severe damage to ve-
hicle components or other property.
vmr2017-101 I
INTRODUCTION
INTRODUCTION
GENERAL INFORMATIONS VIN Decal Description
The information and component/system descrip-
tions contained in this manual are correct at time MANUFACTURED BY :
FABRIQUÉ PAR:
of publication. BRP however, maintains a policy of
continuous improvement of its products without MFD. DATE FAB : 12/2003 MODEL: 1234 2
imposing upon itself any obligation to install them VIN / NIV: 2BPS1234X2V000123 1
on products previously manufactured. 3
TYPE: ATV / VTT
Due to late changes, it may have some differ- MADE IN/FABRIQUÉ AU:
XXXXX
ences between the manufactured product and
the description and/or specifications in this docu- vmr2015-005-004_a
ment. TYPICAL — VEHICLE SERIAL NUMBER DECAL UNDER SEAT

1. VIN (Vehicle Identification Number)
BRP reserves the right at any time to discontinue 2. Vehicle manufacturing date and model number
3. VIN bar code
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
VEHICLE INFORMATION
VEHICLE IDENTIFICATION
NUMBER (VIN) LOCATIONS
vmr2015-005-003_a
TYPICAL — VEHICLE SERIAL NUMBER DECAL ON RH SIDE

1 OF FRAME
2. Vehicle manufacturing date and model number
ENGINE IDENTIFICATION
NUMBER (EIN)
2 3
vmr2015-005-005_a
VIN LOCATIONS
1. VIN decal under seat
2. VIN decal on lower frame member, RH side
3. VIN stamped on lower frame member, RH side
vmr2015-005-001_a
BACK OF 450 ENGINE

1. EIN (Engine Identification Number)
II vmr2017-101
INTRODUCTION
Replacement or repair of any emission related

component must be executed in a manner that
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.
Exceptions include manufacturer's prescribed
changes.
vmr2016-005-001_a
OWNER RESPONSIBILITY
LH SIDE OF 570 ENGINE The owner/operator is required to have engine
maintenance performed to maintain emission
levels within prescribed certification standards.
The owner/operator is not to, and should not al-
low anyone else to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.
EMISSION REGULATIONS
The vehicle you are servicing may have been
certified to applicable emission regulations in
your country or state. Not as an exhaustive list;
this may include standards for engine exhaust
tmr2011-002-002_a
emissions, crankcase emissions, permeation
TYPICAL - RH SIDE OF OTHER ENGINES
emissions and evaporative emissions. Servic-
1. Engine Identification Number (EIN) ing procedures in this manual must be strictly
followed in order to keep the vehicle within the
ENGINE EMISSIONS factory specifications. Failure to follow servicing
procedures in this manual may lead a vehicle to
INFORMATION be out of compliance with applicable emission
regulations.
MANUFACTURER'S When servicing any vehicle; adjustments must be
RESPONSIBILITY kept within published factory specifications. Re-
Manufacturers of engines must determine the placement or repair of any emission related com-
exhaust emission levels for each engine horse- ponent must be executed in a manner that main-
power family and certify these engines with tains emission levels within the applicable certifi-
the United States of America Environmental cation standards. Nobody is allowed to modify the
Protection Agency (EPA). An emissions control engine in any manner that would alter the horse-
information label, showing emission levels and power or allow emission levels to exceed their
engine specifications, must be placed on each predetermined factory specifications. Exceptions
vehicle at the time of manufacture. include manufacturer’s prescribed changes.
The owner/operator is required to have engine
DEALER RESPONSIBILITY maintenance performed to maintain emission lev-
els within the prescribed certification standards.
When servicing any vehicle that carry an emis- The owner/operator is allowed and should not
sions control information label, adjustments must allow anyone else to modify the engine in any
be kept within published factory specifications. manner that would alter the horsepower or allow
emissions levels to exceed their predetermined
factory specifications.
vmr2017-101 III
INTRODUCTION
MANUAL INFORMATION MANUAL LAYOUT

This manual is divided into many major sections as
MANUAL PROCEDURES can be seen in the main table of contents at the
Many of the procedures in this manual are inter- beginning of the manual.
related. Before undertaking any task, you should Each section is divided into various subsections,
read and thoroughly understand the entire section and again, each subsection has one or more divi-
or subsection in which the procedure is contained. sions.
Illustrations and photos show the typical construc-
WARNING tion of various assemblies and, in all cases, may
Unless otherwise specified, the engine not reproduce the full detail or exact shape of the
should be turned OFF and cold for all main- parts used in a particular model vehicle. However,
tenance and repair procedures. they represent parts which have the same or a
similar function.
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 their approved equivalents.
The use of RIGHT and LEFT indications in the text
are always referenced to the driving position (sit-
ting on the vehicle).
vmr2015-005-006_a
TYPICAL
1. Left
2. Right
This manual uses technical terms which may be

different from the ones of the parts catalogs.
When ordering parts always refer to the specific
model PARTS CATALOGS.
NOTICE Most fasteners are metric, and most
components are built with parts dimensioned
using the metric system. Consult the appropri-
ate PARTS CATALOG to obtain and use the cor-
rect parts and fasteners. Mismatched or incor-
rect fasteners could cause damage to the vehi-
cle.
IV vmr2017-101
INTRODUCTION
TYPICAL PAGE
Section 06 ENGINE Page heading

Subsection 01 (MAGNETO) indicates section
and subsection.
Subsection title MAGNETO

Indicates applicable Models
models.
Loctite 243 Drop represents a

service product
Exploded view assists Model
to be applied.
you in identifying parts
and their related Dotted box contains
positions. parts applicable to a
specific model.
Bold face number

1 is used to identify
a part referred to
the text.
NEW indicates that the
part must be replaced NEW
with a new one.
5 Nm
(44 lbfin)
Illustration number
for publishing process. XXX0000
Document number for 55 Page number

publishing process.
mmr2008-001
NOTICE Pay attention to torque specifications.

Some of these are in lbf in instead of lbf ft.
Use appropriate torque wrench.
Typical_iso_2008_en
vmr2017-101 V
INTRODUCTION
TYPICAL PAGE
Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)
Tittle in bold
indicates category
of information to be GENERAL
carried out. NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Reference to a Clean threads before applying a threadlocker. Re-
specific section fer to the SELF-LOCKING FASTENERS and LOC-
or subsection. TITE APPLICATION sections at the beginning of
this manual for complete procedure. TYPICAL
WARNING indicates a general
Torque wrench tightening specifications
view which may
must be strictly adhered to. not represent exact
Locking devices (e.g.: locking tabs, elastic 1 details.
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones. TYPICAL
1. Starting pulley
PROCEDURES NOTE: To remove starting pulley bolts, hold mag- Call-outs pertaining
Indicates component neto flywheel with a socket as shown. to above illustration.
procedures apply to. MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
Indicates specific a clean cloth. Illustration always
procedure to be Magneto Flywheel Removal follows text to which
carried out. Remove muffler, refer to the EXHAUST SYSTEM it applies.
section.
Remove acoustic panel.
Remove rewind starter. mmr2007-016-002
Remove starting pulley no. 2. TYPICAL Italic bold face type-

Models
setting indicates a
Remove the connecting flange retaining the
procedure applicable
rewind starter to the engine housing. to a specific
model(s).
mmr2008-001 57
Bold face number following part

name refers to exploded view
at beginning of subsection.
typical_txt_2008_en
VI vmr2017-101
INTRODUCTION
TIGHTENING TORQUE
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, refer to the following table.
WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices must be replaced when removed (e.g.: locking tabs, elastic stop nuts, self-lock-
ing fasteners, cotter pins, etc.).
In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce-
dure:
1. Manually screw in all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.
NOTICE Be sure to use the recommended tightening torque for the specified fastener used.
Whenever possible, always apply torque on the nut.
Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are used to
secure a part (eg. a cylinder head). Some parts must be torqued according to a specific sequence and
torque pattern as detailed in the installation procedure.
4.8 8.8 9.8 10.9 12.9

Property
class and
head 4.8 8.8 9.8 10.9 12.9
markings
4.8 8.8 9.8 10.9 12.9 12.9
5 8 10 12
Property
class and
12
10
nut
5
markings
A00A8BS
FASTENER FASTENER GRADE/TORQUE

SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5 – 2 N•m 2.5 – 3 N•m 3.5 N•m - 4 N•m 4 N•m - 5 N•m
M4
(13 – 18 lbf•in) (22 – 27 lbf•in) (31 lbf•in - 35 lbf•in) (35 lbf•in - 44 lbf•in)
3 N•m - 3.5 N•m 4.5 N•m - 5.5 N•m 7 N•m - 8.5 N•m 8 N•m - 10 N•m
M5
(27 lbf•in - 31 lbf•in) (40 lbf•in - 49 lbf•in) (62 lbf•in - 75 lbf•in) (71 lbf•in - 89 lbf•in)
6.5 N•m - 8.5 N•m 8 N•m - 12 N•m 10.5 – 15 N•m
M6 16 N•m (142 lbf•in)
(58 lbf•in - 75 lbf•in) (71 lbf•in - 106 lbf•in) (93 – 133 lbf•in)
M8 15 N•m (133 lbf•in) 25 N•m (18 lbf•ft) 32 N•m (24 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 73 N•m (54 lbf•ft)
vmr2017-101 VII
INTRODUCTION
FASTENER INFORMATION Threadlocker Application for

Uncovered Holes (Bolts and Nuts)
NOTICE 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 1
could cause damage to the vehicle or possible
personal injury.
SELF-LOCKING FASTENER
PROCEDURE
2
A00A3LA
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.

2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
A00A6LA on threads and allow to dry.
TYPICAL — SELF-LOCKING FASTENER 3. Choose proper strength Loctite threadlocker.
The following describes common procedures 4. Fit bolt in the hole.
used when working with self-locking fasteners. 5. Apply a few drops of threadlocker at proposed
Use a metal brush or a tap to properly clean a tightened nut engagement area.
threaded hole, then use a solvent. Allow the sol- 6. Position nut and tighten as required.
vent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper Threadlocker Application for Blind
adhesion of the product used for locking the fas- Holes
tener.
LOCTITE® THREADLOCKER 1
APPLICATION PROCEDURE
The following describes common procedures 2
used when working with Loctite products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.
lmr2007-040-004_a
1. On fastener threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.

2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
on threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
VIII vmr2017-101
INTRODUCTION
4. Apply several drops along the threaded hole Threadlocker Application for
and at the bottom of the hole. Pre-Assembled Parts
5. Apply several drops on bolt threads.
6. Tighten as required.
Threadlocker Application for Stud

Installation in Blind Holes 1
1 3
2
A00A3OA
1. Apply here
lmr2007-040-005_a 2. Do not apply
1. On stud threads
2. On threads and in the hole 1. Clean bolts and nuts with solvent.
3. On retaining nut threads
2. Assemble components.
1. Clean threads (stud and hole) with solvent. 3. Tighten nuts.
2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041) 4. Apply a few drops of proper strength Loctite on
on threads and allow to dry. bolt/nut contact surfaces.
3. Apply 2 or 3 drops of proper strength Loctite 5. Avoid touching metal with tip of flask.
threadlocker on female threads and in hole.
NOTE: For preventive maintenance on exist-
NOTE: To avoid a hydro lock situation, do not ap- ing equipment, retighten nuts and apply proper
ply too much Loctite. strength Loctite on bolt/nut contact surfaces.
4. Apply several drops of proper strength Loctite
on stud threads. Threadlocker Application for an
5. Install stud. Adjustment Screw
6. Install cover, part, etc.
7. Apply a few drops of proper strength Loctite on 2
1
uncovered stud threads.
8. Install and tighten retaining nut(s) as required.
A00A3PA
1. Apply here
2. Plunger
1. Adjust screw to proper setting.

2. Apply a few drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
vmr2017-101 IX
INTRODUCTION
NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

a soldering iron (232°C (450°F)).
Application for Stripped Thread Repair 1 2
5
1
6
8
2
1
A00A3QA 4 7
1. Release agent
2. Stripped threads 1 3
3. Form-A-Thread
lmr2007-040-006_a
4. Tape
5. Cleaned bolt 1. Proper strength Loctite
6. Plate 2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
7. New threads (P/N 293 800 038) on both sides of gasket
8. Threadlocker 3. Loctite Primer N only
Standard Thread Repair 1. Remove old gasket and other contaminants us-
Follow instructions on Loctite FORM-A-THREAD ing LOCTITE CHISEL (GASKET REMOVER) (P/N 413
81668 package. 708 500). Use a mechanical means only if nec-
essary.
If a plate is used to align bolt:
NOTE: Avoid grinding.
1. Apply release agent on mating surfaces.
2. Clean both mating surfaces with solvent.
2. Put waxed paper or similar film on the surfaces.
3. Spray Loctite Primer N on both mating surfaces
3. Twist bolt when inserting it to improve thread and on both sides of gasket and allow to dry 1
conformation. or 2 minutes.
NOTE: NOT intended for engine stud repairs. 4. Apply LOCTITE 518 (P/N 293 800 038) on both
Repair of Small Holes/Fine Threads sides of gasket, using a clean applicator.
Option 1: Enlarge damaged hole, then follow 5. Place gasket on mating surfaces and assemble
STANDARD THREAD REPAIR procedure. parts immediately.
Option 2: Apply FORM-A-THREAD on the screw NOTE: If the cover is bolted to blind holes, apply
and insert in damaged hole. proper strength Loctite in the hole and on threads.
Permanent Stud Installation (Light Duty) Tighten fastener.
1. Use a stud of the desired thread length. NOTE: If holes are sunken, apply proper strength
Loctite on bolt threads.
NOTE: DO NOT apply release agent on stud.
6. Tighten as usual.
2. Follow Standard Thread Repair procedure.
3. Allow 30 minutes for Loctite FORM-A-THREAD
to cure.
4. Complete part assembly.
X vmr2017-101
INTRODUCTION
Threadlocker Application for Mounting 2. Spray housing and gasket with LOCTITE 7649
on a Shaft (PRIMER) (P/N 293 800 041).
Mounting with a Press 3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
4. Install according to standard procedure.
1
5. Wipe off excess product.
2 6. Allow 30 minutes for product to cure.
NOTE: Normally used on worn-out housings to
3 prevent leaking or sliding.
A00A3UA
It is generally not necessary to remove gasket
1. Bearing compound applied on outer gasket diameter.
2. Proper strength Loctite
3. Shaft
1. Clean shaft external contact surface.

2. Clean internal contact surface of part to be in-
stalled on shaft.
3. Apply a strip of proper strength Loctite on cir-
cumference of shaft contact surface at inser-
tion or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft. DO NOT use Loctite an-
tiseize or any similar product. No curing period is
required.
Mounting in Tandem
1. Apply retaining compound on internal contact
surface (bore) of parts to be installed.
2. Continue parts assembly in the prescribed or-
der.
Threadlocker Application for Case-In

Components (Metallic Gaskets)
A00A3VA 1
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket

diameter.
vmr2017-101 XI
Subsection 02 (PERIODIC MAINTENANCE SCHEDULE)
PERIODIC MAINTENANCE SCHEDULE

GENERAL
Maintenance is very important for keeping your vehicle in safe operating condition. The vehicle should
be serviced as per the maintenance schedule.
The maintenance schedule does not exempt the pre-ride inspection.
A repair shop or person of the owner's choosing may maintain, replace, or repair emission control
devices and systems. These instructions do not require components or service by BRP or authorized
Can-Am dealers. Although an authorized Can-Am dealer has an in-depth technical knowledge and tools
to service the Can-Am ATV, the emission-related warranty is not conditioned on the use of an authorized
Can-Am dealer or any other establishment with which BRP has a commercial relationship. For
emission-related warranty claims, BRP is limiting the diagnosis and repair of emission-related parts to
the authorized Can-Am dealers. For more information, please refer to the US EPA EMISSION-RELATED
WARRANTY contained herein. Proper maintenance is the owner’s responsibility. A warranty claim
may be denied if, among other things, the owner or operator caused the problem through improper
maintenance or use.
You must follow the instructions for fuel requirements in the fueling section of this manual. Even if gaso-
line containing greater than ten volume percent ethanol is readily available, the US EPA issued a prohibi-
tion against the use of gasoline containing greater than 10 vol% ethanol that applies to this vehicle. The
use of gasoline containing greater than 10 vol% ethanol with this engine may harm the emission control
system.
WARNING
Failure to properly maintain the vehicle according to the maintenance schedule and procedures
can make it unsafe to operate.
SEVERE DUSTY CONDITIONS

Engine Air Filter Maintenance Guideline
Air filter maintenance should be adjusted according to riding conditions.
Air filter maintenance must be increased in frequency in the following dusty conditions:
– Riding on dry sand
– Riding on dry dirt covered surfaces
– Riding on dry gravel roads or similar conditions.
NOTE: Riding in a group in these conditions would increase even more the air filter maintenance.
MAINTENANCE SCHEDULE LEGEND

Operation in trail riding conditions
Operation in severe riding conditions (dusty or muddy) or carrying heavy loads condition
MAINTENANCE SCHEDULE
Make sure to perform proper maintenance at recommended intervals as indicated in the tables. Some
items of the maintenance schedule must be performed in function of the calendar, regardless of the
distance or time of operation.
vmr2017-102 1
EVERY 1 500 KM (1,000 MI) OR 50 HOURS (whichever comes first)

EVERY 750 KM (500 MI) OR 25 HOURS (whichever comes first)
Verify and clean engine air filter. Replace as needed
Verify battery connections
Lubricate rear propeller shaft joint
Inspect tie rod ends and ball joints for play and boots condition
Lubricate front suspension arm bushings
Lubricate rear stabilizer bar bushings
Inspect the drive shaft boots and protectors
Inspect brake pads. Replace as needed
Inspect wheel bearings for abnormal play
Inspect and clean CVT air filter. Replace as needed. (If equipped)
Tighten wheel beadlock bolts (If equipped)
Lubricate lower shock absorber spherical bearings (Outlander LTD and XT-P and Renegade Xxc)
Lubricate upper shock absorber spherical bearings (Outlander LTD)

Adjust valve clearance
Clean muffler spark arrester
Verify and clean throttle body
Replace fuel vent breather filter
Verify CVT drive belt and clean CVT pulleys
Lubricate the one way bearing of the drive pulley
Inspect ACS suspension hoses condition (LTD)
The following must be performed at least once a year:
Change engine oil and filter
Lubricate throttle cable
Inspect and clean brake system
Inspect battery condition
Verify steering system for abnormal play
Verify front differential and rear final drive oil level and look for contamination
Verify gearbox oil level and look for contamination (except 450)
2 vmr2017-102
PERFORM AT THE FIRST 3 000 KM (2,000 MI)AND AT 6 000 KM (4,000 MI) THEN
FOLLOW THE REGULAR SCHEDULE
PERFORM AT THE FIRST 1 500 KM (1,000 MI) AND AT 3 000 KM (2,000 MI) THEN
FOLLOW THE REGULAR SCHEDULE
Replace gearbox oil (except 450)
Clean the vehicle speed sensor (VSS) (except 450)

Verify the cooling system
Test engine coolant strength
Verify fuel system for leaks
Verify fuel pump pressure
Replace spark plugs
Replace front differential oil
Replace rear final drive oil
Replace gearbox oil (except 450)
Inspect input and output shaft seals (gearbox, differential and final drive)
Clean vehicle speed sensor
Clean and lubricate lower and upper steering column half bushings
The following must be performed every 2 years:
Replace the brake fluid
EVERY 12 000 KM (8,000 MI) OR 5 YEARS (whichever comes first)

Replace engine coolant
vmr2017-102 3
Subsection XX (PERIODIC MAINTENANCE PROCEDURES (OUTLANDER))
PERIODIC MAINTENANCE
PROCEDURES (OUTLANDER)
SERVICE TOOLS
Description Part Number Page
TEST CAP ...................................................................................... 529 035 991 ............................................. 9
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ....................................... 9, 22
SERVICE PRODUCTS
AIR FILTER OIL ............................................................................. 219 700 340 ............................................. 3
BRAKE FLUID GTLMA DOT4........................................................ 293 600 131 ..................................... 20, 22
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ........................................... 16
LONG LIFE ANTIFREEZE(F) .......................................................... 619 590 204 ............................................. 7
LONG LIFE ANTIFREEZE .............................................................. 219 702 685 ............................................. 7
SUSPENSION GREASE ................................................................. 293 550 033 ..................................... 18–19
XPS 4-STROKE SYNTH. BLEND OIL (F)........................................ 619 590 109 ............................................. 5
XPS 4-STROKE SYNTH. BLEND OIL............................................. 293 600 121 ............................................. 5
XPS 4-STROKE SYNTHETIC OIL (F).............................................. 619 590 114 ............................................. 5
XPS 4-STROKE SYNTHETIC OIL ................................................... 293 600 112 ............................................. 5
XPS BRAKES AND PARTS CLEANER (USA) ................................. 219 701 705 ........................................... 20
XPS BRAKES AND PARTS CLEANER ........................................... 219 701 776 ........................................... 20
XPS SYNTHETIC GEAR OIL (75W 140) ........................................ 293 600 140 ..................................... 12, 17
XPS SYNTHETIC GEAR OIL (75W 90) .......................................... 293 600 043 ........................................... 16
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 21
GENERAL – Riding on dry dirt covered surfaces

This subsection provides: – Riding on dry gravel trails or similar conditions.
– Fluid level verifications NOTE: Riding in a group in these conditions
– Maintenance procedures. would increase even more the air filter mainte-
nance.
The following systems should be serviced accord-
ing to the PERIODIC MAINTENANCE SCHED- Removing the Engine Air Filter
ULE.
NOTICE Never remove or modify any com-
PROCEDURES ponent in the air filter housing. Otherwise,
engine performance degradation or damage
can occur. The engine is calibrated to operate
AIR INTAKE SYSTEM specifically with these components.
Engine Air Filter Maintenance 1. Remove seat.
Guideline
2. Remove console. Refer to BODY subsection.
As with any ATV, air filter maintenance is critical to
ensure proper engine performance and life span. 3. Rotate air filter cover counterclockwise to re-
move it.
Air filter maintenance should be adjusted accord-
ing to riding conditions. NOTE: A socket wrench may be used to ease re-
moval of the air filter cover.
Air filter maintenance must be increased in fre-
quency and oil must be added to the foam filter
for the following dusty conditions:
vmr2017-103 1
3. Check air filter dirty chamber for cleanliness.

– If any debris or water are found, clean air fil-
ter chamber using a vacuum cleaner.
NOTICE Do not blow compressed air into air
filter chamber.
4. Check air filter housing drain tube (clean cham-
ber).
– If any debris or water are found, refer to SPE-
CIAL PROCEDURES subsection.
– Investigate for contamination source.
vmo2015-005-014_a
1. Air filter cover
4. Remove air filter.
vmr2012-010-017_b
TYPICAL - SOME PARTS REMOVED FOR CLARITY

1. Air filter drain tube
vmo2015-005-015_a Cleaning the Paper Filter

AIR FILTER REMOVAL
1. Ensure that the foam filter is removed from pa-
per filter.
Inspecting and Draining the Engine Air
Filter Housing 2. Tap out heavy dust from the paper filter.
1. Remove LH side panel and extension. Refer to This will allow dirt and dust to get out of the paper
BODY subsection. filter.
2. Drain air filter housing drain tube. NOTE: Paper filter have a limited life span; re-
place filter if too dirty or clogged.
NOTICE It is not recommended to blow com-
pressed air on the paper filter; this could dam-
age the paper fibers and reduce its filtration
ability when used in dusty environments.
NOTICE Do not wash the paper filter with any
cleaning solution.
Cleaning the Foam Filter

1. Spray the foam filter inside and out with air filter
cleaner and follow manufacturer's instructions.
2. Dry the foam filter completely.
vmr2012-010-017_a

1. Air filter housing drain tube
2 vmr2017-103
vbs2009-012-005 vmo2015-005-014_b
TYPICAL - DRY 1. Cover position arrow
2. Locked
NOTE: A second application may be necessary 3. Unlocked
for heavily soiled elements.
Reinstall the console.
Oiling the Foam Filter
1. Spray the recommended air filter oil on the EXHAUST SYSTEM
foam filter previously cleaned and dried. Fol- Cleaning and Inspecting the Muffler
low manufacturer's informations. Spark Arrester
RECOMMENDED PRODUCT The muffler must be periodically purged of accu-
mulated carbon.
AIR FILTER OIL WARNING
(P/N 219 700 340)
Never run engine in an enclosed area. Never
perform this operation immediately after the
engine has been run because exhaust sys-
tem is very hot. Make sure that there are no
combustible materials in the area. Wear eye
protection and gloves. Never stand behind
the vehicle while purging exhaust system.
Respect all applicable laws and regulations.
Select a well-ventilated area and make sure the

muffler is cool.
CAUTION Never perform this operation

immediately after the engine has been running
as exhaust system is very hot.
vbs2009-012-014 Muffler (Transversal Mounting)
TYPICAL - OIL THE FOAM FILTER 1. Place transmission on PARK position.
Reinstall oiled foam filter over the paper filter. 2. Remove the clean out plug of the muffler.
Installing the Engine Air Filter

Slightly grease O-ring seal and plastic body of air
filter. Refer to AIR INTAKE SYSTEM exploded
view.
Install filter assembly in air filter housing.
Ensure air filter cover is properly locked onto the
air filter housing. See indications on filter cover
and housing.
vmr2017-103 3
vmo2015-005-037_a
TYPICAL
1. Muffler
2. Clean out plug
3. Block the end of the muffler with a shop rag and vmr2012-0005-051_a
start engine. TYPICAL — ALL MODELS

1. Screws
4. Momentarily increase engine RPM several 2. Tail pipe
times to purge accumulated carbon out of the
muffler. 3. Remove exhaust tail pipe, gasket (discard) and
spark arrester.
5. Stop engine and allow muffler to cool.
6. Reinstall the clean out plug.
Muffler (Longitudinal Mounting)
1. Remove the muffler cover and discard the
screws.
tmo2011-001-041_a
1. Spark arrester
2. Gasket
3. Exhaust tail pipe
4. Remove carbon deposits from the spark ar-

rester using a brush.
vmr2012-0005-050_a
TYPICAL NOTICE Use a soft brush and be careful to

1. Remove and discard screws avoid damaging spark arrester mesh.
2. Cover
2. Remove and discard the tail pipe retaining

screws.
4 vmr2017-103
Verifying the Engine Oil Level

NOTICE Operating the engine with an im-
proper level may severely damage engine.
NOTE: While checking the oil level, visually in-
spect engine area for leaks.
tmo2011-001-043_a
1. Clean spark arrester
5. Inspect mesh of spark arrester for any damage.

Replace as required.
6. Inspect spark arrester chamber in muffler.
Clean as required. vmr2015-063-100_a
For installation, reverse the removal procedure. TYPICAL - RH SIDE OF ENGINE

1. Dipstick
However pay attention to the following.
Install new gasket and new retaining screws. NOTE: Do not lose the O-ring placed on the dip-
stick.
TIGHTENING TORQUE
With vehicle on a level surface and engine cold,
11 N•m ± 1 N•m not running, check the oil level as follows:
Tail pipe retaining screws
(97 lbf•in ± 9 lbf•in)
1. Unscrew dipstick then remove it and wipe
clean.
LUBRICATION SYSTEM 2. Reinstall dipstick, screw in it completely.
3. Remove and check oil level. It should be near
Recommended Engine Oil or equal to the upper mark.
For the summer season, use:
RECOMMENDED SERVICE PRODUCT
Outside of XPS 4-STROKE SYNTH. BLEND
the U.S. OIL (F) (P/N 619 590 109)
Within the XPS 4-STROKE SYNTH. BLEND
U.S. OIL (P/N 293 600 121)
For all season, use:

RECOMMENDED SERVICE PRODUCT
Outside of XPS 4-STROKE SYNTHETIC OIL
the U.S. (F) (P/N 619 590 114)
Within the XPS 4-STROKE SYNTHETIC OIL
U.S. (P/N 293 600 112)
vmr2015-063-001_a
1. Full
If recommended XPS oil is not available, use a 2. Add
4-stroke SAE 5W 40 engine oil that meets or ex-
ceeds the requirements for API service classifica- To add oil, remove the dipstick. Place a funnel into
tion SJ, SL, SM or SN. Always check the API ser- the dipstick orifice.
vice label certification on the oil container, it must Add a small amount of recommended oil and
contain at least one of the above standards. recheck oil level.
vmr2017-103 5
Repeat the above procedures until oil level 11. Replace oil filter. Refer to ENGINE OIL FILTER
reaches the dipstick's upper mark. Do not over- REPLACEMENT in this subsection.
fill. Wipe off any spillage. 12. Refill engine with recommended engine oil.
Properly tighten dipstick.
MODEL ENGINE OIL CAPACITY
Changing the Engine Oil 450 engines 3 L (3.2 qt (U.S. liq.))
1. Start and warm-up engine. All engines except 450 2 L (2.1 qt (U.S. liq.))
2. Stop engine.
13. After filling, check the oil level, refer to EN-
3. Ensure vehicle is on a level surface. GINE OIL LEVEL VERIFICATION in this sub-
4. Remove dipstick. section.
5. Place a drain pan under the engine drain plug 14. Start engine and let it idle for a few minutes.
area. 15. Ensure oil filter and drain plug areas are not
6. Clean the magnetic drain plug area. leaking.
7. Unscrew magnetic drain plug and discard the 16. Stop engine.
gasket ring. 17. Wait a while to allow oil to flow down to
crankcase, then check oil level again.
CAUTION The engine oil can be very hot.
18. Refill as necessary.
19. Dispose oil and filter as per your local environ-
mental regulations.
Replacing the Engine Oil Filter

Engine Oil Filter Access
To reach oil filter, refer to BODY subsection and
remove the following parts:
– Seat
– Console
– RH side panel and extension
– RH inner fender panel.
vmr2015-063-101_a

1. Magnetic drain plug
2. Access through frame
Allow oil to drain completely from the crankcase.

8. Clean the magnetic drain plug from metal shav-
ings and residue. Presence of debris gives an
indication of internal engine damage.
9. Install a NEW gasket ring on the magnetic drain
plug.
NOTICE Never use the gasket ring a second
time. Always replace by a new one.
vmr2015-029-200_a
10. Install and tighten magnetic drain plug to the 1. Oil filter cover
recommended torque.
Removing the Engine Oil Filter
TIGHTENING TORQUE 1. Clean oil filter area.
20 N•m ± 1 N•m 2. Remove oil filter cover.
Magnetic drain plug
(15 lbf•ft ± 1 lbf•ft)
3. Remove oil filter.
6 vmr2017-103
vmr2016-009-001_a
vmr2006-008-001_a
1. Oil filter screw
2. Oil filter cover 1. O-ring - slightly oil
3. O-ring 2. End of filter - slightly oil
4. Oil filter
5. Install the cover on the engine.
Installing the Engine Oil Filter
6. Tighten oil filter cover screws to recommended
1. Check and clean the oil filter inlet and outlet
torque.
area of dirt and other contaminations.
TIGHTENING TORQUE
10 N•m ± 1 N•m
Oil filter cover screws
7. Reinstall remaining parts if applicable.
COOLING SYSTEM
Recommended Engine Coolant
COOLANT
Finland, LONG LIFE
Norway and ANTIFREEZE(F)
BRP Sweden (P/N 619 590 204)
recommended
product LONG LIFE
vmr2015-063-003_a
All Other
1. Outlet bore to the engine oil providing system ANTIFREEZE
Countries
2. Inlet bore from the oil pump to the oil filter (P/N 219 702 685)
2. Install a NEW O-ring on oil filter cover. Distilled water and
antifreeze solution
3. Install the filter into the cover. Alternative, or _ (50% distilled
if not available
4. Apply engine oil on O-ring and on end of filter. water,
50% antifreeze)
NOTICE Always use ethylene-glycol an-

tifreeze containing corrosion inhibitors specif-
ically formulated for internal combustion
aluminum engines.
To prevent antifreeze deterioration, always use
the same brand. Never mix different brands or
type of antifreeze. Always use the same an-
tifreeze unless cooling system is completely
flushed and refilled.
vmr2017-103 7
Do not use tap water, straight antifreeze or 2. Remove pressure cap.

straight water in the system. Tap water contains
minerals and impurities which build up in the sys- WARNING
tem. During cold weather, straight water causes To avoid potential burns, do not remove the
the system to freeze while straight antifreeze pressure cap if the engine is hot.
thickens and does not have the same efficiency.
3. Using an antifreeze tester, test coolant
Verifying the Engine Coolant Level strength.
WARNING MINIMUM RECOMMENDED COOLANT
In order to avoid potential burns, check STRENGTH
coolant level with engine cold. Do not re- -30°C (-22°F)
move the radiator cap if the engine is hot.
Inspecting the Engine Cooling System
1. Place vehicle on a level surface.
1. Check general condition of hoses and clamps
2. Remove gauge support. Refer to BODY sub- for tightness.
section.
2. Check the leak indicator hose for oil or coolant.
With the vehicle on a level surface, coolant level
should be between the MIN. and MAX. marks of Leaking coolant indicates a defective rotary seal.
the reservoir. Leaking oil indicates a defective oil seal. If either
seal is leaking, both seals must be replaced at the
same time. Refer to WATER PUMP SHAFT AND
SEALS in the COOLING SYSTEM subsection.
vmo2012-012-042_a
TYPICAL
1. Engine coolant reservoir vmr2016-009-002_a
1. Leak indicator hose

NOTE: When checking level at temperature 2. Water pump
lower than 20°C (68°F), it may be slightly lower
than MIN. mark. Another leak indicator hole is visible on the PTO
side. It provides an indication of the PTO gasket
3. Add coolant up to MAX. mark if required. condition. If a liquid leaks from this hole, PTO gas-
4. Use a funnel to avoid spillage. Do not overfill. ket replacement is necessary.
5. Properly reinstall and tighten reservoir cap.
6. Reinstall gauge support.
NOTICE Do not store any objects under the
gauge support.
Checking the Engine Coolant Specific

Gravity
1. Remove gauge support. Refer to BODY sub-
section.
8 vmr2017-103
REQUIRED TOOLS
TEST CAP
(P/N 529 035 991)
VACUUM/PRESSURE
PUMP
(P/N 529 021 800)
COOLING SYSTEM LEAK TEST

vmr2015-063-004_a 110 kPa (16 PSI)
TYPICAL
1. Leak indicator hole If there is no pressure drop after 10 minutes, there
2. PTO cover
3. Crankcase PTO, front side is no leak in the cooling system.
If the pressure drops, check all hoses, radiator,
3. Ensure vent hose on coolant expansion tank is
cylinders and engine base for coolant leaks or air
not obstructed.
bubbles.
Testing the Engine Cooling System Pressure
Cap Replacing the Engine Coolant
1. Remove gauge support. Refer to BODY sub- Draining the Engine Cooling System
section.
2. Remove pressure cap. CAUTION Engine coolant can be very hot.
Coolant draining should be carried out on a
WARNING cold engine.
To avoid potential burns, do not remove the 1. Remove gauge support. Refer to BODY sub-
pressure cap if the engine is hot. section.
2. Remove cooling system pressure cap.
3. Test the pressure cap using a cooling system
tester.
4. Replace the cap if it does not hold the pressure,
or if it opens at a relief pressure that is too low
or too high.
PRESSURE CAP RELIEF PRESSURE
Approximately 110 kPa (16 PSI)
Testing the Engine Cooling System Leak

1. Remove gauge support. Refer to BODY sub-
section.
2. Remove pressure cap.
WARNING vmo2012-012-042_a
TYPICAL
To avoid potential burns, do not remove the 1. Cooling system pressure cap
pressure cap if the engine is hot.
3. Unscrew coolant drain plug.
3. Pressurize cooling system as follows. NOTE: Coolant drain plug is accessible from un-
derneath RH footrest panel.
vmr2017-103 9
vmr2015-029-202_a
vmr2012-013-010_a
TYPICAL - SOME PARTS REMOVED FOR CLARITY 1. Outer exhaust heat shield
1. Coolant drain plug
4. Remove CVT duct outlet.
4. Drain cooling system into a suitable container.
5. Disconnect the lower radiator hose and drain
the remaining coolant.
NOTE: Take note of the hose clamp position be-
fore it is loosened for hose removal.
6. Reinstall coolant drain plug with a NEW sealing
washer.
7. Tighten coolant drain plug to specification.
TIGHTENING TORQUE
10 N•m ± 1 N•m
Coolant drain plug
8. Fill cooling system with recommended coolant,

refer to COOLING SYSTEM FILLING AND
vmr2015-029-203_a
BLEEDING procedure.
1. CVT duct outlet
Filling and Bleeding the Engine Cooling
System 5. Unscrew bleed screws on thermostat housing
covers of both front and rear cylinders.
1. Remove cooling system pressure cap.
2. Remove RH and LH side panels. Refer to
BODY subsection.
3. On LH side of engine, remove outer exhaust
heat shield. Refer to EXHAUST SYSTEM sub-
section.
vmr2015-029-201_a
RH SIDE
1. Front cylinder bleed screw
10 vmr2017-103
2. Before checking or adjusting the valve clear-

ance, turn crankshaft clockwise to TDC ignition
of the respective cylinder, refer to CAMSHAFT
TIMING GEAR in the TIMING CHAIN subsec-
tion.
NOTICE Crankshaft must be turned clock-
wise only to avoid loosening the magneto
retaining bolt.
3. Using a feeler gauge, check the valve clear-
ance.
VALVE CLEARANCE
0.11 mm to 0.19 mm
EXHAUST
(.0043 in to .0075 in)
vmr2015-029-204_a
LH SIDE 0.06 mm to 0.14 mm

INTAKE
1. Rear cylinder bleed screw (.0024 in to .0055 in)
6. Fill cooling system until coolant comes out of If the valve clearance is out of specification, adjust
bleed screws. valves as follows.
7. Squeeze the top of the coolant hose between NOTE: Use the center value of exhaust/intake
the radiator and coolant pump several times to specification to ensure a proper valve adjustment.
bleed all air from the highest point of the hose.
4. Hold the adjustment screw at the proper posi-
8. Install bleed screws using NEW gasket rings. tion and torque the locking nut.
9. Tighten bleed screws.
TIGHTENING TORQUE
5.0 N•m ± 0.6 N•m
Bleed screws
10. Refill coolant tank up to MAX level mark.

11. Install cooling system pressure cap.
12. Run engine at idle until the cooling fan cycles
on for a second time.
13. Stop the engine and let it cool down.
WARNING
Do not remove the pressure cap if the engine
is hot.
14. Check coolant level in the coolant tank. Refer

to VERIFYING THE ENGINE COOLANT LEVEL
vmr2007-036-003_a
in this subsection. 1. Adjustment screw
15. Add coolant if required. 2. Locking nut
3. Feeler gauge
CYLINDER HEAD 5. Repeat the procedure for each valve.

6. Before installing valve covers, recheck valve
Inspecting and Adjusting the Engine clearance.
Valve Clearance
NOTE: Check and adjust valve clearance only
when engine is cold.
1. Remove valve covers, refer to TOP END sub-
section.
vmr2017-103 11
GEARBOX
Recommended Gearbox Oil (Except
450 Engines)
RECOMMENDED
QUANTITY
PRODUCT
XPS SYNTHETIC
Approximately 450 ml
GEAR OIL (75W 140)
(15.2 U.S. oz)
(P/N 293 600 140)
If the recommended oil is not available, use a vmo2012-012-056_a
75W140 gearbox oil that meets the API GL-5 1. Drain plug
2. Oil level plug
specification.
3. Check oil level.
Verifying the Gearbox Oil Level
The oil should be level with the bottom of the oil
NOTE: Prior checking the gearbox oil level, en- level hole.
sure vehicle is on a level surface.
1. To access gearbox oil level plug, refer to BODY NOTICE Operating the gearbox with an im-
subsection and remove the following parts: proper oil level may severely damage gearbox.
– Seat 4. Install the oil level plug with its O-ring. Tighten
– Console plug as per table.
– RH side panel and extension(s) TIGHTENING TORQUE
– RH footrest panel.
5 N•m ± 0.6 N•m
Oil level plug
Replacing the Gearbox Oil

Draining the Gearbox Oil
1. Start engine and operate vehicle to warm-up
the gearbox oil.
NOTE: Running engine at idle is not sufficient, ve-
hicle transmission must be operated.
2. Position vehicle on a level surface.
3. Place a drain pan under the gearbox drain plug
area.
4. Clean drain plug area.
5. Remove magnetic drain plug and sealing
vmr2015-063-102_a
washer. Discard sealing washer.
TYPICAL
1. Oil level plug
WARNING
2. Remove the gearbox oil level plug. The gearbox oil can be very hot.
6. Remove oil level plug and its O-ring.

NOTE: Allow oil to completely flow out of gear-
box.
12 vmr2017-103
2. Inspect and clean the air inlet and outlet open-

ings from inside the CVT cover.
3. Inspect and clean the air outlet duct connected
to the exhaust system heat shield under the
seat.
NOTE: If a lot of debris or grime are found in the
CVT system, it may be necessary to remove the
ducts and thoroughly clean them.
4. Reinstall CVT cover.
vmo2012-012-056_a
Inspecting the Drive Belt
2. Oil level plug 1. Inspect belt for cracks, fraying or abnormal
wear. Replace if necessary.
7. Clean magnetic drain plug and pay attention to
any debris present on drain plug. 2. Check drive belt width at cord level. Replace if
it is out of specification.
NOTE: Presence of excessive debris provides an
indication of a gearbox problem. DRIVE BELT WIDTH
8. Reinstall magnetic drain plug with a NEW seal- SERVICE LIMIT 30 mm (1.181 in)
ing washer.
TIGHTENING TORQUE
20 N•m ± 2 N•m
Magnetic drain plug
9. Dispose gearbox oil as per your local environ-

mental regulations.
Filling the Gearbox Oil
1. Fill the gearbox through the oil level hole until
the oil reaches the bottom of the oil level hole.
2. Install the oil level plug with its O-ring. Tighten vmr2006-021-005_a
plug as per table. 1. Drive belt
2. Cord in drive belt
TIGHTENING TORQUE
5 N•m ± 0.6 N•m Drive Pulley, Driven Pulley and
Oil level plug
(44 lbf•in ± 5 lbf•in) One-Way Bearing Maintenance
Refer to CONTINUOUSLY VARIABLE TRANSMIS-
Cleaning the Vehicle Speed Sensor SION (CVT) subsection.
(VSS)
Remove the VSS. Refer to GEARBOX AND 4X4 FUEL SYSTEM
COUPLING UNIT subsection. Inspecting and Cleaning the Throttle
Remove all metal particles and oil from the VSS Body
magnet.
1. Remove the air intake housing, refer to AIR IN-
NOTE: A dirty VSS will cause erratic speedometer TAKE SYSTEM subsection.
readings.
2. Visually inspect throttle plate and throttle body
venturi for cleanliness.
CONTINUOUSLY VARIABLE
3. Clean inside throttle body if necessary. Refer to
TRANSMISSION (CVT) ELECTRONIC FUEL INJECTION (EFI) subsec-
Cleaning the CVT Air Inlet/Outlet tion.
1. Remove CVT cover, refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT) subsection.
vmr2017-103 13
Lubricating the Throttle Cable

The throttle cable must be lubricated with a sili-
cone based lubricant.
WARNING
Always use a silicone-based lubricant. Using
another lubricant (like a water-based lubri-
cant) could cause the throttle lever/cable to
become sticky and stiff.
Open the throttle lever housing.
V07I0HA 1
1. Inner housing protector
Remove the cable from the throttle lever housing.

NOTE: Slide cable in clip slot and remove the end
of cable from clip.
V07I0FY
V07I0FB
1. Remove these screws
Separate the housing.

Slide rubber protector back to expose throttle ca-
ble adjuster.
V07I0IA
Remove the throttle body side cover.
V07I0GA 1 2 3 4
1. Cable protector
2. Throttle cable adjuster
3. Lock nut
4. Throttle lever housing
Screw in the throttle cable adjuster.

Remove inner housing protector.
14 vmr2017-103
vmo2006-007-032_a
vmr2015-043-019_d
1. Throttle body
2. Side cover screws 1. Vent breather filter
2. Vent inlet check valve
Insert the needle of the lubricant can in the end of
throttle cable adjuster. Inspecting the Fuel System
1. Visually inspect fuel tank for cracks, wear
marks, signs of leakage or any other damages.
2. Visually inspect fuel system hoses for proper
rooting, cracking, wear marks, signs of leakage
or any other damages.
3. Carry out a FUEL TANK LEAK TEST, refer to
FUEL TANK AND FUEL PUMP subsection.
WARNING
All fuel system leaks must be repaired. Dam-
aged, worn or leaking fuel system com-
ponents should be replaced to ensure fuel
system tightness.
V07I0JA
Testing the Fuel Pump Pressure
Refer to FUEL TANK AND FUEL PUMP subsec-
TYPICAL
tion for procedure.
NOTE: Place a rag around the throttle cable ad-
juster to prevent the lubricant from splashing. ELECTRICAL SYSTEM
Add lubricant until it runs out at throttle body end Inspecting the Battery
of the throttle cable.
Visually inspect battery casing for cracks or other
Reinstall and adjust the cable. Refer to ELEC- damage. If casing is damaged, replace battery
TRONIC FUEL INJECTION subsection. and thoroughly clean battery rack with water and
sodium bicarbonate (baking soda).
Replacing the Fuel Tank Vent Breather
Filter Inspect battery posts condition and battery re-
tainer plate.
Ensure breather filter is installed with the flow ar-
row pointing towards the vent inlet check valve. For battery testing, refer to CHARGING SYSTEM
subsection.
vmr2017-103 15
Replacing the Spark Plug 2. With vehicle on a level surface, check oil level
by removing filler plug. Oil level must reach the
Spark Plug Access lower edge.
For access to the LH spark plug, remove the LH 3. Reinstall filler plug with a NEW sealing washer.
inner fender panel.
For access to the RH spark plug, remove the RH TIGHTENING TORQUE
side panel and extension(s). 22.5 N•m ± 2.5 N•m
Filler plug
Removing the Spark Plug
1. Remove spark plug cable from spark plug. Replacing the Front Differential Oil
2. Clean the spark plug area using pressurized air. 1. Place vehicle on a level surface. Set transmis-
3. Remove spark plug. sion in park position.
Installing the Spark Plug 2. Clean filler and drain plug areas.
Prior to installation, ensure that contact surfaces 3. Place a drain pan under the front differential.
of the cylinder head and spark plug are free of 4. Remove filler plug.
grime.
5. Remove drain plug.
1. Using a wire feeler gauge, set electrode gap as
specified in TECHNICAL SPECIFICATIONS.
2. Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) over the spark plug threads to
prevent possible seizure.
NOTICE Do not apply antiseize lubricant on
the first 2 spark plug threads.
3. Hand screw spark plug into cylinder head, then
tighten to specification using a torque wrench
and an appropriate socket.
TIGHTENING TORQUE
20 N•m ± 2 N•m
Spark plug
(15 lbf•ft ± 1 lbf•ft) vmr2016-107-002_a
BOTTOM VIEW OF VEHICLE
DRIVE SYSTEM NOTE: Allow enough time for oil to flow out.
6. Install and tighten drain plug to specification.
Verifying the Front Differential Oil
Level TIGHTENING TORQUE
1. Clean filler plug prior to checking oil level. Drain plug
7.5 N•m ± 0.5 N•m
7. Refill front differential with recommended oil.

CAPACITY RECOMMENDED OIL
XPS SYNTHETIC
GEAR OIL (75W 90)
500 ml (17 U.S. oz)
(P/N 293 600 043) or a
75W 90 (API GL-5) gear oil
8. Reinstall filler plug with a NEW sealing washer.

9. Tighten filler plug to specification.
vmr2016-107-001_a
RH SIDE OF VEHICLE
16 vmr2017-103
TIGHTENING TORQUE
22.5 N•m ± 2.5 N•m
Filler plug
Verifying the Rear Final Drive Oil Level

1. Ensure vehicle is on a level surface.
2. Clean filler plug area.
3. Remove filler plug.
vmr2016-009-004_b
LH REAR SIDE OF VEHICLE

1. Filler plug
2. Drain plug
NOTE: Allow enough time for oil to flow out.

6. Install drain plug.
TIGHTENING TORQUE
7.5 N•m ± 0.5 N•m
Drain plug
vmr2016-009-004_a 7. Refill the rear final drive.

LH REAR SIDE OF VEHICLE
1. Filler plug QUANTITY RECOMMENDED OIL
XPS SYNTHETIC
4. Verify the oil level by inserting a wire with a 90°
GEAR OIL (75W 140)
bend through the oil filler hole. 250 ml
(P/N 293 600 140)
(8 U.S. oz)
5. Oil level must be within the following specifica- or a 75W 140
tion from the bottom of oil filler hole. (API GL-5) gear oil
OIL LEVEL 8. Reinstall filler plug with a NEW sealing washer.
20 mm ± 5 mm (9/16 in ± 3/16 in) TIGHTENING TORQUE
6. Reinstall filler plug with a NEW sealing washer. 22.5 N•m ± 2.5 N•m
Filler plug
TIGHTENING TORQUE
Filler plug
22.5 N•m ± 2.5 N•m Inspecting Drive Shaft Boot and
(17 lbf•ft ± 2 lbf•ft) Protector
1. Visually inspect each drive shaft boot for grease
Replacing the Rear Final Drive Oil leak, cracks or opening.
1. Ensure vehicle is on a level surface. 2. Check if the drive shaft boot protectors are
2. Clean filler and drain plug areas. fixed firmly, not torn or otherwise damaged.
3. Place a drain pan under rear final drive. 3. Replace if necessary.
4. Unscrew filler plug.
Inspecting Drive Shaft Joint
5. Remove drain plug.
Turn and move drive shaft back and forth to detect
excessive play.
Inspecting Rear Propeller Shaft U-Joint

Check yoke U-joints for wear, backlash or axial
play. Replace if necessary.
vmr2017-103 17
Lubricating Rear Propeller Shaft STEERING SYSTEM

U-Joint
Inspecting the Steering System
PROPELLER SHAFT U-JOINT LUBRICATION
Steering Column
Use Hi-temp bearing grease NLGI-2 or an equivalent
Turn and move steering column back and forth to
detect any abnormal play.
WHEELS AND TIRES If abnormal play is detected, inspect upper and
Checking the Wheel Lug Nut Torque lower steering column half bushings. Replace
halve bushings and O-rings as necessary, refer to
Tighten wheel lug nuts to the specified torque us- STEERING SYSTEM subsection.
ing the illustrated sequence.
If steering column feels stiff, refer to STEERING
TIGHTENING TORQUE COLUMN HALF BUSHING CLEANING AND LU-
100 N•m ± 10 N•m BRICATION in this subsection.
Wheel lug nuts
(74 lbf•ft ± 7 lbf•ft) Tie-Rod End
Check tie-rod end ball joint for:
– Damage
– Pitting
– Abnormal play.
Replace if necessary.
Cleaning and Lubricating Steering

Column Half Bushing
Clean, inspect and lubricate upper and lower
steering column half bushings and O-rings. Refer
to STEERING SYSTEM subsection.
SUSPENSION
Inspecting Shock Absorber
vmr2012-038-004_a Check shock absorber for any leaks, replace if nec-
TIGHTENING SEQUENCE essary.
Inspecting Wheel Bearing HPG Shock Absorber (without Remote

Reservoir)
1. Safely lift and support the vehicle.
Check shock absorber for abnormal play:
2. Hold wheel by the top and the bottom and try – Front to back
to move it by pulling and push alternately with
both hands. Check for any play. – Up and down.
3. If there is any looseness detected, replace the If any play is detected, replace shock absorber
wheel bearing. refer to STEERING SYSTEM bushings. Refer to REAR SUSPENSION subsec-
subsection. tion.
NOTE: To properly locate play during this inspec- Lubricating Front Suspension Arm
tion, be sure to check other components for wear
Lubricate suspension arm at grease fittings.
or looseness (ball joints, suspension pivots, etc).
If necessary repair or replace all defective parts SUSPENSION ARM LUBRICATION
before checking the wheel bearing condition. Be
SUSPENSION GREASE (P/N 293 550 033)
careful not to misinterpret a loose ball joint as a
loose wheel bearing.
18 vmr2017-103
5. Check ball joint bellows for:

– Damage
– Cracks.
Inspecting Rear Suspension Trailing

Arm
1. Check trailing arms for:
– Cracks
– Pitting
– Bending
– Distortion.
vmr2012-040-012_a 2. Check trailing arm for abnormal play:
TYPICAL
1. Grease fittings – Side to side
– Up and down.
3. If any play is detected, inspect:
– Spacers
– Bearings
– Inner spacers.
Inspecting and Lubricating Rear

Stabilizer Bar Bushing
Rear Stabilizer Bar Bushing Inspection
Inspect bushings for:
– Cracks
– Damage
vmr2012-040-013_a – Abnormal wear.
TYPICAL
1. Grease fittings Lubricating Rear Stabilizer Bar Bushing
Lubricate bushings at grease fittings.
Inspecting Front Suspension Arm
LUBRICATION
1. Check suspension arm for:
– Cracks SUSPENSION GREASE
Stabilizer bar bushing
(P/N 293 550 033)
– Pitting
– Bending
– Distortion.
2. Check suspension arm for abnormal play:
– Side to side
– Up and down.
3. If any play is detected, inspect:
– Wear plates
– Bushings
– Sleeves.
4. Check ball joint for:
– Damage
– Pitting
– Play. vmr2012-041-018_a
TYPICAL
1. Grease fittings
vmr2017-103 19
BRAKES
Recommended Brake Fluid
Always use brake fluid meeting the specification
DOT 4 only such as the BRAKE FLUID GTLMA DOT4
(P/N 293 600 131) or an equivalent.
WARNING
To avoid damage to the braking system, do
not use other brake fluid types.
vmo2015-005-026_b
Verifying the Brake Fluid Reservoir 1. Rear brake fluid reservoir
Level
With vehicle on a level surface, check brake fluid Adding Brake Fluid
in reservoirs for proper level. Clean filler cap.
NOTE: A low level may indicate leaks or worn
brake pads. WARNING
Clean filler cap before removing.
Front Brake Reservoir
Turn steering in the straight-ahead position to en- Remove screws retaining the reservoir cap.
sure reservoir is level.
Remove reservoir cap.
Check the brake fluid level, the reservoir is full
when the fluid reaches of the top of window. Add fluid as required using a clean funnel. Do not
overfill.
Visually inspect lever boot condition.
Check for cracks, tears, etc. Replace if damaged. NOTICE Brake fluid can damage plastic
and painted surface. Wipe off and clean any
spillage.
Reinstall reservoir cap and tighten screws.
NOTE: Ensure filler cap diaphragm is pushed in-
side the cap before closing the brake fluid reser-
voir.
Inspecting and Cleaning Brake System

NOTICE Do not clean brake components in
petroleum based solvent. Use brake system
cleaner only. Soiled brake pads must be re-
placed with new ones.
To clean parts from the brake system, use the fol-
lowing recommended products or an equivalent.
vmo2012-012-046_a
TYPICAL RECOMMENDED PRODUCT

Rear Brake Reservoir XPS BRAKES AND
For United States of
PARTS CLEANER (USA)
Remove the seat. America
(P/N 219 701 705)
With vehicle on a level surface, liquid should be XPS BRAKES AND
between MIN. and MAX. level marks of brake For all other countries PARTS CLEANER
pedal fluid reservoir. (P/N 219 701 776)
Brake Pads
1. Measure brake pad lining thickness.
20 vmr2017-103
BRAKE PAD MINIMUM THICKNESS – Check cleanliness of master cylinder rod and
boot.
1 mm (1/32 in)
– Check master cylinder boot for cracks or
NOTE: The brake pad grooves are wear indica- damage. Replace as necessary.
tors. Hand Lever
Check hand lever as follows:
– Lever pivot bolt cleanliness
– Lever pivot bolt movement.
Brake Pedal
1. Check brake pedal as follows:
– Brake pedal pivot movement
tmr2011-037-008_a
BRAKE PAD GROOVE

– Brake pedal pivot cleanliness.
2. If required, clean then lubricate brake pedal
NOTICE Brake pads must always be replaced pivot using XPS SYNTHETIC GREASE (P/N 293
in pairs. 550 010).
Brake Caliper Brake Hoses
1. Remove caliper then check the following com- 1. Check hoses for leaks, crushed, deformations,
ponents: cracking or scrapes.
– Check brake pad pin NOTE: Any deformation can restrict the proper
– Check caliper boots for cracks flow of fluid and cause braking problems.
– Check caliper movement on its support
– Check pistons movement Replacing the Brake Fluid
– Check pistons for scratches, rust or other Draining the Brake Fluid
damages.
1. Clean and remove reservoir cover with its di-
2. Clean the following components using the rec- aphragm.
ommended product or an equivalent:
2. Connect a clear hose onto bleeder.
– Brake pads
– Caliper support and slider
– Caliper pistons and pin.
NOTE: Do not remove pistons from caliper for
cleaning them.
3. Lubricate caliper slider using an appropriate
BRAKE CALIPER SYNTHETIC GREASE.
Brake Disc
1. Check brake disc as follows:
– Check disc thickness
– Check disc surfaces
– Check disc warpage.
NOTE: Refer to BRAKE DISC INSPECTION in tmr2011-037-101_a
TYPICAL
BRAKES subsection for details. 1. Caliper bleeder
2. Clean brake disc using the recommended prod-
uct or an equivalent. 3. Loosen bleeder.
4. Pump brake lever(s) and/or brake pedal until no
Master Cylinder more fluid flows out.
1. Check master cylinder as follows: 5. Repeat draining procedure for the other bleed-
– Leaks or damages. ers.
– Brake fluid level.
vmr2017-103 21
NOTE: To locate all bleeders according to ve- Bleeding the Brake System (Using a Vacuum
hicle configuration, refer to EXPLODED VIEW Pump)
and BRAKE CIRCUIT CONFIGURATIONS. See NOTE: Brake fluid reservoir must be kept full to
BRAKES subsection. prevent air from being pumped into the system.
Filling the Brake Fluid 1. Unscrew all bleeders until brake fluid comes
1. Add recommended brake fluid to MAX. mark. out then close it.
Do not overfill. NOTE: To locate all bleeders according to ve-
hicle configuration, refer to EXPLODED VIEW
and BRAKE CIRCUIT CONFIGURATIONS. See
BRAKES subsection.
2. Install the Vacuum/pressure pump onto
bleeder.
REQUIRED TOOL
VACUUM/PRESSURE
PUMP
(P/N 529 021 800)
3. Place pump to vacuum position.

4. Pump vacuum pump a few times.
vmo2012-012-046_a 5. Loosen bleeder.
TYPICAL - BRAKE FLUID RESERVOIR
6. Continue to pump until no more air bubbles ap-
pear in clear hose.
7. Close then tighten bleeder.
TIGHTENING TORQUE
5.5 N•m ± 1.5 N•m
Bleeder
8. Add recommended brake fluid to MAX. mark.

Do not overfill.
9. Perform bleeding procedure for the other bleed-
ers.
10. Check brakes operation:
– If brakes feel spongy, bleed system again
then carry out the BRAKE SYSTEM PRES-
vmo2012-012-035_a SURE VALIDATION as detailed in BRAKES
TYPICAL - UNDER THE SEAT subsection.
1. Brake fluid reservoir
Bleeding the Brake System (Manual
NOTE: If applicable, ensure filler cap diaphragm is Procedure)
fully retracted before closing the cap.
NOTE: Brake fluid reservoir must be kept full to
RECOMMENDED BRAKE FLUID prevent air from being pumped into the system.
BRAKE FLUID GTLMA DOT4 (P/N 293 600 131) 1. Connect a clear hose onto bleeder.
2. Pump up system pressure slowly using brake
WARNING pedal and/or lever(s) until resistance is felt.
Use only DOT 4 brake fluid from a sealed con- 3. Depress and hold brake pedal and/or lever(s).
tainer. 4. Open bleeder and then close it.
Do not use brake fluid from an old or already
opened container. 5. Release brake pedal and/or lever(s) slowly.
22 vmr2017-103
NOTE: Do not release brake pedal and/or lever(s)

until bleeder has been closed.
6. Repeat procedure until fluid flows out without
any air bubbles.
7. Tighten bleeder.
TIGHTENING TORQUE
5.5 N•m ± 1.5 N•m
Bleeder
8. Perform bleeding procedure for the other bleed-

ers.
NOTE: To locate all bleeders according to ve-
hicle configuration, refer to EXPLODED VIEW
and BRAKE CIRCUIT CONFIGURATIONS. See
BRAKES subsection.
9. Check brakes operation:
– If brakes feel spongy, bleed system again
then carry out the BRAKE SYSTEM PRES-
SURE VALIDATION as detailed in BRAKES
subsection.
BODY
Inspecting Seat Latch Operation
Ensure seat latch functions properly and that seat
is properly secured when latched.
FRAME
Inspecting the Frame
Inspect frame for damages such as:
– Cracks
– Dents
– Twisting
– Deformation
– Corrosion
– Loose fasteners.
Pay particular attention to:
– Front and rear frame extensions (body mod-
ules)
– Underside of frame
– Suspension attachment points
– Engine attachment points.
Inspecting the Tow Hitch

1. Ensure tow hitch receptacle module is solidly
mounted.
2. Inspect hitch for cracks and other damages.
3. Repair or replace if necessary.
vmr2017-103 23
Section 01 MAINTENANCE
Subsection 05 (STORAGE PROCEDURE)
STORAGE PROCEDURE
SERVICE PRODUCTS
BRP HEAVY DUTY CLEANER ....................................................... 293 110 001 ........................................... 55
XPS ALL PURPOSE CLEANER ..................................................... 219 701 709 ........................................... 55
XPS ATV CLEANING KIT ............................................................... 219 701 713 ........................................... 55
XPS ATV FINISHING SPRAY.......................................................... 219 701 704 ........................................... 55
XPS ATV WASH ............................................................................. 219 701 702 ........................................... 54
XPS FUEL STABILIZER.................................................................. 413 408 601 ........................................... 53
XPS LUBE...................................................................................... 293 600 016 ..................................... 54–55
XPS STORAGE OIL (EXCEPT U.S. COUNTRY) ............................. 413 711 600 ........................................... 53
XPS STORAGE OIL (U.S. COUNTRY ONLY) ................................. 413 711 900 ........................................... 53
GENERAL ENGINE
If the ATV is not used or is to be stored for more Engine Internal Lubrication
than 4 months, be sure to perform the storage Engine internal parts must be lubricated to protect
procedures described below. them from rust formation during the storage pe-
Where applicable, refer to the appropriate sub- riod.
sections in this manual for details of the required Proceed as follows:
tasks as outlined in these procedures.
1. Remove side body panels.
PROCEDURES 2. Remove spark plugs.
NOTE: To facilitate the inspection and ensure 3. Spray storage oil into each cylinder (see follow-
adequate lubrication of components, it is rec- ing table).
ommended to clean the entire vehicle. Refer to NOTE: Use the storage oil as per country availabil-
VEHICLE CLEANING in this subsection. ity.
RECOMMENDED PRODUCTS
FUEL SYSTEM
XPS STORAGE OIL (EXCEPT U.S. COUNTRY)
Fuel System Protection (P/N 413 711 600)
Pour fuel stabilizer in fuel tank and fill up fuel tank. XPS STORAGE OIL (U.S. COUNTRY ONLY)
Start vehicle to allow for fuel stabilizer to spread (P/N 413 711 900)
through the fuel system.
4. In drowned mode, press start button, 1 or 2
Follow the manufacturer's instructions for proper seconds maximum, to lubricate cylinders.
use.
5. Reinstall spark plugs.
RECOMMENDED FUEL SYSTEM PROTECTION NOTE: Do not run engine during storage period.
XPS FUEL STABILIZER (P/N 413 408 601)
Engine Air Intake System
NOTICE Fuel stabilizer should be added Remove parts required for access to engine air in-
prior to engine lubrication to ensure fuel sys- let hose, refer to AIR INTAKE SYSTEM subsec-
tem components protection against varnish tion.
deposits. Block engine air inlet hose using a rag to prevent
intrusion of small animals.
CVT Protection
1. Remove drive belt. Refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT).
2. Inspect and clean pulleys.
vmr2015-009 53
3. Protect pulleys by spraying XPS LUBE (P/N 293

600 016) on pulley faces.
NOTE: Do not reinstall drive belt.
4. Close CVT cover.
5. Remove CVT outlet from exhaust system heat
shield and from CVT outlet hose.
vmr2015-009-001_a
ELECTRICAL SYSTEM
Battery
Remove battery from ATV.
Store and charge battery as per battery manufac-
turer's recommendations.
vmr2012-007-001_a DRIVE SYSTEM

TYPICAL
1. CVT cover Lubricate rear propeller shaft U-joints.
2. Exhaust system heat shield
3. CVT outlet
CHASSIS
6. Block CVT outlet hose using a rag.
Lubrication
Lubricate front and rear suspension as applicable.
Tire Pressure
Inflate tires to recommended pressure.
Vehicle Cleaning
Wash and dry the vehicle.
NOTICE Never use a high pressure washer to
clean the vehicle. USE LOW PRESSURE ONLY
(such as a garden hose). The high pressure can
cause electrical or mechanical damages.
vmr2012-007-002_a
Remove any dirt or rust.
TYPICAL To clean plastic parts, use only flannel cloths and
1. CVT outlet hose
XPS ATV WASH (P/N 219 701 702) or soapy water.
Exhaust System To clean vinyl parts, use only flannel cloths and a
mild non abrasive multipurpose cleaner.
Block muffler outlet using a rag to avoid intrusion
of small animals.
54 vmr2015-009
RECOMMENDED PRODUCT FOR PLASTIC PARTS

XPS ATV Wash
(P/N 219 701 702)
Soapy water
NOTICE It is necessary to use flannel cloths

on plastic parts to avoid damaging surfaces.
Never clean plastic parts with strong deter-
gent, degreasing agent, paint thinner, acetone,
products containing chlorine, etc. To avoid
damaging the glossy finish on Polypropylene
body parts, never use:
– Petroleum based cleaning products
– XPS ATV FINISHING SPRAY (P/N 219 701 704)
– XPS ATV CLEANING KIT (P/N 219 701 713).
RECOMMENDED PRODUCT FOR VINYL PARTS
XPS ALL PURPOSE CLEANER (P/N 219 701 709)
To clean heavily soiled parts of the vehicle, includ-

ing metallic parts use the following.
RECOMMENDED PRODUCT FOR HEAVILY
SOILED PARTS
BRP HEAVY DUTY CLEANER (P/N 293 110 001)
Inspect the vehicle and repair any damage. Touch

up all metal spots where paint has been scratched
off.
Spray all metal parts with an appropriate lubricant
for rust protection.
RECOMMENDED RUST PROTECTION
XPS LUBE (P/N 293 600 016)
Vehicle Protection
Protect the vehicle with a cover to prevent dust
accumulation during storage.
NOTICE The vehicle has to be stored in a cool
and dry place, and covered with an opaque
tarpaulin. This will prevent sun rays and grime
from affecting plastic components and vehicle
finish.
vmr2015-009 55
Subsection 06 (PRESEASON PREPARATION)
PRESEASON PREPARATION
Proper vehicle preparation is required after a stor-
age period.
Any worn, broken or damaged parts found must
be replaced.
Remove rags that were installed for storage: en-
gine air inlet hose, CVT outlet hose and muffler.
Clean drive and driven pulleys to remove storage
protective lubricant, then reinstall drive belt. Refer
to CONTINUOUSLY VARIABLE TRANSMISSION
(CVT).
Remove parts required to allow inspection of
entire engine air inlet system. Check for animal
nests and other foreign material. Reinstall re-
moved parts.
Drain fuel tank and fill with fresh fuel if a fuel sta-
bilizer was not used for storage.
Reinstall battery. Refer to CHARGING SYSTEM
subsection.
Inflate tires to the recommended pressure.
Using the MAINTENANCE SCHEDULE, perform
the items titled EVERY 3 000 km (2,000 mi) OR
100 HOURS OF OPERATION OR 1 YEAR.
tmr2011-004-001_aen
TYPICAL
1. Use this schedule
NOTE: If the EVERY 6 000 km (4,000 mi) OR 200

HOURS OF OPERATION OR 2 YEARS mainte-
nance service is due, also perform the related
items as per the MAINTENANCE SCHEDULE.
Test drive vehicle.
vmr2015-010 57
Subsection XX (SPECIAL PROCEDURES)
SPECIAL PROCEDURES
SERVICE PRODUCTS
XPS LUBE...................................................................................... 293 600 016 ........................................... 2
GENERAL WHAT TO DO IF WATER IS IN

NOTE: Component failures resulting from these THE AIR FILTER HOUSING
events are not warrantable. Inspect the drain reservoir underneath the air filter
Refer to the appropriate subsections in this man- housing to validate if water is present.
ual for details of the required tasks as outlined in
these procedures.
WHAT TO DO IF WATER IS IN
THE CVT
The CVT drain plug is located on the rear portion
of the CVT cover. It is accessible from the rear LH
fender.
Inspect the CVT drain plug to validate if water is
present.
vmo2012-012-054_a
TYPICAL
1. Air filter housing drain reservoir
If water is present, press clamp and remove reser-

voir to drain water from air filter housing.
If one of the following conditions is met, refer to
WHAT TO DO IF VEHICLE IS IMMERSED IN WA-
TER:
– If more than 50 ml (2 U.S. oz) of water (approxi-
mately 5 drain reservoirs) is found in the air filter
vmo2013-007-012_a housing.
1. Drain plug – If any deposits are present in the drain reservoir.
2. Spring clamp
NOTICE Failure to service vehicle properly
NOTICE If water is present in the CVT, it could may lead to component permanent damage.
result in belt slippage. The engine will acceler-
ate but the vehicle will remain still.
WHAT TO DO IF VEHICLE IS
If water is present, remove CVT drain plug to ex- TURNED OVER
pel water.
In the event the vehicle was rolled over tilted on
Reinstall the drain plug and secure it using the it's side; put the vehicle back on its wheel, wait 3
spring clamp. to 5 minutes, then check the following:
NOTE: Make sure hose is properly inserted on – Inspect air filter housing for oil accumulation,
CVT cover nipple. if any oil is found, clean air filter and air filter
If an appreciable amount of water is drained from housing.
the CVT cover, remove the cover and properly ser- – Check engine oil level and refill if necessary.
vice the CVT. – Check engine coolant level and refill if neces-
sary.
– Check gearbox oil level and refill if necessary.
vmr2013-008 1
Subsection XX (SPECIAL PROCEDURES)
– Check rear final drive oil level and refill if neces- Replace the engine oil (without starting the en-
sary. gine).
– Inspect suspension components and steering Replace gearbox oil.
system components.
Inspect fuel tank for water intrusion. If in doubt,
– Inspect body and chassis for any damages. flush fuel tank and refill with new fuel.
– Start engine. If the oil pressure light stays on,
Inspect fuel tank vent system for water intrusion.
stop engine immediately and investigate the
Clean as required. Replace breather filter. Carry
problem.
out a fuel pump pressure test.
– After restarting engine, check for indicator
lights or messages displayed in the multifunc- Inspect brake system for water intrusion. Replace
tion gauge. Correct as required. brake fluid as required.
Limited model: Inspect ACS intake hose for any Inspect all lights for water intrusion. Dry as re-
trace of oil. Clean thoroughly if oil is found in hose. quired.
If oil reached compressor, disassemble compres- Inspect multifunction switch for water intrusion.
sor and clean thoroughly. Dry as required.
Remove spark plugs. Crank engine in drowned
WARNING mode to expel any water.
Do not use vehicle if any of the controls,
steering, suspension or brakes are damaged CAUTION Keep away from spark plug
or inoperative. holes to avoid being splashed when cranking
engine.
WHAT TO DO IF VEHICLE IS Add a small quantity of engine oil in cylinders (ap-
IMMERSED IN WATER proximately 2 teaspoonfuls).
In the event the vehicle was immersed, proceed Install spark plugs (replace if required).
with the following.
WARNING
NOTICE A vehicle that was immersed may Before starting engine, use B.U.D.S. and
be damaged or prone to malfunctions (short check vehicle for fault codes.
and long term) if not serviced promptly and ap-
propriately. Do not crank or start engine. Start the engine and allow it to run at idle speed
Drain the entire air intake system. Inspect the until the engine reaches its operating tempera-
throttle body. Remove parts as required. ture.
Inspect and clean air box as needed. Remove Stop the engine.
parts as required. Change engine oil and filter.
Replace the air filter. NOTE: Change oil as many times as necessary,
Drain, inspect and clean the CVT. until there is no whitish appearance in engine oil.
Limited model: Inspect ACS hose. If water is Replace front differential oil.
present, disassemble and dry compressor. Replace rear final drive oil.
Inspect front differential and rear final drive vents. Lubricate front and rear suspensions and propeller
Clean or replace as necessary shaft joints.
Drain muffler and exhaust pipes (removal re- Spray all metal parts with XPS LUBE (P/N 293 600 016).
quired). Test drive to confirm proper operation.
Clean muffler spark arrester..
Remove fuse box covers. Check for presence of
water. Dry as necessary.
Disconnect, clean and dry the following electrical
connectors:
– ECM
– Multifunction gauge
– DPS.
2 vmr2013-008
Section 02 ENGINE, CVT AND GEARBOX
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)
ENGINE REMOVAL AND INSTALLATION

SERVICE TOOLS
ENGINE LIFTING TOOL ................................................................ 529 035 898 ........................................... 68
NEW
5 ± 1 N•m
(44 ± 9 lbf•in)
NEW
4 ± 1 N•m
(35 ± 9 lbf•in)
NEW
NEW
4.9 ± 0.4 N•m
(43 ± 4 lbf•in)
NEW
NEW
62.5 ± 7.5 N•m

(46 ± 6 lbf•ft)
NEW = Component must be replaced when removed.

vmr2015-012-001_a
vmr2015-012 63
Section 02 ENGINE, CVT AND GEARBOX (450)
PROCEDURES
ENGINE REMOVAL
1. Place vehicle on a workstation equipped with
an engine-lifting hoist.
2. Set transmission to park "P" and engage parking
brake.
3. Carry out procedures in following table.
REFERENCES
OPERATIONS
(SUBSECTION)
Disconnect and remove
CHARGING SYSTEM
battery from vehicle
vmr2015-012-003_a
FUEL TANK AND MASTER BRAKE CYLINDER

Release fuel pressure Step 1: Remove these fasteners
FUEL PUMP Step 2: Move master cylinder assembly back
PERIODIC
Drain engine coolant MAINTENANCE
PROCEDURES
Remove LH and RH inner
fender panels
Remove front body module
Remove LH and RH BODY
footrest panels
Remove LH footrest
support
Remove muffler
EXHAUST SYSTEM
Remove exhaust pipe
4. Secure throttle body towards front of vehicle to vmr2015-012-006_a

make room for engine removal. 1. Master cylinder assembly moved back
vmr2015-012-002_a vmr2015-012-004_a
Step 1: Cut locking ties COOLING SYSTEM HOSE DISCONNECT
Step 2: Loosen clamps Step 1: Disconnect radiator hose at water pump
Step 3: Move throttle body Step 2: Disconnect return hose at thermostat
5. Carry out procedures in following illustrations.
64 vmr2015-012
vmr2015-012-101_a
1. Remove front propeller shaft bolt and washer
vmr2015-012-005_a
ENGINE GROUND AND STARTER CABLE DISCONNECT

Step 1: Disconnect engine ground wire
Step 2: Disconnect starter power wire
Step 3: Cut locking ties (3)
vmr2015-012-102_a
4 X 4 COUPLING UNIT DISCONNECT

1. Disconnect motor connector
2. Disconnect light switch connector
3. Remove locking tie
vmr2015-012-007_a
SHIFT ROD DISCONNECT

Step 1: Remove spring
Step 2: Remove fasteners and bushing
Step 3: Move shift rod
vmr2015-012-103_a
ENGINE MOUNT NUT REMOVAL, RH SIDE

1. Remove nuts
NOTE: Do not remove engine mount bolts at this

time.
vmr2015-012-009_a
1. Remove rear propeller shaft bolt
vmr2015-012 65
NOTE: Refer to ELECTRONIC FUEL INJECTION

(EFI) subsection for fuel injector disconnect.
vmr2015-012-014_a
CVT AIR INLET DUCT DISCONNECT

1. Loosen clamps
2. Remove CVT air inlet adapter
vmr2015-012-016_a
CRANKCASE VENT DISCONNECT

1. Disconnect crankcase vent hose from engine
vmr2015-012-015_a
CVT AIR OUTLET DUCT DISCONNECT

Step 1: Loosen clamps
Step 2: Remove CVT air outlet adapter
vmr2015-012-012_a
FRONT ENGINE MOUNT REMOVAL

1. Upper engine mount
2. Remove these screws
vmr2015-012-013_a
FUEL AND IGNITION DISCONNECT

Step 1: Disconnect spark plug wire
Step 2: Disconnect fuel injector hose
Step 3: Disconnect fuel injector connector
Step 4: Disconnect MAPTS sensor
66 vmr2015-012
6. Remove the gear switch connector and VSS

connectors from their support.
7. Disconnect magneto connector from voltage
regulator rectifier.
vmr2015-012-017_a
AIR INTAKE MANIFOLD REMOVAL

1. Remove air intake manifold
vmr2012-043-013_b
TYPICAL
1. Magneto connector
8. Remove magneto harness from its location

along vehicle and gather it in a bundle near
engine.
NOTE: It may be necessary to slightly lift the rear
body module to ease magneto harness removal.
Refer to BODY subsection.
vmr2015-012-018_a
COOLANT TEMPERATURE SENSOR REMOVAL

Step 1: Cut this locking tie
Step 2: Disconnect coolant temp sensor
vmr2015-012-028_a
MAGNETO HARNESS ROUTING (SOME PARTS REMOVED FOR

CLARITY)
1. Magneto harness
2. Voltage regulator connector to disconnect (gray)
3. Locking ties to remove
vmr2015-012-019_a
ELECTRICAL DISCONNECTS
Step 1: Disconnect OPS connector
Step 2: Disconnect VSS connector
Step 3: Disconnect Gear Switch connector
Step 4: Cut this locking tie
Step 5: Disconnect CPS connector (rear view)
vmr2015-012 67
Engine Lifting
REQUIRED TOOL
ENGINE LIFTING TOOL (P/N 529 035 898)
vmr2015-012-022_a
RH SIDE, ENGINE MOUNTING PLATE REMOVAL

1. Remove these fasteners
2. Remove right side engine mounting plates
vmr2015-012-021_a
1. Install engine lifting tool

2. Move battery tray to make room
1. Install extension tool (P/N 529 035 619) onto

engine lifting tool to ease engine manoeuvring.
2. Attach hoist to extension tool and slightly pick
up some engine weight with the hoist.
vmr2015-012-024_a
LH SIDE, ENGINE MOUNTING BOLT REMOVAL

1. Engine mounting bolts
vmr2015-012-023_a
1. Install extension tool

2. Hoist attached to extension tool
vmr2015-012-029_a
LH SIDE, ENGINE MOUNT BRACKET REMOVAL

Step 1: Remove engine mount bracket bolts
Step 2: Remove engine mounts
68 vmr2015-012
Remove the engine mount brackets on the right ENGINE INSTALLATION

hand side.
Reverse the removal procedure. However, pay at-
tention to the following.
When installing a part, refer to its applicable
subsection for tightening torques and products
required.
Inspect condition of engine mounts.
Install engine on vehicle.
Install all engine retaining bolts loosely.
Install front and rear propeller shafts. Tighten re-
taining screws to specification.
Tighten engine mounting bolts to specification.
TIGHTENING TORQUE
62.5 N•m ± 7.5 N•m
Engine retaining bolts
vmr2015-012-026_a
REAR PROPELLER SHAFT DISCONNECT

1. Slightly lift engine and move forward Reconnect all hoses, adapters and electrical con-
2. Disconnect rear propeller shaft nections.
If applicable, fill engine as per specification with
engine oil. Refer to LUBRICATION SYSTEM sub-
section.
Fill and bleed cooling system. Refer to PERIODIC
MAINTENANCE PROCEDURE subsection.
Check for any leaks.
Install all remaining removed parts.
Test drive vehicle to confirm proper operation.
ENGINE MOUNTS
REPLACEMENT
NOTE: Use the same procedure for the front and
vmr2015-012-025_a
rear engine mounts.
TYPICAL FRONT PROPELLER SHAFT DISCONNECT
1. Move engine rearward Engine Mount Removal
2. Disconnect front propeller shaft
Insert a punch into one engine mount bushing and
push the opposite bushing out.
tmr2011-007-011
TYPICAL
vmr2015-012-027_a
vmr2015-012 69
Engine Mount Installation

Push in each mount bushing until it bottoms out.
70 vmr2015-012
Subsection 02 (AIR INTAKE SYSTEM)
AIR INTAKE SYSTEM

AIR FILTER HOUSING
1.6 ± 0.4 N•m

(14 ± 4 lbf•in)
Loctite 5150
(silicone sealant)
6 ± 1 N•m
(53 ± 9 lbf•in)
Suspension
grease
6 ± 1 N•m
(53 ± 9 lbf•in)
Loctite 5150
(silicone sealant)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
To throttle body
To engine
vmr2015-013-001_aen
vmr2015-013 71
GENERAL
NOTICE Never modify the air intake system.
Otherwise, engine performance degradation
or damage can occur. The engine is calibrated
to operate specifically with these components.
PROCEDURES
AIR FILTER
For air filter servicing, refer to PERIODIC MAIN-
TENANCE PROCEDURES subsection.
vmr2012-010-002_a
AIR FILTER HOUSING TYPICAL
1. CVT air inlet screws
Air Filter Housing Removal
1. Remove front body module. Refer to BODY 4. Remove ECM retaining screws.
subsection.
2. Remove dashboard support retaining screws.
Pull aft pins from grommets and move support
toward front.
vmr2012-010-001_a
1. ECM retaining screws
5. Remove engine harness connectors (HIC) from

air filter housing.
vmr2015-013-006_a 6. Move ECM aside.
DASHBOARD SUPPORT REMOVAL
1. Screws to remove
3. On LH side, remove screws securing CVT air

inlet to air filter housing.
vmr2012-009-005_a
TYPICAL
1. Engine harness connectors (HIC)
72 vmr2015-013
7. Remove air intake tube retaining screw. 10. Remove link rod from shift lever.
vmr2012-010-003_a
vmr2012-010-006_a
1. Air intake tube retaining screw
TYPICAL
1. Link rod retaining bolt
8. Move air intake tube forward for access to LH
coolant tank screw. 11. Carefully move link rod downward.
9. Remove coolant tank retaining screws. 12. Remove the following locking ties.
vmr2013-010-001_a
1. Locking tie to remove - location shown

vmr2012-010-004_a
AIR INTAKE TUBE MOVED FOR ACCESS

1. LH coolant tank retaining screw
vmr2012-010-009_a
1. Locking ties to remove

vmr2012-010-005_a
13. Remove crankcase vent hose from air filter
1. RH coolant tank retaining screw
housing.
vmr2015-013 73
vmr2015-013-003_a
vmr2015-013-002_a
SCREW ACCESSED FROM UNDER SHIFT LEVER
1. Remove crankcase vent hose here 1. Screw
14. Remove fasteners retaining aft end of air filter 15. Detach throttle body from intake adapter and
housing. air filter housing.
vmr2012-010-012_a
vmr2015-013-004_a
FASTENERS LOCATED NEAR FORWARD SEAT ANCHORAGE 1. Clamp screws to loosen
1. Nuts (2)
16. Slightly lift air filter housing upward.
17. Move throttle body aside to make room.
vmr2012-010-013_a
SCREW LOCATED UNDER COOLANT TANK

1. Screw
74 vmr2015-013
vmr2015-013-005 _a
1. Air filter housing

2. Throttle body
18. Remove air filter housing by pulling it towards

rear.
vmr2012-010-016_a
AIR FILTER HOUSING REMOVAL
19. Remove remaining components from air filter

housing.
Air Filter Housing Inspection

Check air filter housing for cracks or other dam-
age. Replace if necessary.
Air Filter Housing Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Refer to applicable exploded views for tightening
torque.
vmr2015-013 75
Subsection XX (EXHAUST SYSTEM (TRANSVERSAL MOUNTING))
EXHAUST SYSTEM (TRANSVERSAL

MOUNTING)
Single Cylinder Models
Max Models
10 ± 2 N•m
(89 ± 18 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
NEW
Bolt down,
nut facing outwards
40 ± 1 N•m NEW
(30 ± 1 lbf•ft) 13 ± 1 N•m
(115 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
See tightening
sequence
vmr2017-130-101_a
vmr2017-130 1
Twin Cylinder Models
Max Models
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
13 ± 1 N•m
(115 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
NEW
Bolt down,
nut facing outwards
40 ± 1 N•m
(30 ± 1 lbf•ft)
10 ± 2 N•m
(89 ± 18 lbf•in) See tightening
sequence
9 ± 1 N•m
(80 ± 9 lbf•in) 9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
See tightening PRO series

sequence
vmr2017-130-102_a
2 vmr2017-130
GENERAL
WARNING
Never touch exhaust system components im-
mediately after the engine has run.
PROCEDURES
MUFFLER
Removing the Muffler vmr2015-014-503_a
1. Loosen exhaust pipe clamp.

Inspecting the Muffler
Check muffler and cover for cracks or other dam-
ages. Replace if necessary.
Check if the rubbers support are brittle, hard or
otherwise damaged. Replace if needed.
Installing the Muffler

Reverse the removal procedure.
vmr2015-014-501_a
HEAT SHIELD
1. Clamp nut
Removing the Heat Shield
2. Remove muffler retaining bolts. 1. Refer to BODY and remove following LH body
panels.
vmr2015-014-502_a
1. Bolt
2. Washer
3. Nut
vmr2015-027-002_a
3. Remove the muffler. LH SIDE

1. Side panel
2. Side panel extension
3. Rear panel extension (Max models)
2. Remove outer heat shield retaining bolts.

NOTICE Do not use an impact tool to remove
or install heat shield bolts.
vmr2017-130 3
MAX Models
4. Remove heat shield extension retaining bolts.
vmr2015-014-505_a
TYPICAL - OUTER HEAT SHIELD - SHORT MODEL SHOWN

1. Heat shield bolts
3. Remove muffler for rear and inner heat shield

removal.
vmr2013-011-002_a
1. Outer heat shield extension

2. M6 x 16 bolts
vmr2015-014-509_a
vmr2015-014-511_a
TYPICAL - REAR HEAT SHIELD REMOVAL
1. Rear heat shield TYPICAL
2. M6 x 25 bolt 1. Inner heat shield extension
3. M6 elastic nut 2. M6 x 16 bolts
4. M6 x 16 bolts with washers
Installing the Heat Shield

Refer to exploded view for torque specifications,
and following illustration for rear heat shield tight-
ening sequence.
vmr2015-014-512_a
TYPICAL - INNER HEAT SHIELD REMOVAL

1. Inner heat shield
2. M6 x 16 bolts
4 vmr2017-130
vmr2015-027-101_a
REAR HEAT SHIELD TIGHTENING SEQUENCE
HEAD PIPE (SINGLE CYLINDER vmr2015-014-508_a
1. Retaining nuts
MODELS)
4. Remove front head pipe from vehicle.
Removing the Head Pipe
NOTE: The space to remove the front head pipe
1. Remove MUFFLER See procedure in this sub- is limited. Remove it without forcing it.
section.
2. Refer to BODY and remove RH and LH inner Inspecting the Head Pipe
fender panels. Check head pipe for cracks, bending or other dam-
ages. Replace if needed.
Installing the Head Pipe

Install NEW exhaust gasket and pipe exhaust re-
taining nuts.
TIGHTENING TORQUE
13 N•m ± 1 N•m
Head pipe nuts
Exhaust System Tightening Sequence

vmr2015-027-003_a
Install all nuts and bolts loosely.
LH ILLUSTRATED, RH SIMILAR Install springs.
1. Remove inner fender panel (both sides)
Tighten all fasteners as per following tightening
3. From RH side of vehicle, remove head pipe re- sequence. Refer to exploded view for torque
taining nuts. specifications.
vmr2015-014-002_a
EXHAUST SYSTEM TIGHTENING SYSTEM SEQUENCE
vmr2017-130 5
Y-PIPE (TWIN CYLINDER HEAD PIPE (TWIN CYLINDER

MODELS) MODELS - FRONT CYLINDER)
Removing the Y-Pipe Removing the Front Head Pipe
1. Remove MUFFLER. See procedure in this sub- 1. Remove Y-PIPE See procedure in this subsec-
section. tion.
2. Remove OUTER HEAT SHIELD. See procedure 2. Refer to BODY and remove LH and RH inner
in this subsection. fenders.
3. Remove the following parts:
– Springs from head pipe
– Y-pipe retaining nuts on rear cylinder
– Y-pipe from vehicle.
vmr2015-027-003_a
3. From RH side of vehicle, remove head pipe re-

taining nuts.
vmr2015-027-005_a
1. Springs (4)
2. Y-pipe retaining nuts on rear cylinder (2)
Inspecting the Y-Pipe

Check Y-pipe for cracks, bending or other dam-
Installing the Y-Pipe

Install NEW exhaust gasket and exhaust pipe re-
taining nuts.
Properly position exhaust pipe before tightening.
vmr2015-027-004_a
Refer to EXHAUST SYSTEM TIGHTENING SE- 1. Head pipe retaining nuts
QUENCE.
TIGHTENING TORQUE
Head pipe nuts 13 N•m ± 1 N•m
(rear cylinder) (115 lbf•in ± 9 lbf•in)
6 vmr2017-130
vmr2015-027-100_a
EXHAUST SYSTEM TIGHTENING SYSTEM SEQUENCE
vmr2015-027-006_a
1. Head pipe

is limited. Remove it without forcing it.
Inspecting the Front Head Pipe

Check head pipe for cracks, bending or other dam-
Installing the Front Head Pipe

Install NEW exhaust gaskets and nuts.
Refer to EXHAUST SYSTEM TIGHTENING SE-
QUENCE.
TIGHTENING TORQUE
13 N•m ± 1 N•m
Head pipe nuts

Install springs.
sequence. Refer to exploded view for torque
specifications.
vmr2017-130 7
Subsection XX (EXHAUST SYSTEM (OUTLANDER XMR))
EXHAUST SYSTEM (OUTLANDER XMR)

1000R
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
650/850/1000R
9 ± 1 N•m
(80 ± 9 lbf•in) 13 ± 1 N•m
(115 ± 9 lbf•in)
NEW
40 ± 1 N•m
(30 ± 1 lbf•ft)
NEW
570
NEW
13 ± 1 N•m
(115 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)

vmr2017-105-100_a
vmr2017-105 1
GENERAL
WARNING
Never touch exhaust system components im-
mediately after the engine has run.
PROCEDURES
MUFFLER
Removing the Muffler vmr2015-014-503_a
570 Model 650, 850 and 1000R Models

1. Loosen exhaust pipe clamp. 1. Loosen exhaust pipe clamp.
vmr2015-014-501_a
1. Clamp nut
2. Remove muffler retaining bolts.
vmr2012-011-003_a
LH SIDE — PARTS REMOVED FOR CLARITY

1. Muffler
2. Loosen clamp
2. Remove muffler retaining bolts.
vmr2015-014-502_a
1. Bolt
2. Washer
3. Nut
3. Remove the muffler.
vmr2012-011-002_a
LH SIDE — PARTS REMOVED FOR CLARITY

1. Muffler
2. Remove bolts
3. Remove the muffler.
2 vmr2017-105
Inspecting the Muffler

Check muffler and cover for cracks or other dam-
ages. Replace if necessary.
Check if the rubbers supports are brittle, hard or
otherwise damaged. Replace if needed.
Installing the Muffler

Install a NEW exhaust gasket (all models except
570).
TIGHTENING TORQUE vmr2015-014-505_a
OUTER HEAT SHIELD

40 N•m ± 1 N•m 1. Heat shield bolts
Exhaust pipe clamp
3. Remove muffler for rear and inner heat shield
removal.
HEAT SHIELD
Removing the Heat Shield
1. Refer to BODY and remove following LH body
panels.
vmr2015-014-509_a
REAR HEAT SHIELD REMOVAL

1. Rear heat shield
2. M6 x 25 bolt
3. M6 elastic nut
4. M6 x 16 bolts with washers
vmr2015-027-002_a
LH SIDE
1. Side panel
2. Side panel extension
3. Rear panel extension (Max models)
2. Remove outer heat shield retaining bolts.

NOTICE Do not use impact tool to remove or
install heat shield bolts.
vmr2016-308-001_a
FRONT INNER HEAT SHIELD
vmr2017-105 3
Refer to exploded view for torque specifications,

and following illustration for rear heat shield tight-
ening sequence.
vmr2015-014-512_a
INNER HEAT SHIELD

1. Inner heat shield
2. M6 x 16 bolts vmr2015-027-101_a
REAR HEAT SHIELD TIGHTENING SEQUENCE

1000R model
4. Remove heat shield extension retaining bolts. Y-PIPE
Removing the Y-Pipe
1. Remove MUFFLER. See procedure in this sub-
section.
2. Remove OUTER HEAT SHIELD. See procedure
in this subsection.
– Springs from head pipe
– Y-pipe retaining nuts on rear cylinder
– Y-pipe from vehicle.
vmr2013-011-002_a
1. Outer heat shield extension

2. M6 x 16 bolts
vmr2015-027-005_a
TYPICAL
1. Springs (4)
2. Y-pipe retaining nuts on rear cylinder (2)
vmr2015-014-511_a
1. Inner heat shield extension Inspecting the Y-Pipe

2. M6 x 16 bolts
Check Y-pipe for cracks, bending or other dam-
Installing the Heat Shield ages. Replace if needed.
4 vmr2017-105
Installing the Y-Pipe

Install NEW exhaust gasket and exhaust pipe re-
taining nuts.
Properly position exhaust pipe before tightening.
QUENCE.
TIGHTENING TORQUE
Head pipe nuts 13 N•m ± 1 N•m
(rear cylinder) (115 lbf•in ± 9 lbf•in)
HEAD PIPE (FRONT CYLINDER) vmr2015-027-004_a
1. Head pipe retaining nuts

Removing the Front Head Pipe
1. Remove Y-PIPE See procedure in this subsec-
tion.
2. Refer to BODY and remove LH and RH inner
fenders.
vmr2015-027-006_a
1. Head pipe
vmr2015-027-003_a
is limited. Remove it without forcing it.
3. From RH side of vehicle, remove head pipe re-
taining nuts. Inspecting the Front Head Pipe
Check head pipe for cracks, bending or other dam-
Installing the Front Head Pipe

Install NEW exhaust gaskets and nuts.
QUENCE.
TIGHTENING TORQUE
13 N•m ± 1 N•m
Head pipe nuts
vmr2017-105 5

Install springs.
sequence. Refer to exploded view for torque
specifications.
vmr2015-027-100_a
570 - TIGHTENING SEQUENCE
vmr2016-113-002_a
650, 850 AND 1000R - TIGHTENING SEQUENCE
6 vmr2017-105
Subsection 04 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM
SERVICE TOOLS
ADAPTER HOSE ........................................................................... 529 035 652 ........................................... 85
DISCONNECT TOOL ..................................................................... 529 035 714 ........................................... 85
PRESSURE GAUGE....................................................................... 529 035 709 ........................................... 85
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 87
vmr2015-015 83
10 ± 1 N•m
(89 ± 9 lbf•in)
Engine oil
NEW
NEW 12 ± 1 N•m
(106 ± 9 lbf•in)
Engine oil 12 ± 1 N•m
(106 ± 9 lbf•in)
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
Engine oil
NEW
10 ± 1 N•m
(89 ± 9 lbf•in)
30 ± 2 N•m
(22 ± 1.5 lbf•ft)
vmr2015-015-001_a
84 vmr2015-015
INSPECTION NOTE: To remove adapter hose from oil pressure

gauge, use the disconnect tool.
ENGINE OIL PRESSURE REQUIRED TOOL
NOTE: The engine oil pressure test should be
DISCONNECT TOOL (P/N 529
done with a warm engine (100°C (212°F)) and the 035 714)
recommended oil.
Remove the oil pressure switch, refer to OIL Reinstall the oil pressure switch.
PRESSURE SWITCH in this subsection.
Install the pressure test gauge with the proper TROUBLESHOOTING
adapter hose in the oil pressure switch bore.
REQUIRED TOOL LOW OR NO OIL PRESSURE
1. Oil level is too low
PRESSURE GAUGE - Refill engine with recommended engine oil. Re-
(P/N 529 035 709) fer to OIL LEVEL VERIFICATION in the PERIODIC
MAINTENANCE PROCEDURES subsection.
ADAPTER HOSE - Check for high oil consumption, refer to HIGH
(P/N 529 035 652) OIL CONSUMPTION in the TROUBLESHOOT-
ING subsection.
- Check for engine oil leaks. For leak indicator
hole, refer to COOLING SYSTEM INSPECTION
in the PERIODIC MAINTENANCE PROCEDURES
subsection. Repair if necessary.
2. Use of unsuitable engine oil type.
- Replace engine oil by the recommended engine
oil.
3. Clogged oil filter.
- Replace oil and oil filter at the same time.
4. Defective oil pressure switch.
- Test oil pressure switch, see procedure in this
subsection.
5. Defective or worn oil pump.
- Check oil pump, see procedure in this subsection.
vmr2015-015-101_a
1. Pressure test gauge assembly 6. Defective engine oil pressure regulator.

2. Hose adapter installed in oil pressure switch bore - Check engine oil pressure regulator, see proce-
dure in this subsection.
Start engine and measure oil pressure as per fol-
lowing table. 7. Worn plain bearings in crankcase.
The engine oil pressure should be within the fol- - Check plain bearings clearance, refer to BOTTOM
lowing values. END subsection.
PRESSURE 1300 RPM 6000 RPM 8. Clogged engine oil strainer.

- Clean engine oil strainer, see procedure in this
Minimal 70 kPa (10 PSI) 350 kPa (51 PSI) subsection.
Nominal 300 kPa (44 PSI) 450 kPa (65 PSI)
OIL CONTAMINATION
Maximal 550 kPa (80 PSI) 700 kPa (102 PSI)
1. Defective water pump seal ring or rotary seal.
If the engine oil pressure is out of specifications, - Check for oil or coolant leak from indicator hole
check the points described in TROUBLESHOOT- near water pump, refer to COOLING SYSTEM
INSPECTION in the PERIODIC MAINTENANCE
ING in this subsection. PROCEDURES subsection. Replace seals if nec-
Remove oil pressure gauge and adapter hose. essary.
vmr2015-015 85
2. Cylinder head or cylinder base gasket leak. Oil Pressure Switch Activation
- Retighten cylinder head to specified torque, refer The oil pressure switch activates when the engine
to TOP END subsection. Replace gasket if tight- oil pressure is lower than following specified pres-
ening does not solve the problem.
sure range.
3. Engine internal damage.
OIL PRESSURE SWITCH ACTIVATION RANGE
- Repair engine.
30 kPa ± 10 kPa (4.35 PSI ± 1.45 PSI)
HIGH OIL CONSUMPTION
To check the function of the oil pressure switch,
1. Leaking breather oil seal. an oil pressure test has to be performed. Refer to
- Check if the oil seal of the breather (underneath ENGINE OIL PRESSURE in this subsection.
PTO side ball bearing of balancer shaft) is brittle,
hard or damaged. Refer to BOTTOM END sub- If the engine oil pressure is good, perform the oil
section. pressure switch resistance test.
2. Valve stem seals worn or damaged.
Oil Pressure Switch Resistance Test
- Replace valve stem seals. Refer to TOP END sub-
section. Disconnect the connector from the oil pressure
switch.
3. Worn piston rings (blue exhaust smoke).
Using a multimeter set to , check the OPS resis-
- Replace piston rings. Refer to TOP END subsec-
tion. tance as per following table.
OPS ENGINE NOT ENGINE NOT
PROCEDURES CONNECTOR RUNNING RUNNING
PIN RESISTANCE ( )
OIL PRESSURE SWITCH (OPS) Close to 0 Close to 0
Engine
Oil Pressure Switch Location 1 (normally (normal closed
ground
closed switch) switch
OPS ENGINE NOT ENGINE

CONNECTOR RUNNING RUNNING
PIN RESISTANCE ( )
Infinitely high
Close to 0 when pressure
Engine
1 (normally reaches
ground
closed switch) 30 kPa ± 10 kPa
(4.35 PSI ± 1.45 PSI)
vmr2015-015-100_a
OPS LOCATION - RIGHT SIDE OF ENGINE
Oil Pressure Switch Access

Refer to BODY subsection and remove the follow-
ing components:
– Seat
– Console
– RH side panel and extension.
86 vmr2015-015
vmr2015-015-100_a
vmr2008-124-104_a
TYPICAL
If resistance values are incorrect, replace the oil

pressure switch.
If the values are correct, check the continuity of
the wiring harness.
Disconnect the ECM connector and check conti-
nuity of circuit between switch and ECM.
OPS CIRCUIT MEASUREMENT
Resistance ( )
OPS PIN ECM pin
@ 20°C (68°F)
vmr2015-015-002_a
1 E2 Close to 0 1. Oil pressure switch
Oil Pressure Switch Installation

Tighten oil pressure switch to specification.
OIL PRESSURE SWITCH
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
12 N•m ± 1 N•m
Tightening torque
Plug switch connector.
OIL STRAINER
Oil Strainer Access
Engine must be lifted or removed to access the
vmr2008-124-104_b
oil strainer. Refer to the ENGINE REMOVAL AND
TYPICAL
INSTALLATION subsection.
Oil Pressure Switch Removal Oil Strainer Removal

Disconnect and unscrew oil pressure switch. Drain engine oil, refer to ENGINE OIL CHANGE
in the PERIODIC MAINTENANCE PROCEDURES
subsection.
vmr2015-015 87
Remove: Inspect O-ring on the oil collector and rubber ring

– Retaining screws on the oil strainer cover if brittle, cracked or hard.
– Oil strainer cover Replace the defective parts.
– Gasket. Clean both contact surfaces of oil strainer cover.
Check and clean the oil inlet and outlet area for dirt
and other contaminations.
vmr2015-015-005_a
vmr2015-015-018_a
1. Oil inlet to the oil pump
1. Retaining screws 2. Oil return from the oil pressure regulator system
2. Oil strainer cover 3. Oil return from the engine oil circulation
3. Gasket
Remove: Oil Strainer Installation

– Oil collector with O-ring For installation, reverse the removal procedure.
– Oil strainer. Tighten oil strainer cover screws as per following
sequence.
OIL STRAINER COVER SCREWS
10 N•m ± 1 N•m
Tightening torque
vmr2015-015-004_a
1. Oil collector
2. O-ring
3. Oil strainer
Oil Strainer Cleaning and Inspection

Clean oil strainer with a part cleaner then use an
air gun to dry it.
WARNING vmr2015-015-003_a
Always wear eye protector. Chemicals can TIGHTENING SEQUENCE

cause a rash break out in and an injury to
your eyes. Tighten magnetic drain plug to specification.
Check engine oil strainer for cracks or other dam-

age. Replace if damaged.
88 vmr2015-015
MAGNETIC DRAIN PLUG Remove:

– Oil pressure regulator plug
Gasket ring NEW
– Compression spring
30 N•m ± 2 N•m – Valve piston.
Tightening torque
NOTE: Oil pressure regulator plug on oil pump
Reinstall engine in vehicle, refer to ENGINES RE- housing is spring loaded.
MOVAL AND INSTALLATION subsection.
Refill engine at the proper level with the recom-
mended oil, refer to PERIODIC MAINTENANCE
PROCEDURES subsection.
Start engine and let idle for a few minutes.
Ensure oil filter and magnetic drain plug areas are
not leaking.
Stop engine.
Wait a while to allow oil to flow down to crankcase
then check oil level. Refill as necessary.
ENGINE OIL PRESSURE vmr2015-015-007_a
1. Oil pressure regulator plug

REGULATOR 2. Compression spring
3. Valve piston
Oil Pressure Regulator Location
The oil pressure regulator is located in the oil Oil Pressure Regulator Inspection
pump housing (engine MAG side, behind mag- Inspect valve piston for scoring or other damages.
neto cover). Check compression spring for free length.
COMPRESSION SPRING FREE LENGTH
NEW NOMINAL 64 mm (2.52 in)
SERVICE LIMIT 62 mm (2.441 in)
Replace both parts if important wear or damage

are present.
Clean bore and threads in the oil pump housing
from metal shavings and other contaminations.
Oil Pressure Regulator Installation

vmr2015-015-006_a
For installation, reverse the removal procedure.
1. Oil pressure regulator plug Tighten oil pressure regulator plug screw to spec-
2. Oil pump housing
ification.
NOTE: The oil pressure regulator system works OIL PRESSURE REGULATOR PLUG SCREW
when the oil pressure exceeds 500 kPa (73 PSI).
12 N•m ± 1 N•m
Tightening torque
Oil Pressure Regulator Removal (106 lbf•in ± 9 lbf•in)
Remove:
– Engine from vehicle (refer to ENGINE RE- OIL PUMP
MOVAL/INSTALLATION subsection) The oil pump is located on the engine MAG side
– Water pump cover (refer to COOLING SYSTEM (refer to ENGINE OIL PRESSURE REGULATOR).
subsection)
– Magneto cover (refer to MAGNETO AND
STARTER subsection).
vmr2015-015 89
Oil Pump Removal Remove:

Remove: – Oil pump cover screws
– Engine from vehicle (refer to ENGINE RE- – Oil pump module with O-ring.
MOVAL AND INSTALLATION subsection) NOTICE Do not loose oil pump cover O-ring.
– Water pump cover (refer to COOLING SYSTEM
subsection) NOTICE Pay attention not to drop the dowel
– Magneto cover (refer to MAGNETO AND pins inside the engine.
STARTER subsection).
Remove only if necessary:
– Retaining ring (discard it)
– Drive gear
– Needle pin.
vmr2015-015-019_a
1. Oil pump cover screws

2. Oil pump module
3. O-ring, sealing to crankcase MAG side
vmr2015-015-008_a
1. Retaining ring (discard) Remove:

2. Drive gear
3. Needle pin – O-ring
4. Balancer shaft
– Oil pump cover
NOTICE Never use the retaining ring a sec- – Dowel pins.
ond time. Always replace by a NEW one.
Remove only if necessary:
– Pin
– Intermediate gear.
vmr2015-015-010_a
1. O-ring
2. Oil pump cover
3. Dowel pins
4. Oil pump housing
Use screwdrivers to remove oil pump gear.

vmr2015-015-009_a
1. Pin
2. Intermediate gear
90 vmr2015-015
vmr2015-015-011_a
1. Flat screwdrivers
2. Oil pump gear
Remove: vmr2015-015-013_a
– Needle pin 1. Oil pump shaft assembly
2. Outer rotor
3. Oil pump housing
Oil Pump Inspection

Inspect oil pump shaft assembly, housing and
cover for marks or other damages.
Replace O-ring if damaged, brittle or hard.
vmr2015-015-012_a
1. Needle pin
Remove:
– Oil pump shaft assembly vmr2015-015-006_b
– Outer rotor. 1. O-ring
Check inner rotor for corroded pin holes or other

damages. If so, replace oil pump shaft assembly.
Check the inside of oil pump housing and its cover
for scoring or other damages. If so, change the
complete oil pump assembly.
1
R400motr126A
1. Pittings on the teeth
vmr2015-015 91
Clean oil passages and make sure they are not

clogged.
C
1
R400motr127A
vmr2015-015-014_a 1. Outer rotor

OIL PUMP HOUSING 2. Inner rotor
1. Suction side of the oil pump
2. Outlet from the engine oil pressure regulator valve OUTER AND INNER ROTOR CLEARANCE
SERVICE LIMIT
A
B 0.25 mm (.0098 in)
C
If clearance between inner and outer rotor ex-

ceeds the tolerance, replace oil pump shaft
assembly. Ensure to also check oil pump housing
and cover. If damaged, replace the complete oil
pump assembly.
If clearance between outer rotor and its bore in
oil pump exceeds the tolerance, replace the com-
plete oil pump assembly.
vmr2015-015-015_a
Measure the axial clearance of the oil pump as
OIL PUMP COVER shown.
1. Oil from the pump to the oil filter in the magneto cover
2. Oil from the pump suction side to the oil pump
vmr2015-015-016_a
CRANKCASE MAG SIDE

1. Bores for dowel pins
2. Oil return from the oil pressure regulator system
3. Oil inlet to the oil pump (leads to strainer on engine bottom)
Using a feeler gauge, measure the clearance be-

tween inner and outer rotor.
92 vmr2015-015
NOTE: When the axial clearance of the oil pump

shaft assembly increases, the oil pressure de-
creases.
Oil Pump Installation

When installing the oil pump rotors, make sure
both markings are on the same side.
R1004motr51A 1
1. Markings on inner and outer rotor
vmr2015-015-020_a
MEASUREMENT "A" NOTICE Never apply any sealing compound

1. Oil pump housing surface
2. Oil pump rotor surface on split surfaces of oil pump.
Check oil pump cover for damages and for sur- Tightening oil pump cover screws as per following
face straightness with a straight edge and a feeler sequence.
gauge. OIL PUMP COVER SCREWS
10 N•m ± 1 N•m
Tightening torque
vmr2015-015-021_a vmr2015-015-006_c
MEASUREMENT "B" TIGHTENING SEQUENCE

1. Oil pump cover surface
2. Straight edge NOTE: After tightening the oil pump cover
3. Feeler gauge
screws check for smooth operation of the oil
Add measurement A to measurement B to obtain pump assembly.
axial clearance. Install the O-ring on oil pump cover.
OIL PUMP AXIAL CLEARANCE
SERVICE LIMIT 0.10 mm (.0039 in)
vmr2015-015 93
vmr2015-015-006_b
1. O-ring
After engine is completely reassembled, start en-

gine and make sure oil pressure is within specifi-
cations (refer to ENGINE OIL PRESSURE TEST in
this subsection).
94 vmr2015-015
LUBRICATION SYSTEM
SERVICE TOOLS
ADAPTER HOSE ........................................................................... 529 035 652 ........................................... 46
DISCONNECT TOOL ..................................................................... 529 035 714 ........................................... 46
PRESSURE GAUGE....................................................................... 529 035 709 ........................................... 46
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ..................................... 48, 52
vmr2016-029 43
COMPONENTS
20 ± 2 N•m
(15 ± 1,5 lbf•ft)
NEW
Loctite 243
12 ± 1 N•m
(106 ± 9 lbf•in)
NEW
10 ± 1 N•m
(89 ± 9 lbf•in)
Engine oil
Engine oil
NEW
6 ± 0,7 N•m
(53 ± 6 lbf•in) Loctite 243 20 ± 2 N•m
(15 ± 1,5 lbf•ft)
Engine oil
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
7 ± 0,5 N•m
(62 ± 4 lbf•in)
Engine oil
Engine oil

vmr2015-028-001_a
44 vmr2016-029
ENGINE LUBRICATION CIRCUIT
vmr2007-033-001_a
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
vmr2016-029 45
INSPECTION NOTE: To remove adapter hose from oil pressure

gauge, use the disconnect tool.
ENGINE OIL PRESSURE REQUIRED TOOL
NOTE: The engine oil pressure test should be DISCONNECT TOOL
done with a warm engine 100°C (212°F) and the (P/N 529 035 714)
recommended oil.
Remove the oil pressure switch. Refer to OIL Reinstall the oil pressure switch and remaining
PRESSURE SWITCH in this subsection. components.
Install the pressure test gauge with the proper
adapter hose in the OPS engine bore. TROUBLESHOOTING
REQUIRED TOOL LOW OR NO OIL PRESSURE
1. Oil level is too low.
PRESSURE GAUGE
(P/N 529 035 709) - Refill engine with recommended engine oil. Re-
fer to OIL LEVEL VERIFICATION in the PERIODIC
ADAPTER HOSE - Check for high oil consumption, refer to HIGH OIL
(P/N 529 035 652) CONSUMPTION in thisTROUBLESHOOTING.
- Check for engine oil leaks. For leak indicator
hose and leak indicator hole, refer to COOLING
SYSTEM INSPECTION in the PERIODIC MAIN-
TENANCE PROCEDURES subsection. Repair if
necessary.
2. Use of unsuitable engine oil type.
- Replace engine oil by the recommended engine
oil.
3. Clogged oil filter.
- Replace oil and oil filter at the same time.
4. Defective oil pressure switch.
- Test oil pressure switch, see procedure in this
subsection.
5. Defective or worn oil pump.
- Check oil pump, see procedure in this subsection.
vmr2015-028-100_a 6. Defective engine oil pressure regulator.
TYPICAL - Check engine oil pressure regulator, see proce-
1. Gauge connected in OPS engine bore
The engine oil pressure should be within the fol- 7. Worn plain bearings in crankcase.
lowing values. - Check plain bearing clearance, refer to BOTTOM
OIL PRESSURE 1250 RPM 6000 RPM END subsection.
300 kPa 8. Clogged engine oil strainer.

MINIMAL 70 kPa (10 PSI)
(44 PSI) - Clean engine oil strainer, see procedure in this
subsection.
150 kPa 350 kPa
NOMINAL
(22 PSI) (51 PSI) OIL CONTAMINATION
250 kPa 450 kPa
MAXIMAL 1. Defective water pump seal ring or rotary seal.
(36 PSI) (65 PSI)
- Check for oil or coolant leak from indicator near
If the engine oil pressure is out of specifications, water pump, refer to COOLING SYSTEM IN-
SPECTION in the PERIODIC MAINTENANCE
check the points described in TROUBLESHOOT- PROCEDURES subsection. Replace seal if nec-
ING in this subsection. essary.
Remove oil pressure gauge and adapter hose.
46 vmr2016-029
2. Cylinder head or cylinder base gasket leak.

- Retighten cylinder head to specified torque, refer
to TOP END subsection. Replace gasket if tight-
ening does not solve the problem.
3. Engine internal damage.
- Repair engine.
4. Oil cooler gasket leak.
- Replace oil cooler gasket and change engine oil.
HIGH OIL CONSUMPTION

1. Leaking breather oil seal.
- Check if the oil seal of the breather is brittle, hard vmr2012-012-003_a
or damaged. Refer to BOTTOM END subsection.
TYPICAL
1. Remove
2. Valve stem seals worn or damaged.
- Replace valve stem seals. Oil Pressure Switch Activation
3. Worn piston rings (blue exhaust smoke). The oil pressure switch activates when the engine
- Replace piston rings. oil pressure is lower than following specified pres-
sure range.
PROCEDURES OIL PRESSURE SWITCH ACTIVATION RANGE
30 kPa ± 10 kPa (4.35 PSI ± 1.45 PSI)
OIL PRESSURE SWITCH (OPS)
Oil Pressure Switch Location To check the function of the oil pressure switch,
an oil pressure test has to be performed. Refer to
ENGINE OIL PRESSURE in this subsection.
If the engine oil pressure is good, perform the oil
pressure switch resistance test.
Testing the Oil Pressure Switch

Resistance
Disconnect the connector from the oil pressure
switch.
Check resistance as per following tables.
OPS ENGINE NOT
ENGINE
CONNECTOR RUNNING
PIN RESISTANCE ( )
Close to 0
vmr2015-114-002_a Engine
1 (normally closed
1. Oil pressure switch ground
switch)
Oil Pressure Switch Access
Refer to BODY subsection and remove the fol-
lowing
– Seat
– Console
Remove OPS cover.
vmr2016-029 47
OPS Tighten oil pressure switch to specification.

ENGINE ENGINE RUNNING
CONNECTOR
SERVICE PRODUCT
PIN RESISTANCE ( )
LOCTITE 243 (BLUE)
Oil pressure switch
Infinite (open) when (P/N 293 800 060)
Engine pressure reaches
1
ground 30 kPa ± 10 kPa TIGHTENING TORQUE
(4.35 PSI ± 1.45 PSI)
12 N•m ± 1 N•m
Oil pressure switch
ENGINE OIL PRESSURE

REGULATOR
Oil Pressure Regulator Location
The oil pressure regulator is located on the engine
magneto side, integrated in the magneto cover.
vmr2006-014-009_a
If resistance values are incorrect, replace the oil

pressure switch.
If the values are correct, check wiring.
Removing the Oil Pressure Switch

Unplug the oil pressure switch connector.
Unscrew and remove oil pressure switch.
vmr2015-028-002_a
Installing the Oil Pressure Switch 1. Engine oil pressure regulator
NOTE: The oil pressure regulator system works

when the oil pressure exceeds 400 kPa (58 PSI).
Oil Pressure Regulator Access

Refer to BODY subsection and remove the fol-
lowing:
– Seat
– Console
– RH side panel and extension
– RH footboard panel.
Removing the Oil Pressure Regulator

Remove plug screw and pull oil pressure regulator
out.
vmr2015-114-002_a
1. Oil pressure switch
Apply required service product on threads of oil

pressure switch.
48 vmr2016-029
vmr2015-028-003_a
1. Plug screw
2. Gasket ring vmr2006-042-009_a
3. Pressure regulator housing
4. Spring 1. Oil pump
5. Pressure regulator valve
Removing the Oil Pump
Inspecting the Oil Pressure Regulator Remove the PTO cover. Refer to PTO COVER in
Inspect pressure regulator housing and valve for the BOTTOM END subsection.
scoring or other damages.
1. Remove:
Check spring for free length. – Retaining ring
SPRING FREE LENGTH – Oil pump gear
NEW NOMINAL 39 mm (1.535 in) – Needle pin
– Thrust washer.
NOTE: Replace worn or damaged components.

Clean bore and thread in the magneto housing
from metal shavings and other contaminations.
Installing the Oil Pressure Regulator

Pay attention to the following details.
NOTE: At installation always replace the gasket
ring of the plug screw by a NEW one.
OIL PUMP
Oil Pump Location tmr2011-010-011_a
1. Thrust washer
The oil pump is located on the engine PTO side 2. Needle pin
(behind PTO cover). 3. Oil pump gear
4. Retaining ring
2. Remove oil pump cover screws and pull oil

pump cover out.
vmr2016-029 49
vmr2006-042-011_a
1. Retaining screws
vmr2006-042-012_a
2. Oil pump cover
1. Oil pump bore
3. Remove oil pump shaft with needle pin and in- 2. Outer rotor
3. Oil pump shaft
ner rotor. 4. Needle pin
5. Inner rotor
4. Remove outer rotor.
Check inner rotor for corrosion pin holes or other
damages. If so, replace oil pump shaft assembly.
vmr2006-042-013_a
1. Pittings on the teeth

tmr2011-010-012_a
1. Outer rotor Using a feeler gauge, measure the clearance of

2. Needle pin
3. Oil pump shaft inner and outer rotors as shown.
4. Inner rotor
CLEARANCE OF INNER AND OUTER ROTOR
Inspecting the Oil Pump SERVICE LIMIT 0.25 mm (.0098 in)
Inspect oil pump and oil pump cover bore for
marks, scratches or other damages. Check for
scratches in crankcase between outer rotor and
oil pump bore. If so, replace damaged parts.
Check oil pump cover for damages and for surface
straightness with a straightedge.
50 vmr2016-029
A
A
2 1
vmr2006-042-014_a
1. Outer rotor vmr2006-042-016

2. Inner rotor
OIL PUMP COVER — MEASUREMENT “B”
A. 0.25 mm (.0098 in)
Substract measurement B from measurement A
If clearance of inner and outer rotors exceeds the
to obtain axial clearance.
tolerance, replace oil pump rotors. Ensure to also
check oil pump cover. If damaged, replace the OIL PUMP AXIAL CLEARANCE
complete oil pump assembly.
If clearance between outer rotor and its bore in
crankcase exceeds the tolerance, replace the NOTE: When the axial clearance of the oil pump
complete oil pump rotors and/or the crankcase. assembly increases, the oil pressure decreases.
Using a depth gauge, measure the axial clearance
of the oil pump as shown. Installing the Oil Pump
NOTE: When installing the oil pump rotors, make
sure both markings are on the outer side.
vmr2006-042-015
OIL PUMP — MEASUREMENT “A”
vmr2015-114-005_a
1. Markings
After reinstallation of the remaining parts, check

for smooth operation of the oil pump assembly.
Testing the Oil Pump Function

After engine is completely reassembled, start en-
gine and make sure oil pressure is within specifi-
cations (refer to ENGINE OIL PRESSURE in this
subsection).
vmr2016-029 51
ENGINE OIL STRAINER TIGHTENING TORQUE

Oil Strainer Location Oil strainer screws
6 N•m ± 0.7 N•m
The engine oil strainer is located between both
crankcase halves.
REED VALVE
Removing the Oil Strainer
The engine is equipped with a reed valve which
Remove engine from vehicle.
prevents accumulation of larger oil quantities in
Separate crankcase halves. Refer to BOTTOM the crankcase. The reed valve is fitted into the
END subsection. crankcase.
Remove screws and retaining plate.
Pull out engine oil strainer.
vmr2006-042-018_a
1. Reed valve
2. Stopper
3. Screws
Removing the Reed Valve

vmr2006-042-017_a
Remove:
1. Engine oil strainer
2. Retaining plate – Engine from vehicle
3. Screws
– PTO cover (refer to PTO COVER in the BOT-
Cleaning and Inspecting the Oil TOM END subsection)
Strainer – Reed valve retaining screws
– Stopper plate
Clean engine oil strainer with a part cleaner then
use an air gun to dry it. – Reed valve.
WARNING Inspecting the Reed Valve

Always wear eye protector. Chemicals can Check reed valve for cracks or other damage.
cause a rash break out and injure your eyes. Replace reed valve if damaged.
Check engine oil strainer for cracks or other dam- Installing the Reed Valve
age. Replace if damaged. The installation is the reverse of the removal pro-
cedure.
Installing the Oil Strainer
cedure.
SERVICE PRODUCT
LOCTITE 243 (BLUE)
Oil Strainer screws
(P/N 293 800 060)
52 vmr2016-029
Subsection 05 (COOLING SYSTEM)
COOLING SYSTEM
SERVICE TOOLS
BLIND HOLE PULLER KIT ............................................................ 529 036 056 ......................................... 104
HANDLE ........................................................................................ 420 877 650 ......................................... 105
OIL SEAL PUSHER........................................................................ 529 035 757 ......................................... 105
SEAL PUSHER .............................................................................. 529 035 766 ......................................... 105
SERVICE PRODUCTS
DOW CORNING 111 ..................................................................... 413 707 000 ......................................... 106
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 99
vmr2015-016 95
RADIATOR
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
NEW
10 ± 2 N•m
(89 ± 18 lbf•ft)
Engine
10 ± 2 N•m
(89 ± 18 lbf•ft)

vmr2015-016-100_a
96 vmr2015-016
WATER PUMP AND THERMOSTAT
10 ± 1 N•m
(89 ± 9 lbf•in)
2,5 ± 0,3 N•m

(22 ± 3 lbf•in)
Engine oil
NEW 5 ± 0,6 N•m

Molycote 111 (44 ± 5 lbf•in)
6 ± 0,7 N•m
NEW NEW (53 ± 6 lbf•in)
Loctite 243
16 ± 2 N•m
(142 ± 18 lbf•in)
CTS
See ELECTRONIC FUEL
INJECTION (EFI)
NEW
NEW

vmr2015-016-001_a
vmr2015-016 97
GENERAL Thermostat Removal

Install a hose pincher on both radiator hoses.
WARNING
Never start engine without coolant. Engine
parts and ceramic 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
must be strictly adhered to. vmr2015-016-102_a
Locking devices when removed (e.g.: locking 1. Hose pinchers
tabs, elastic stop nuts, self-locking fasteners, 2. Coolant return hose from thermostat
3. Radiator coolant outlet hose
etc.) must be installed or replaced with new
ones where specified. If the efficiency of a Remove thermostat housing screws and pull ther-
locking device is impaired, it must be re- mostat housing off cylinder head.
newed.
INSPECTION
PROCEDURES
THERMOSTAT
The thermostat is a single action type, located on
the RH rear side of the cylinder head.
Thermostat Access
Remove the RH side body panel.
vmr2015-016-003_a
1. Thermostat housing
2. Screws
Remove thermostat with gasket.
vmr2015-016-101_a
1. Valve cover
98 vmr2015-016
Radiator Removal
1. Drain engine coolant. Refer to PERIODIC
2. Remove front body module. Refer to BODY
subsection.
3. Disconnect radiator and fan assembly.
vmr2015-016-004_a
1. Thermostat with gasket
Thermostat Test
To test thermostat, put it in water and heat the
water.
THERMOSTAT OPENING TEMPERATURE
STARTS TO OPEN FULLY OPEN
65°C (149°F) 75°C (167°F)
vmr2015-016-103_a
Replace thermostat if it does not begin to open at
1. Radiator hoses
specified temperature.
Check gasket to see if it is brittle, hard or dam-
aged. If so, replace gasket.
Thermostat Installation
For installation, reverse the removal procedure,
pay attention to the following details.
Tighten thermostat cover screws to specification.
THERMOSTAT COVER SCREWS
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
6 N•m ± 0.7 N•m
Tightening torque
Refill and bleed cooling system, refer to PERI- vmr2015-029-104_a
ODIC MAINTENANCE PROCEDURES subsec- Step 1: Disconnect cooling fan connector

Step 2: Remove the harness connector from the fan shroud
tion.
Check cooling system for leaks.
RADIATOR
Radiator Inspection
Check radiating fins for clogging or damage.
Remove insects, mud or other obstructions with
compressed air or low pressure water.
vmr2015-016 99
Refill and bleed cooling system, refer to PERI-

ODIC MAINTENANCE PROCEDURES subsec-
tion.
RADIATOR COOLING FAN

Radiator Cooling Fan Operation
The ECM controls the radiator cooling fan via the
input of the coolant temperature sensor (CTS) and
the manifold air pressure and temperature sensor
(MAPTS). Refer to the following tables.
CHECK
ENGINE COOLING GAUGE
vmr2015-016-104_a
ENGINE
TYPICAL TEMP. FAN MESSAGE
LIGHT
1. Remove fan motor vent hose
95°C
NOTE: Take note of the rooting of vent hose on Turns ON
(203°F)
vehicle to ease reinstallation.
93°C
Turn OFF
(199°F)
Check
115°C
ON Turns ON engine
(239°F)
Hi Temp
118°C Limp
ON Flashes
(244°F) Home
Radiator Cooling Fan Fuse Location

The fuse (F9) is located in front fuse box under
gauge support.
Radiator Cooling Fan Test

1. Disconnect radiator cooling fan connector.
vmr2015-029-103_a
Step 1: Remove upper retaining bolts

Step 2: Remove radiator from bushings
Radiator Installation
Ensure that rubber bushings are properly installed
between frame and fan shroud.
Ensure that vent hose of the cooling fan motor is
properly rooted as prior to removal.
NOTICE If the vent hose of the cooling fan
motor is not properly rooted, the fan motor
may be damaged due to improper venting.
vmr2015-029-101_a
Tighten radiator upper retaining bolts to specifica- 1. Cooling fan connector

tion.
2. Connect cooling fan connector pin B to a suit-
RADIATOR UPPER RETAINING BOLTS able 20 A fuse jumper and then directly to the
10 N•m ± 2 N•m positive battery post.
Tightening torque
100 vmr2015-016
3. Connect cooling fan connector pin A (BK wire) COOLING FAN TROUBLESHOOTING CHART
directly to the negative battery post.
Is fan working? YES  Everything is OK
4. Check if cooling fan works properly.
– If cooling fan does not work, replace it. NO 
– If cooling fan works properly, refer to RADI- Check FAN fuse (F9) Replace fuse
ATOR COOLING FAN TROUBLESHOOTING Is fuse burnt?
YES  Is fan working?
CHART.
5. Reconnect radiator cooling fan connector.
NO 
Bypass fan relay R1
Radiator Cooling Fan Troubleshooting (refer to RELAY
OPERATION TEST)
NOTE: The following troubleshooting chart as-
sumes that the engine is operating in the fan 
activation temperature range. Refer to RADIA-
Replace relay
TOR COOLING FAN OPERATION. Fan turns? YES  Is fan working?
NO 
Apply 12 Vdc
and a ground to
fan connector
(refer to RADIATOR
COOLING FAN TEST)

Replace fan
Fan turns? NO  Is fan working?
YES 
Check CTS
(refer to
ELECTRONIC FUEL
INJECTION (EFI)
subsection)

CTS works? NO  Replace CTS
Is fan working?
YES 
Check wiring harness
and connectors
(refer to WIRING
DIAGRAM)

Harness and Repair or replace
connectors good?
NO  defective part(s)
YES 
Try a new ECM  Is fan working?
Radiator Cooling Fan Removal

1. Proceed with RADIATOR REMOVAL. See pro-
cedure in this subsection.
vmr2015-016 101
2. Remove radiator cooling fan retaining screws. COOLANT TEMPERATURE

SENSOR (CTS)
The coolant temperature sensor is located next to
the thermostat housing on the RH rear side of the
cylinder head.
Refer to ELECTRONIC FUEL INJECTION subsec-
tion.
WATER PUMP HOUSING

NOTE: The water pump housing is located on the
engine MAG side (RH).
Water Pump Housing Location

The water pump housing is located on the RH side
vmr2012-013-008_a
of the engine.
1. Cooling fan retaining screws
Water Pump Housing Access
3. Remove radiator cooling fan. Remove RH side panel and extension, refer to
BODY subsection.
Radiator Cooling Fan Installation
The installation is the reverse of the removal pro- Water Pump Housing Removal
cedure. However, pay attention to the following. Drain cooling system, refer to PERIODIC MAIN-
Tighten cooling fan retaining screws to specifica- TENANCE PROCEDURES subsection.
tion. Remove radiator outlet hose from water pump
RADIATOR COOLING FAN SCREWS housing.
10 N•m ± 2 N•m Remove screws retaining water pump housing.
Tightening torque
RADIATOR COOLING FAN RELAY

(R1)
Relay Location (Radiator Cooling Fan)
The relay (R1) is located in front fuse box under
gauge support.
Relay Operation Test (Radiator Cooling

Fan)
1. Remove relay (R1).
2. Bypass relay using a jumper. Refer to WIRING vmr2015-016-005_a

DIAGRAM to locate proper terminals. 2. Sealing ring
3. Screws
3. If the radiator cooling fan is activated, replace 4. Water pump housing
the relay.
Pull on water pump housing to remove it.
Relay Continuity Test (Radiator
Cooling Fan) Water Pump Housing Inspection
Refer to POWER DISTRIBUTION AND GROUNDS Check if gasket is brittle, hard or damaged.
subsection. Replace as required.
102 vmr2015-016
WATER PUMP IMPELLER

Water Pump Impeller Removal
1
Remove water pump housing, see procedure in
this subsection.
Unscrew impeller from water pump shaft.
R400motr138A
WATER PUMP COVER

1. Gasket vmr2015-016-007_a
1. Impeller
Water Pump Housing Installation
The installation is the opposite of the removal pro- Water Pump Impeller Inspection
cedure. Check impeller for cracks or other damages. Re-
place impeller if damaged.
NOTICE To prevent leaking, make sure the
gasket is properly inserted in the water pump Water Pump Impeller Installation
housing groove when you reinstall the water
pump cover. The installation is the opposite of the removal pro-
cedure.
Install a NEW gasket ring on water pump housing NOTE: Be careful not to damage the impeller
screw. blades during installation.
Tightening sequence for screws on water pump
cover is as per following illustration (criss-cross). WATER PUMP SHAFT AND
WATER PUMP HOUSING SCREWS SEALS
Gasket ring NEW Water Pump Shaft and Seal Removal
10 N•m ± 1 N•m Remove water pump housing, refer to WATER
Tightening torque
(89 lbf•in ± 9 lbf•in) PUMP HOUSING in this subsection.
Remove impeller.
Remove magneto cover, refer to the MAGNETO
AND STARTER subsection.
Remove circlip from the water pump gear using
the appropriate pliers. Discard the circlip.
vmr2015-016-006_a
TIGHTENING SEQUENCE
vmr2015-016 103
vmr2015-016-008_a
1. Circlip
2. Water pump gear vmr2015-016-014_a
1. Water pump shaft

Remove: 2. Soft hammer
– Water pump gear 3. Magneto cover
– Needle pin Install expander snugly against outer part of rotary

– Thrust washer. seal.
REQUIRED TOOL
BLIND HOLE PULLER KIT

(P/N 529 036 056)
Pull outer part of rotary seal out.
vmr2015-016-009_a
1. Water pump gear

2. Needle pin
3. Thrust washer
Push the water pump shaft with inner portion of

the rotary seal from inside of magneto cover.
REQUIRED TOOL
Soft hammer
vmr2015-016-015_a
1. Outer part of rotary seal

2. Expander
3. Magneto cover
NOTICE Always replace rotary seal and wa-

ter pump shaft together. Also install a NEW oil
seal at the same time.
104 vmr2015-016
Water Pump Shaft and Gear Inspection

Inspect water pump gear for:
– Wear
– Cracks
– Broken teeth
– Damage on snap mechanism to the needle pin.
Replace if damaged.
Inspect shaft and rotary seal for wear or damages.
R400motr144A 1 Water Pump Shaft and Seal

Installation
1. Water pump shaft with rotary seal
Remove oil seal from inside magneto cover using However, pay attention to the following.
an appropriate pusher.
NOTICE When replacing water pump shaft,
always replace circlip, oil seal, water pump
shaft and rotary seal with new parts.
Install the water pump shaft oil seal.
REQUIRED TOOLS
HANDLE (P/N 420
877 650)
OIL SEAL PUSHER
(P/N 529 035 757)
vmr2015-016-010_a
1. Oil seal behind the rotary seal

2. Rotary seal bore
NOTICE Be careful not to damage the surface

of the rotary seal bore in magneto cover.
vmr2015-016-012_a
1. Oil seal for water pump shaft

2. Oil seal pusher
3. Handle
Install the water pump shaft assembly.

REQUIRED TOOL
SEAL PUSHER
(P/N 529 035 766)
NOTE: Never use oil or grease in the press fit area

of the oil seal and rotary seal bores.
vmr2015-016-011_a
1. Special area for oil seal removal Lubricate the sealing lip of the oil seal.
vmr2015-016 105
OIL SEAL SEALING LIP

DOW CORNING 111
Service product
(P/N 413 707 000)
Apply a light coat of engine oil on the water pump

shaft.
Press the water pump shaft assembly into the
magneto cover using the outside area of the ro-
tary seal.
R400motr150A 1
1. Surface used to press water pump shaft assembly in place
NOTICE Never use a hammer for rotary seal

installation. To avoid damaging the ceramic
component, seal must be installed using a
press.
vmr2015-016-013_a

2. Water pump ceramic seal installer
NOTE: After installation water pump shaft with

rotary seal must rotate freely.
Install magneto cover, refer to MAGNETO AND
STARTER subsection.
Install all other removed parts.
106 vmr2015-016
COOLING SYSTEM
SERVICE TOOLS
HANDLE ........................................................................................ 420 877 650 ........................................... 66
OIL SEAL PUSHER........................................................................ 529 035 757 ........................................... 66
ROTARY SEAL PUSHER PLATE .................................................... 529 036 130 ........................................... 64
SEAL PUSHER .............................................................................. 529 035 766 ..................................... 64, 67
SERVICE PRODUCTS
DOW CORNING 111 ..................................................................... 413 707 000 ........................................... 67
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 56
vmr2016-030 53
RADIATOR
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
NEW
10 ± 2 N•m
(89 ± 18 lbf•ft)
Engine
10 ± 2 N•m
(89 ± 18 lbf•ft)

vmr2015-029-100_a
54 vmr2016-030
WATER PUMP AND THERMOSTAT

NEW
6 ± 0.7 N•m
5 ± 0.6 N•m (53 ± 6 lbf•in) 5 ± 0.6 N•m
(44 ± 5 lbf•in) NEW (44 ± 5 lbf•in)
NEW
Loctite
243 6 ± 0.7 N•m
(53 ± 6 lbf•in)
Loctite
243
CTS See Electronic
Fuel Injection (EFI)
16 ± 2 N•m
(142 ± 18 lbf•in)
NEW
20 ± 2 N•m
(15 ± 1 lbf•ft)
10 ± 1 N•m
(89 ± 9 lbf•in)
NEW
NEW
2.5 ± 0.3 N•m

(22 ± 3 lbf•in) Engine
oil
Molycote NEW
111
NEW
Engine oil

vmr2013-013-002_a
vmr2016-030 55
GENERAL 3. Pull thermostat and gasket.

NOTICE Never start engine without coolant.
Some engine parts such as the rotary seal on
the water pump shaft can be damaged.
PROCEDURES
THERMOSTAT
Thermostat Location
The thermostat is located in the thermostat hous-
ing at the top of the front cylinder (RH side).
vmr2016-030-001_a
1. Thermostat with gasket
Testing the Thermostat

To check thermostat, put it in water and heat the
water.
THERMOSTAT OPENING TEMPERATURE
STARTS TO OPEN FULLY OPEN
65°C (149°F) 75°C (167°F)
vmr2015-029-002_a
Replace thermostat if it does not begin to open at
THERMOSTAT LOCATION specified temperature.
1. Front cylinder
Check if gasket is brittle, hard or damaged. If so,
replace gasket.
Removing the Thermostat
1. Drain engine coolant, refer to PERIODIC MAIN- Installing the Thermostat
TENANCE PROCEDURES subsection. The installation is the reverse of the removal pro-
2. Remove thermostat housing screws and re- cedure. However, pay attention to the following.
move thermostat cover.
SERVICE PRODUCT
Thermostat cover LOCTITE 243 (BLUE)
retaining screws (P/N 293 800 060)
TIGHTENING TORQUE
Thermostat cover 6 N•m ± 0.7 N•m
retaining screws (53 lbf•in ± 6 lbf•in)

tion.
RADIATOR
vmr2015-115-003_a
THERMOSTAT Inspecting the Radiator

1. Thermostat cover
2. Thermostat housing Check radiator fins for clogging or damage.
3. Cover screws
4. Bleed screw
56 vmr2016-030
Remove insects, mud or other obstructions with

compressed air or low pressure water.
Removing the Radiator

1. Drain engine coolant. Refer to PERIODIC
2. Remove front body module. Refer to BODY
subsection.
3. Disconnect radiator and fan assembly.
vmr2015-029-105_a
1. Remove fan motor vent hose
NOTE: Take note of the rooting of vent hose on

vehicle to ease reinstallation.
vmr2015-029-102_a
1. Radiator hoses
vmr2015-029-103_a
Step 1: Remove upper retaining bolts

Step 2: Remove radiator from bushings
Installing the Radiator

Ensure that rubber bushings are properly installed
between frame and fan shroud.
vmr2015-029-104_a
Step 1: Disconnect cooling fan connector Ensure that vent hose of the cooling fan motor is
Step 2: Remove the harness connector from the fan shroud properly rooted as prior to removal.
NOTICE If the vent hose of the cooling fan
motor is not properly rooted, the fan motor
may be damaged due to improper venting.
Tighten radiator upper retaining bolts to specifica-
tion.
TIGHTENING TORQUE
Radiator upper retaining 10 N•m ± 2 N•m
bolts (89 lbf•in ± 18 lbf•in)
vmr2016-030 57

tion.
COOLANT TEMPERATURE
SENSOR (CTS)
Refer to ELECTRONIC FUEL INJECTION (EFI)
subsection.
RADIATOR COOLING FAN

Radiator Cooling Fan Operation vmr2015-029-101_a
1. Cooling fan connector

The ECM controls the radiator cooling fan via the
input of the coolant temperature sensor (CTS). Re- 2. Connect cooling fan connector pin B to a suit-
fer to the following table. able 20 A fuse jumper and then directly to the
CHECK positive battery post.
ENGINE COOLING GAUGE
TEMP. FAN
ENGINE
MESSAGE
3. Connect cooling fan connector pin A (BK wire)
LIGHT directly to the negative battery post.
95°C __ __
4. Check if cooling fan works properly.
Turns ON
(203°F) – If cooling fan does not work, replace it.
93°C – If cooling fan works properly, refer to RADI-
Turn OFF __ __
(199°F) ATOR COOLING FAN TROUBLESHOOTING
Check
CHART.
115°C
ON Turns ON engine 5. Reconnect radiator cooling fan connector.
(239°F)
Hi Temp
118°C Limp
Troubleshooting the Radiator Cooling
(244°F)
ON Flashes
Home Fan
NOTE: The following troubleshooting chart as-
Radiator Cooling Fan Fuse Location sumes that the engine is operating in the fan
activation temperature range. Refer to RADIA-
The radiator cooling fan fuse (F9) is located in the TOR COOLING FAN OPERATION.
front fuse box, under the gauge support.
vmr2015-044-006_a
Testing the Radiator Cooling Fan

1. Disconnect radiator cooling fan connector.
58 vmr2016-030
COOLING FAN TROUBLESHOOTING CHART 2. Remove radiator cooling fan retaining screws.
Is fan working? YES  Everything is OK
NO 
Check FAN fuse (F9) Replace fuse
Is fuse burnt?
YES  Is fan working?
NO 
Bypass fan relay R1
(refer to RELAY
OPERATION TEST)

Replace relay
Fan turns? YES  Is fan working?
NO  vmr2012-013-008_a
Apply 12 Vdc 1. Cooling fan retaining screws

and a ground to
3. Remove radiator cooling fan.
fan connector
(refer to RADIATOR
COOLING FAN TEST) Installing the Radiator Cooling Fan
 cedure. However, pay attention to the following.
Replace fan
Fan turns? NO  Is fan working?
Tighten cooling fan retaining screws to specifica-
tion.
YES  TIGHTENING TORQUE
Check CTS Radiator cooling fan 10 N•m ± 2 N•m
(refer to screws (89 lbf•in ± 18 lbf•in)
ELECTRONIC FUEL
INJECTION (EFI)
subsection) RADIATOR COOLING FAN RELAY
 (R1)
Replace CTS Relay Location (Radiator Cooling Fan)
CTS works? NO  Is fan working? The radiator cooling fan relay (R1) is located in the
front fuse box, under the gauge support.
YES 
Check wiring harness
and connectors
(refer to WIRING
DIAGRAM)

Harness and Repair or replace
connectors good?
NO  defective part(s)
YES  vmr2015-044-006_a
Try a new ECM  Is fan working?

Testing the Radiator Cooling Fan Relay
Removing the Radiator Cooling Fan Relay Operation Test
1. Proceed with RADIATOR REMOVAL. See pro- 1. Remove relay (R1).
cedure in this subsection. 2. Bypass relay using a jumper. Refer to WIRING
DIAGRAM to locate proper terminals.
vmr2016-030 59
3. If the radiator cooling fan is activated, replace

the relay.
Relay Continuity Test
Refer to POWER DISTRIBUTION AND GROUNDS
subsection.
WATER PUMP HOUSING

Water Pump Housing Location
The water pump housing is located on the engine
MAG side.
Water Pump Housing Access tmr2015-016-003_a
Remove RH footrest panel, refer to BODY sub- 1. Gasket

section.
Installing the Water Pump Housing
Removing the Water Pump Housing The installation is the reverse of the removal pro-
WARNING
To avoid potential burns, do not remove the NOTICE To prevent leaking, take care that the
radiator cap or loosen the coolant drain plug gasket is exactly in groove when you reinstall
if the engine is hot. the water pump housing.
Tighten screws of water pump housing in a criss-
1. Drain engine coolant. Refer to PERIODIC cross sequence to specification.
TIGHTENING TORQUE
2. Remove radiator outlet hose from water pump
housing. Water pump housing 10 N•m ± 1 N•m
screws (89 lbf•in ± 9 lbf•in)
3. Remove screws retaining water pump housing.
WATER PUMP IMPELLER

Removing the Water Pump Impeller
1. Proceed with WATER PUMP HOUSING RE-
MOVAL. See procedure in this subsection.
2. Remove impeller by unscrewing it counter-
clockwise.
vmr2016-030-002_a

2. Sealing ring
3. Screws
4. Water pump housing
4. Pull water pump housing to remove it.
Inspecting the Water Pump Housing

Check if gasket is brittle, hard or damaged and re- vmr2015-115-002_a
place as necessary. 1. Turn counterclockwise to unscrew
60 vmr2016-030
NOTICE Water pump shaft and impeller have

right-hand threads.
Inspecting the Water Pump Impeller

Check impeller for cracks or other damage. Re-
place impeller if damaged.
Installing the Water Pump Impeller

NOTICE Be careful not to damage impeller
fins during installation.
WATER PUMP SHAFT AND

SEALS
Use these guidelines to service these parts. tmr2011-011-050_a
DEFECTIVE PART ACTION 1. Inner part of rotary seal
Replace:
- Rotary seal
Rotary seal
- Oil seal
(assembled engine)
Replace:
- Rotary seal
Oil seal
- Oil seal
(assembled engine)
Replace:
- Water pump
shaft assembly
Water pump shaft
(including rotary seal)
- Oil seal
vbs2008-011-005
(engine disassembled)
TYPICAL - INNER PART OF ROTARY SEAL REMOVED
Water Pump Seals Replacement 3. Carefully bend down the outer part of rotary
(Assembled Engine) seal lip using a small chisel.
NOTE: Read and thoroughly understand the en-
tire procedure before starting it.
Seals Removal
1. Remove the following parts, see procedure in
this subsection.
– WATER PUMP HOUSING
– WATER PUMP IMPELLER.
2. Carefully pry out inner part of the rotary seal
using 2 screwdrivers.
vmr2016-030 61
5. Thoroughly remove sealing residue and burr of

rotary seal using a scraper.
NOTICE Be careful not to damage water
pump shaft.
tmr2011-011-051_a
tmr2011-011-053_a
1. Small chisel
1. Scraper
4. Use 2 screwdrivers and carefully remove the
outer part of the rotary seal. 6. Install 2 wooden screws in the seal.
tmr2011-011-054_a
1. Wooden screws
2. Oil seal
7. Remove oil seal from crankcase by pulling

screws with pliers.
tmr2011-011-052_a
1. Screwdrivers
NOTICE Be careful not to damage the

crankcase while removing outer part of the
rotary seal.
62 vmr2016-030
vbs2008-011-034
OIL SEAL INSTALLATION
5. Ensure that the oil seal is properly seated in wa-

tmr2011-011-055_a ter pump cavity.
1. Pull on screws to remove seal
8. Check water pump shaft axial play.

NOTE: If axial play is not adequate, engine must
be disassembled to replace water pump shaft.
9. Clean oil seal seat.
vbs2008-011-035_a
TYPICAL
1. Oil seal properly seated
6. Apply engine oil on water pump shaft.

7. Place rotary seal onto water pump shaft and pull
out water pump shaft by hand.
NOTICE Do not install the rotary seal com-
tmr2011-011-056_a
pletely into the crankcase to prevent the water
Seals Installation pump shaft plastic gear from breaking. Push it
1. Apply engine oil on water pump shaft. partially in, then pull the shaft.
2. Apply grease on the lips of the oil seal. 8. Place a robust M8 flat washer (P/N 420 227
3. Carefully install oil seal over the water pump 935) onto water pump shaft.
shaft. 9. Install a M8 x 1.25 nut (P/N 233 281 414) onto
4. Push oil seal into the water pump cavity. water pump shaft by hand.
10. Thread nut 1-1/2 turns to pull the shaft into
REQUIRED TOOL
rotary seal.
17 mm (11/16 in) deep socket
vmr2016-030 63
tmr2011-011-057_a
1. Rotary seal
2. M8 robust flat washer (P/N 420 227 935)
3. M8 x 1.25 nut (P/N 233 281 414)
11. Remove M8 nut. tmr2011-011-058_a
NOTE: The robust M8 flat washer must remain on ROTARY SEAL PUSHER PLATE ASSEMBLY
1. 4 x tubes (70 mm (2.75 in) length)
water pump shaft. 2. 4 x screws M6 x 85
3. Plane surface on pusher bolt
REQUIRED TOOLS
ROTARY SEAL PUSHER PLATE (P/N 529 036 130) 12. Install rotary seal installation tools on
crankcase as follows.
4x M6 x 85 screws (P/N 420 440 347)
NOTE: Make sure pusher bolt has a plane
4x tubes 70 mm (2.75 in) surface.
SEAL PUSHER (P/N 529 035 766) 12.1 Apply a little grease at the end of tool
pusher bolt.
12.2 Ensure that pusher bolt is completely un-
screwed.
12.3 Install rotary seal pusher plate on
crankcase by tightening M6 screws.
NOTICE Do not use pneumatic or elec-
tric tools for tightening screws.
529036130
ROTARY SEAL PUSHER PLATE (P/N 529 036 130)
tmr2011-011-059_a
ROTARY SEAL PUSHER PLATE INSTALLATION

1. Rotary seal pusher plate
2. Tube (70 mm (2.75 in) length)
3. M6 x 85 screw
4. Pusher bolt
529035766
SEAL PUSHER (P/N 529 035 766) 12.4 Install seal pusher between rotary seal
pusher plate and water pump shaft.
64 vmr2016-030
vbs2008-011-040
tmr2011-011-060_a WATER PUMP SHAFT PROPERLY ADJUSTED WITH ROTARY

SEAL PUSHER INSTALLATION SEAL
1. Seal pusher aligned with pusher bolt
NOTICE The water pump shaft must
12.5 Tighten the pusher bolt by hand until it be properly adjusted with rotary seal.
stops against the seal pusher. The water pump shaft must move freely
13. Carefully thread the pusher bolt 1-1/2 turns. while pushing it toward the crankcase.
14. Ensure that the rotary seal is going straight 18. Install the following parts, see procedure in
into crankcase. this subsection.
15. Remove rotary seal installation tools from – WATER PUMP IMPELLER
crankcase. – WATER PUMP HOUSING .
16. Repeat steps 9 TO 15 until rotary seal is com- 19. Refill and bleed cooling system. Refer to PE-
pletely seated in the crankcase. RIODIC MAINTENANCE PROCEDURES sub-
section.
20. Check cooling system for leaks.
Water Pump Shaft and Seals

Replacement (Disassembled Engine)
Water Pump Shaft and Seals Removal
1. Remove the following parts, see procedure in
this subsection:
– WATER PUMP HOUSING
– WATER PUMP IMPELLER
vbs2008-011-037
– WATER PUMP GEARS.
ROTARY SEAL PROPERLY SEATED ON CRANKCASE
2. Push out water pump shaft with inner portion of
17. Carry out the final adjustment of the water rotary seal from inside of crankcase MAG side.
pump shaft as follows.
REQUIRED TOOL
17.1 Install M8 x 1.25 nut (P/N 233 281 414)
onto water pump shaft. Soft hammer
17.2 Carefully thread M8 nut until the rotary

seal is flush with the end of water pump
shaft threads.
vmr2016-030 65
tmr2011-011-010_a tmr2011-011-011_a
1. Water pump shaft 1. Oil seal

2. Crankcase MAG side 2. Machined surface for rotary seal
3. Install a blind hole puller expander snugly

against outer part of rotary seal and pull seal
out.
tmr2011-011-012_a
OIL SEAL REMOVAL - VIEW FROM INSIDE CRANKCASE MAG

SIDE
1. Orifices for oil seal removal
Water Pump Shaft and Seals Installation

vmr2007-034-105_a
4. Remove oil seal from inside of crankcase MAG cedure. However, pay attention to the following.
side using a pusher tool. Use tightening torque values specified in the ex-
ploded view.
NOTICE Be careful not to damage the rotary
seal surface in crankcase. NOTE: Never apply oil on the press fit area of the
oil seal and rotary seal.
Clean rotary seal surface of any old sealant.
Install oil seal.
REQUIRED TOOL
OIL SEAL PUSHER
(P/N 529 035 757)
HANDLE
(P/N 420 877 650)
When installing the oil seal on the pusher, make

sure the sealing lip points outwards.
66 vmr2016-030
Push NEW oil seal in place.
mmr2009-112-028_a
WATER PUMP SHAFT ASSEMBLY

1. Surface where rotary seal is pushed by tool
NOTICE Never use a hammer for rotary seal

installation. Only use a press to avoid damag-
ing the ceramic component.
tmr2011-011-014_a
1. Oil seal
2. Installer handle with oil seal pusher
Apply DOW CORNING 111 (P/N 413 707 000) on seal-

ing lip of the oil seal.
tmr2011-011-015_a

2. Water pump seal installer
NOTICE After installation, water pump shaft

with rotary seal must rotate freely.
tmr2011-011-011_b
1. Sealing lip
2. Oil seal properly installed
Apply engine oil on the water pump shaft and in-

termediate shaft.
Slide NEW water pump shaft assembly into
crankcase.
REQUIRED TOOL
SEAL PUSHER
(P/N 529 035 766)
vmr2016-030 67
WATER PUMP GEARS

Water Pump Gears Identification
vmr2015-029-001_a
CRANKCASE PTO SIDE

1. Water pump intermediate drive gear
2. Circlip
vmr2012-013-009_a
3. Water pump intermediate shaft
4. Crankcase PTO side
1. Water pump shaft
2. Water pump gear Water Pump Drive Gear
4. Water pump intermediate shaft See BOTTOM END subsection.
5. Water pump drive gear (See BOTTOM END subsection)
Inspecting the Water Pump Gears Water Pump Gears Removal

Water Pump Gear Water Pump Gear
Inspect water pump gear for wear and damage on 1. Remove circlip retaining water pump gear and
the snap mechanism to the needle pin. Replace if discard it.
damaged.
tmr2011-011-008_a
CRANKCASE MAG SIDE

tmr2011-011-008_a 1. Circlip
CRANKCASE MAG SIDE 2. Water pump gear
1. Circlip
2. Water pump gear 2. Remove the following parts:
Water Pump Intermediate Drive Gear – Water pump gear
– Needle pin
Check water pump intermediate drive gear for
wear or broken teeth. Replace if damaged. – Thrust washer.
68 vmr2016-030
NOTICE A missing thrust washer will cause a

leaking rotary seal.
tmr2011-011-009_a
CRANKCASE MAG SIDE

1. Water pump gear
2. Needle pin
3. Thrust washer
tmr2011-011-009_a
Water Pump Intermediate Drive Gear 1. Water pump gear

2. Needle pin
1. Remove circlip retaining water pump interme- 3. Thrust washer
diate drive gear and discard it. NOTE: Ensure water pump gear snaps properly
onto needle pin.
Install NEW circlip to retain water pump gear.
NOTICE Never use the circlip a second time.
Always install a NEW one.
vmr2015-029-001_a
CRANKCASE PTO SIDE

2. Circlip
4. Crankcase PTO side

– Water pump intermediate drive gear
– Needle pin. tmr2011-011-008_a
1. Circlip
Water Pump Drive Gear 2. Water pump gear
See BOTTOM END subsection. Water Pump Intermediate Drive Gear

Install the following parts on water pump interme-
Installing the Water Pump Gears diate shaft.
Water Pump Gear – Needle pin
Install the following parts on water pump shaft. – Water pump intermediate drive gear.
– Thrust washer Install NEW circlip to retain water pump interme-
– Needle pin diate drive gear.
– Water pump gear. NOTICE Never use the circlip a second time.
Always install a NEW one.
vmr2016-030 69
Water Pump Drive Gear

See BOTTOM END subsection.
70 vmr2016-030
Subsection 06 (MAGNETO AND STARTER)
MAGNETO AND STARTER

SERVICE TOOLS
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ......................................... 119
CRANKSHAFT PROTECTOR (MAG).............................................. 420 876 557 ......................................... 115
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 113
HANDLE ........................................................................................ 420 877 650 ......................................... 120
MAGNETO PULLER ...................................................................... 529 035 748 ......................................... 115
STARTER DRIVE NEEDLE INSTALLER ......................................... 529 035 934 ......................................... 120
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ......................................... 118
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ......................................... 120
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 116
LOCTITE 5910 ............................................................................... 293 800 081 ......................................... 111
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ......................................... 111
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ......................................... 116
SUPER LUBE GREASE.................................................................. 293 550 030 ......................................... 118
vmr2015-017 107
10 ± 1 N•m 10 ± 1 N•m
(89 ± 9 lbf•in) (89 ± 9 lbf•in)
25 ± 3 N•m
6 ± 0,7 N•m (18 ± 2 lbf•ft)
(53 ± 6 lbf•in)
Multi Purpose Grease BP LS3
Loctite 243
NEW
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 5910
25 ± 3 N•m
(18 ± 2 lbf•ft)
11 ± 1 N•m
(97 ± 9 lbf•in)
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
Loctite 243
Drei Bond sealing compound
180 ± 10 N•m
(133 ± 7 lbf•ft)

vmr2015-017-001_a
108 vmr2015-017
10 ± 1 N•m
(89 ± 9 lbf•in)
Super Lube Grease
Isoflex Grease
Topas NB52
Isoflex Grease
Topas NB52
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)

vmr2015-017-023_a
vmr2015-017 109
PROCEDURES
MAGNETO COVER
Magneto Cover Removal
1. Remove engine from vehicle.
2. Remove 4WD coupling unit.
3. Lock crankshaft at TDC (refer to BOTTOM END)
subsection.
4. Disconnect stator, CPS and vehicle speed sen-
sor connectors.
5. Remove: vmr2015-017-008_a
– Water pump cover, refer to COOLING SYS- 1. M6 screws

2. M8 screws
TEM subsection 3. Magneto cover
– Starter, refer to procedure in this subsection.
9. Remove magneto cover.
6. Remove bearing cover screws.
NOTE: Lift the magneto cover from the provided
7. Remove bearing cover. area using two flat screwdrivers prying equally at
the same time.
vmr2015-017-002_a
1. Screws vmr2015-017-003_a
2. Bearing cover
1. Special area for removal of magneto cover
8. Remove magneto cover screws:
8.1 Start removing M6 screws.
8.2 Then remove the M8 screws.
vmr2015-017-004_a
1. Special area for removal of magneto cover
NOTE: Do not loose oil pump cover O-ring when

removing the magneto cover.
110 vmr2015-017
uniform coat on the plate (spread as necessary).

When ready, apply the sealant on magneto cover
and bearing cover mating surfaces.
NOTE: It is recommended to apply this specific
sealant as described here to get an 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).
vmr2015-017-022_a
1. O-ring
2. Oil pump cover
Magneto Cover Inspection and

Cleaning
Check magneto cover and bearing cover for
cracks or other damages. Replace if necessary.
Clean all metal component in a solvent.
Clean magneto cover, crankcase and bearing
cover sealing surfaces using a combination of
LOCTITE CHISEL (GASKET REMOVER) (P/N 413 708
500) and a brass brush. First brush in one direc-
tion, then make the final brushing perpendicularly
F12R17A
(90°) to the first pass.
NOTICE Do not wipe with rags. Use a new Apply Loctite 5910 all around the magneto cover
clean hand towel only. mating surface except the areas described below.
NOTE: Do not apply in excess as it will spread out
WARNING inside cover.
Wear safety glasses and work in a well
ventilated area when working with strong
chemical products. Also wear suitable
non-absorbent gloves to protect your hands.
Magneto Cover Installation

Put ball bearings of output shaft exactly in place,
refer to OUTPUT SHAFT in the GEARBOX AND
4X4 COUPLING UNIT subsection.
Use LOCTITE 5910 (P/N 293 800 081) on mating sur-
faces.
vmr2015-017-005_a
IMPORTANT: When beginning the application of 1. Mating surface on the magneto cover
the sealant, the assembly and the first torquing 2. No need to apply Loctite 5910
should be done within 10 minutes. It is suggested
to have all you need on hand to save time. NOTE: Ensure that oil pump cover O-ring is in
place before installing the magneto cover.
Use a plexyglass plate and apply some sealant
on it. Use a soft rubber roller50 mm to 75 mm
(2 in to 3 in), available in arts products suppliers
for printing, and roll the sealant to get a thin
vmr2015-017 111
Install a NEW gasket ring on M6 magneto cover

screw beside the CPS.
NOTICE Never use the gasket ring a second
time. Always install a new one.
vmr2015-017-022_a
1. O-ring
2. Oil pump cover
Install the magneto cover.
vmr2015-017-007_a
1. Gasket ring
2. Screw M6
3. CPS (Crankshaft Position Sensor)
Tighten the M6 magneto cover screws as per fol-

lowing sequence.
vmr2015-017-006_a
1. Magneto cover
2. Crankshaft MAG side
Tighten the M8 magneto cover screws as per fol-

lowing sequence.
vmr2015-017-008_c
M6 SCREWS TIGHTENING SEQUENCE
M6 MAGNETO COVER SCREWS

Gasket ring NEW
10 N•m ± 1 N•m
Tightening torque
Install the bearing cover.

vmr2015-017-008_b
Tighten bearing cover screws in a criss-cross se-
quence to specification.
M8 MAGNETO COVER SCREWS BEARING COVER SCREWS
25 N•m ± 3 N•m 25 N•m ± 3 N•m
Tightening torque Tightening torque
(18 lbf•ft ± 2 lbf•ft) (18 lbf•ft ± 2 lbf•ft)
112 vmr2015-017
Let the sealant dry before starting engine. Refer 3. Connect multimeter between YELLOW wires.
to the manufacturer's label for the sealant curing 4. Read resistance.
time.
RESISTANCE @
TERMINAL
20°C (68°F)
STATOR
1 and 2
Stator Connector Access
1 and 3 0.15 - 0.30
NOTE: The stator is directly connected to the volt-
age regulator/rectifier. 2 and 3
YL
YL
YL
V07G05A
vmr2015-017-100_a
TYPICAL TYPICAL
1. Voltage regulator/rectifier location
5. If any reading is out of specification, replace sta-
tor.
6. Re-plug connectors properly.
Stator Static Test: Insulation

REQUIRED TOOL
FLUKE 115 MULTIMETER

(P/N 529 035 868)
1. Set multimeter to .
2. Connect multimeter between any YELLOW
wire (on stator connector) and engine ground.
3. Read resistance.
vmr2015-030-101_a
RESISTANCE @
1. Voltage regulator/rectifier TEST PROBES
2. Three YELLOW wires 20°C (68°F)
Any YELLOW wire and
Stator Static Test: Continuity Infinite (open circuit)
engine ground
1. Disconnect the stator connector on the voltage
regulator/rectifier.
REQUIRED TOOL

(P/N 529 035 868)
vmr2015-017 113
Check if stator wires are brittle, hard or otherwise

damaged.
Stator Installation
However, pay attention to the following.
NOTICE When installing the stator take care
to route wires properly and install holding
strip.
YL
YL There is only one position for the stator (notch in
YL
the magneto cover).
V07G07A
TYPICAL
4. If there is a resistance or continuity, the stator

coils and/or the wiring is shorted to ground and
needs to be repaired or replaced.
Stator Dynamic Test: AC Voltage

Stator Removal
Remove magneto cover, refer to procedure in this
subsection.
Remove: vmr2015-017-010_a
1. Thread for holding strip

– Holding strip screw 2. Notch for stator
– Holding strip 3. Crank position sensor
– Stator screws
– Stator. ROTOR
Rotor Removal
Remove magneto cover, refer to procedure in this
subsection.
Lock crankshaft. Refer to BOTTOM END subsec-
tion.
Remove:
– Nut retaining rotor
– Lock washer.
vmr2015-017-009_a
1. Holding strip screw

2. Holding strip
3. Stator screws
4. Stator
Stator Inspection
Check stator windings and insulation for cracks or
other damages. If damaged replace it.
114 vmr2015-017
vmr2015-017-011_a vmr2015-017-012_a
1. Nut 1. Rotor
2. Lock washer 2. Magneto puller
3. Rotor
Screw magneto puller bolt to remove rotor.
Remove crankshaft plug screw.
Rotor Inspection
Check inner side of rotor for scratches or other
damage.
Blow pressurized air in the rotor oil bore and make
sure it is not clogged.
Check keyway of the rotor for wear or damages.
Check if trigger wheel teeth are bent or otherwise
damaged.
vmr2015-017-019_a
1. Crankshaft plug screw

3. Rotor
Remove rotor.
REQUIRED TOOL
CRANKSHAFT PROTECTOR
(MAG) (P/N 420 876 557)
MAGNETO PULLER (P/N 529 vmr2015-017-013_a
035 748) ROTOR

1. Keyway
2. Trigger wheel
NOTE: Use grease to place protector on crank- 3. Oil bore
shaft end prior to screw on the magneto puller.
Check woodruff key and keyway on the crank-
shaft for wear or damages.
Replace parts as necessary.
Rotor Installation
vmr2015-017 115
Use PULLEY FLANGE CLEANER (P/N 413 711 809) to Tighten rotor retaining nut to specification.
clean following parts:
ROTOR RETAINING NUT
– Crankshaft taper
– Oil passage in crankshaft taper LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
– Thread on crankshaft
– Oil bore in rotor 180 N•m ± 10 N•m
Tightening torque
– Rotor taper.
NOTICE Taper on crankshaft and rotor must
be free of grease.
STARTER
Starter Access
To access starter, refer to BODY subsection and
remove the following:
– Seat
– Console
– RH side panel and extension panel
Starter Operational Test

1. Disconnect starter power cable from starter so-
lenoid and pull cable out to RH side of vehicle.
vmr2015-017-014_a
CRANKSHAFT MAG SIDE

1. Keyway
2. Oil passage
3. Threads
Install crankshaft plug screw.

CRANKSHAFT PLUG SCREW
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
35 N•m ± 4 N•m
Tightening torque
vmr2015-017-101_a
1. Starter
2. Starter power cable connection at starter
3. Starter power cable
4. Starter power cable connection at solenoid
vmr2015-017-025_a
1. Crankshaft plug screw

Slide rotor onto crankshaft. The woodruff key and

the keyway must be aligned.
116 vmr2015-017
vmr2012-033-003_a
1. Power cable from starter solenoid to starter

2. Power cable from battery to starter solenoid (not visible) vmr2015-017-102_a
3. Fuel tank
4. RH rear fender 1. Radiator coolant hose
2. Hose support
3. Remove support screws
2. Using booster cables, carefully supply current
from a 12 volt battery directly to the starter 5. Disconnect the RED (+) power cable from
power cable. starter.
NOTICE First connect the red jumper cable
from the booster battery to the starter cable.
Momentarily connect the BLACK (-) cable from
the booster battery to engine ground last.
If the starter turns, test other starting system
components. Refer to STARTING SYSTEM sub-
section.
Starter Removal
1. Make sure the ignition switch is in the OFF po-
sition.
2. Disconnect the BLACK (-) battery cable from
the battery. vmr2008-139-009_d
TYPICAL
WARNING 6. Clean starter and surrounding area.
Always disconnect BLACK (-) battery cable 7. Remove starter mounting screws.
first and reconnect last.
3. Remove body parts as listed in STARTER AC-

CESS.
4. Remove the radiator coolant hose support from
engine.
vmr2015-017-015_a
1. Starter mounting screws

2. Starter
vmr2015-017 117
8. Pull starter out from gear box. STARTER TERMINAL AND RETAINING NUT
Starter Installation DIELECTRIC GREASE

Service product
(P/N 293 550 004)
Reverse the removal procedure. However, pay
particular attention to the following. 6 N•m ± 0.5 N•m
Tightening torque
Make sure the starter and engine mating surfaces
are free of debris. Serious problems may arise if
the starter is not properly aligned.
vmr2008-139-009_e
1. Starter mounting screws

2. Starter terminal retaining nut
vmr2015-017-016_a
Connect the BLACK (-) battery cable last.
1. Clean starter mating surfaces
STARTER O-RING WARNING

SUPER LUBE GREASE Always connect the RED (+) starter cable first,
Service product then the BLACK (-) battery cable last. When-
(P/N 293 550 030)
ever connecting the RED (+) cable to the
Lubricate starter O-ring. starter motor, always make sure the BLACK
(-) battery cable is disconnected to prevent
electric shock.
Test starter operation.
STARTER DRIVE
Starter Drive Removal
Remove drive pulley, refer to CONTINUOUSLY
VARIABLE TRANSMISSION subsection.
Remove:
– Retaining screws
– Starter drive cover.
vmr2015-017-017_a NOTE: Do not lose shim and/or spring during re-
1. Lubricate starter O-ring moval of starter drive cover.
Install starter and tighten retaining screws to Pull out starter drive.
specification
STARTER MOUNTING SCREWS
10 N•m ± 1 N•m
Tightening torques
Connect the RED (+) cable to the starter and

tighten nut to specification.
118 vmr2015-017
vmr2015-017-018_a vmr2015-017-020_a
1. Retaining screws 1. Starter drive needle bearing

2. Starter drive cover
3. Shim Check starter drive cover for cracks and clean it
4. Spring
5. Starter drive before reinstallation.
Check bore inside starter drive cover if damaged,
Starter Drive Inspection worn or otherwise damaged. Replace as neces-
Check if starter drive pinion is free of movement. sary.
NOTE: Centrifugal weights avoid disengaging of
the pinion while starting the engine.
Starter Drive Needle Bearing
Replacement
3 Starter Drive Needle Bearing Removal
2 Remove needle bearing.
REQUIRED TOOL
BLIND HOLE BEARING

PULLER SET (P/N 529 036 117)
R400motr217A 1
1. Starter drive pinion
2. Starting position (spring released)
3. Gear is engaged drive pulley fixed half (spring loaded)
Check needle bearing excessive play and smooth

operation. If damaged see STARTER DRIVE
NEEDLE BEARING REPLACEMENT in this sub-
section.
vmr2015-017-024_a
1. Starter drive needle bearing

2. Blind hole bearing puller
Starter Drive Needle Bearing Installation

Install needle bearing.
vmr2015-017 119
REQUIRED TOOL
STARTER DRIVE NEEDLE
INSTALLER (P/N 529 035 934)
HANDLE (P/N 420 877 650)
vmr2015-017-021_a

2. Starter drive needle bearing installer
3. Handle
Starter Drive Installation

Apply multi-purpose grease inside starter drive
pinion cover.
Clean out all residues of grease from:
– Needle bearing in the crankcase
– Starter drive journals
– Starter drive cover bore
– Spring.
Lubricate needle bearing and starter drive cover
bore with specified service product.
NEEDLE BEARING AND STARTER DRIVE
COVER BORE LUBRICATION
ISOFLEX GREASE
Service product TOPAS NB 52 (P/N 293
550 021)
120 vmr2015-017
MAGNETO AND STARTER

SERVICE TOOLS
CRANKSHAFT LOCKING BOLT..................................................... 529 035 617 ........................................... 76
CRANKSHAFT PROTECTOR ......................................................... 529 036 034 ........................................... 76
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................................... 74–75
MAGNETO PULLER ...................................................................... 529 035 748 ........................................... 76
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ........................................... 81
DREI BOND SEALING COMPOUND ............................................ 420 297 906 ........................................... 73
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 76
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ..................................... 78–79
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ..................................... 80–81
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ........................................... 73
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ..................................... 77–78
vmr2016-031 71
6 ± 0,7 N•m
(53 ± 6 lbf•in)
Engine oil See ELECTRONIC FUEL
INJECTION (EFI)
10 ± 1 N•m
(89 ± 9 lbf•in)
5 ± 0,6 N•m
(44 ± 5 lbf•in)
Drei Bond sealing compound

Loctite 243
Multi Purpose Grease BP LS3 Loctite 243
10 ± 1 N•m 4 ± 0,5 N•m

(89 ± 9 lbf•in) (35 ± 4 lbf•in)
NEW 10 ± 1 N•m
150 ± 10 N•m (89 ± 9 lbf•in)
(111 ± 7 lbf•ft)
Engine oil
Loctite 648
30 ± 2 N•m
(22 ± 1,5 lbf•ft) Loctite 767 (antiseize lubricant)
Engine oil
25 ± 3 N•m
(18 ± 2 lbf•ft)

vmr2015-030-001_a
72 vmr2016-031
PROCEDURES
MAGNETO COVER
Magneto Cover Access
ing:
– Seat
– Console
Removing the Magneto Cover

Drain engine oil (refer to ENGINE OIL CHANGE vmr2015-030-003_a
in the PERIODIC MAINTENANCE PROCEDURES 1. Magneto cover
subsection). 2. Retaining screws
Remove crankshaft position sensor (CPS) and cut Pull out magneto cover.
tie raps.
Disconnect the stator connector on the voltage Inspecting and Cleaning the Magneto
regulator/rectifier, refer to STATOR CONNECTOR Cover
ACCESS in this subsection. Check magneto cover for cracks or other damage.
Remove dipstick with O-ring. Replace if necessary.
NOTE: Clean all metal components in a non-
ferrous metal cleaner. Use LOCTITE CHISEL (GAS-
KET REMOVER) (P/N 413 708 500), or suitable
equivalent.
WARNING
Wear safety glasses and work in a well
ventilated area when working with strong
chemical products. Also wear suitable
non-absorbent gloves to protect your hands.
Installing the Magneto Cover

Install a NEW magneto cover gasket.
vmr2015-030-002_a
1. Dipstick Apply DREI BOND SEALING COMPOUND (P/N 420

2. O-ring 297 906) on stator cable grommet as shown in next
3. Crank position sensor (CPS)
illustration.
Remove magneto cover retaining screws.
vmr2016-031 73
tmr2011-012-006_a
vmr2015-030-100_a
1. Stator cable grommet (apply Drei Bond sealing compound)
TYPICAL
Tighten screws using the following sequence. 1. Voltage regulator/rectifier location
vmr2015-030-101_a
vmr2015-030-003_b
1. Voltage regulator/rectifier
TIGHTENING SEQUENCE 2. Three YELLOW wires
TIGHTENING TORQUE Testing the Stator Static Continuity

10 N•m ± 1 N•m 1. Disconnect the stator connector on the voltage
Magneto cover screws
(89 lbf•in ± 9 lbf•in) regulator/rectifier.
Refill engine with recommended oil. REQUIRED TOOL

STATOR (P/N 529 035 868)
Stator Connector Access
NOTE: The stator is directly connected to the volt- 2. Set multimeter to .
age regulator/rectifier. 3. Connect multimeter between YELLOW wires.
4. Read resistance.
RESISTANCE @
TERMINAL
20°C (68°F)
1 and 2
1 and 3 0.15 - 0.30
2 and 3
74 vmr2016-031
4. If there is a resistance or continuity, the stator

coils and/or the wiring is shorted to ground and
needs to be repaired or replaced.
Removing the Stator

Remove MAGNETO COVER. See procedure in
this subsection.
Remove screws securing the wire holding strip.
YL
YL Remove stator retaining screws then the stator.
YL
V07G05A
TYPICAL
5. If any reading is out of specification, replace sta-

tor.
Testing the Stator Insulation

REQUIRED TOOL

(P/N 529 035 868)
1. Set multimeter to . tmr2013-014-001_a
2. Connect multimeter between any YELLOW 1. Holding strip screws

2. Wire holding strip
wire (on stator connector) and engine ground. 3. Stator retaining screws
3. Read resistance. 4. Stator
TEST PROBES
RESISTANCE @ Inspecting the Stator
20°C (68°F)
Check stator windings and insulation for cracks or
Any YELLOW wire and
Infinite (open circuit)
other damages. If damaged replace it.
engine ground
Check if stator wires are brittle, hard or otherwise
damaged.
Installing the Stator

NOTICE When installing the stator take care
to route wires properly and install retaining
strip.
NOTE: There is only one position for the stator
YL (notch in the magneto housing cover).
YL
YL
V07G07A
TYPICAL
vmr2016-031 75
vmr2006-041-007_a
1. Screw M16
vmr2015-030-004_a 2. Washer
3. Rotor
1. Threads for cable holding strip
2. Notch for stator
Remove rotor.
SERVICE PRODUCT
REQUIRED TOOLS
LOCTITE 243 (BLUE)
Holding strip screws
(P/N 293 800 060) CRANKSHAFT PROTECTOR
(P/N 529 036 034)
TIGHTENING TORQUE
MAGNETO PULLER
4 N•m ± 0.5 N•m
Holding strip screws (P/N 529 035 748)
NOTE: Use grease to place protector on crank-
TIGHTENING TORQUE
shaft end prior to screw on the magneto puller.
10 N•m ± 1 N•m
Stator retaining screws
ROTOR
Removing the Rotor
this subsection.
Lock crankshaft (refer to CRANKSHAFT LOCKING
PROCEDURE in the BOTTOM END subsection).
REQUIRED TOOL
CRANKSHAFT LOCKING BOLT
(P/N 529 035 617)
vmr2006-041-010_a
Heat screw in order to break the Loctite. 1. Rotor

2. Magneto puller
Remove screw and washer securing rotor to
crankshaft. Screw magneto puller bolt to remove rotor.
Inspecting the Rotor

Check inner side of rotor for scratches or other
damage.
Blow pressurized air in the rotor oil bore and make
sure it is not clogged.
76 vmr2016-031
Oil sprag clutch and install sprag clutch gear.
tmr2011-012-007_a
1. Rotor
vmr2006-041-015_b
2. Oil bore
1. Sprag clutch
Check keyway of the rotor for wear or damages. 2. Sprag clutch housing
3. Sprag clutch gear
Check if trigger wheel teeth are bent or otherwise 4. Apply engine oil here
damaged. Slide rotor onto crankshaft. The woodruff key and
Check woodruff key and keyway on the crank- the keyway must be aligned.
shaft for wear or damages. Rotate starter double gear counterclockwise to
Replace parts as necessary. align intermediate gear teeth with sprag clutch
gear.
Installing the Rotor
Use PULLEY FLANGE CLEANER (P/N 413 711 809) to
clean following parts:
– Crankshaft taper
– Oil passage in crankshaft taper
– Thread in crankshaft
– Rotor taper
– Oil bore in rotor.
NOTICE Taper on crankshaft and rotor must
be free of grease.
vmr2006-041-012_b
1. Starter double gear

tmr2011-012-008_a
1. Crankshaft (MAG side)

2. Oil passage
3. Threads
vmr2016-031 77
SERVICE PRODUCT
LOCTITE 648 (GREEN)
Rotor retaining screw
(P/N 413 711 400)
TIGHTENING TORQUE
150 N•m ± 10 N•m
Rotor retaining screw
SPRAG CLUTCH
Removing the Sprag Clutch
vmr2006-041-013_a
1. Sprag clutch housing screws
this subsection. 2. Rotor
3. Sprag clutch
Heat screws in order to break the Loctite. 4. Sprag clutch housing
Loosen sprag clutch housing screws located in-
side rotor. Inspecting the Sprag Clutch
Inspect sprag clutch and sprag clutch housing for
wear and damage.
Also check the collar of the sprag clutch gear.
Rotate sprag clutch gear in sprag clutch.
NOTE: Sprag clutch must lock in counterclock-
wise direction.
tmr2011-012-004_a
1. Rotor
2. Sprag clutch housing screws
Remove rotor (refer to ROTOR in this subsection).

Remove sprag clutch gear.
Remove sprag clutch housing screws and sprag
clutch housing.
vmr2006-041-014_a
SPRAG CLUTCH FUNCTIONAL TEST

1. Lock
NOTE: Sprag clutch, housing and gear must be

replaced at the same time, if damaged.
Installing the Sprag Clutch

However, pay attention to the following details.
Use PULLEY FLANGE CLEANER (P/N 413 711 809) to
clean following:
– Threads in sprag clutch housing
– Threads of sprag clutch housing screws.
78 vmr2016-031
Apply LOCTITE 648 (GREEN) (P/N 413 711 400) on

threads of sprag clutch housing screws.
Install screws but do not torque yet.
Apply engine oil on sprag clutch and sprag clutch
gear needle bearing.
vmr2006-041-015_a
1. Rotor
Inspecting the Sprag Clutch Gear

Inspect gear, especially teeth and sprag clutch col-
lar, for wear and other damage.
vmr2006-041-015_b Check needle bearing condition. Replace sprag
1. Sprag clutch clutch gear if necessary.
2. Sprag clutch housing
4. Apply engine oil here
Install rotor, refer to ROTOR in this subsection.

Tighten sprag clutch housing screws to specifica-
tion.
TIGHTENING TORQUE
Sprag clutch housing 30 N•m ± 2 N•m
screws (22 lbf•ft ± 1 lbf•ft)
SPRAG CLUTCH GEAR

Removing the Sprag Clutch Gear
Remove ROTOR. See procedure in this subsec-
tion.
vmr2006-041-016_a
Pull sprag clutch gear out of the rotor. INSPECT
1. Teeth
2. Collar
3. Needle bearing
Installing the Sprag Clutch Gear

NOTE: Apply engine oil on needle bearing and col-
lar of sprag clutch gear.
STARTER DRIVE GEARS

Starter Drive Gear Location
The starter drive gears are located on the engine
MAG side behind the magneto cover.
vmr2016-031 79
Removing the Starter Drive Gear

this subsection.
Remove location pins, starter double gear and in-
termediate gear.
vmr2015-030-102_a
1. Starter
2. Starter power cable connection at starter
3. Starter power cable
4. Starter power cable connection at solenoid
vmr2006-041-017_a
2. Starter double gear
3. Starter gear
4. Location pins
Inspecting the Starter Drive Gear

Inspect gears and location pins for wear and dam-
age.
Replace parts as necessary.
Installing the Starter Drive Gear vmr2012-033-003_a
The installation is the reverse of the removal pro- 1. Power cable from starter solenoid to starter
2. Power cable from battery to starter solenoid (not visible)
cedure. Pay attention to the following details. 3. Fuel tank
4. RH rear fender
Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) on starter gear before installing 2. Using booster cables, carefully supply current
the starter double gear. from a 12 volt battery directly to the starter
Apply engine oil on location pins. power cable.
NOTICE First connect the red jumper cable
ELECTRIC STARTER from the booster battery to the starter cable.
Momentarily connect the BLACK (-) cable from
Starter Access the booster battery to engine ground last.
To access starter electrical terminal, refer to
BODY subsection and remove the following: If the starter turns, test other starting system
– Seat components.
– Console Removing the Starter
1. Ensure ignition switch is set to OFF.
2. Disconnect BLACK (-) cable from battery.
Testing the Starter Operation
WARNING
1. Disconnect starter power cable from starter so-
lenoid and pull cable out to RH side of the vehi- Always disconnect BLACK (-) cable first and
cle. reconnect last.
80 vmr2016-031
3. Remove body parts as listed in STARTER AC- NOTICE When connecting the RED (+) cable
CESS. to the starter motor, make sure the battery ca-
4. Disconnect RED (+) cable from starter. bles are disconnected.
5. Clean starter area. SERVICE PRODUCT
6. Remove starter retaining screw (from RH side Starter terminal and DIELECTRIC GREASE
of engine). retaining nut (P/N 293 550 004)
TIGHTENING TORQUE
DIELECTRIC GREASE
Service product
(P/N 293 550 004)
Starter terminal and 6 N•m ± 0.5 N•m
retaining nut (53 lbf•in ± 4 lbf•in)
When installing remaining removed parts, refer to

applicable subsections.
Connect battery cables.
WARNING
Always connect RED (+) cable first then
BLACK (-) cable last.
vmr2015-030-103_a
1. Starter Test starter operation.

2. Starter power cable to disconnect
3. Starter retaining screw to remove
7. Carefully pry starter out of the engine

crankcase.
Installing the Starter

Reverse the removal procedure. However, pay
particular attention to the following.
Make sure the starter and engine mating surfaces
are free of debris. Serious problems may arise if
the starter is not properly aligned.
Lubricate starter O-ring.
SERVICE PRODUCT
LOCTITE 767
Starter O-ring and
(ANTISEIZE LUBRICANT)
mating surface
(P/N 293 800 070)
Bring starter close to its location. Rotate it so

that its mounting ear allows installation in engine
crankcase and on its alignment pin.
Push starter in place and align mounting ear to in-
stall screw.
TIGHTENING TORQUE
25 N•m ± 3 N•m
Starter mounting screw
vmr2016-031 81
Subsection 07 (INTAKE MANIFOLD)
INTAKE MANIFOLD
See
ELECTRONIC FUEL
INJECTION (EFI)
0.7 ± 0.1 N•m

(6 ± 1 lbf•in)
Loctite 6 ± 0.7 N•m

10 ± 1 N•m 243 (53 ± 6 lbf•in)
(89 ± 9 lbf•in)
See
ELECTRONIC FUEL
INJECTION (EFI)
See 20 ± 2 N•m
ELECTRONIC FUEL (15 ± 1.5 lbf•ft)
INJECTION (EFI)
Engine
oil
vmr2015-018-001_a
vmr2015-018 121
PROCEDURES
INTAKE MANIFOLD
Intake Manifold Access
ing:
– Console
– LH side panel and extension
Refer to EXHAUST SYSTEM subsection and re-
move the outer exhaust system heat shield.
vmr2015-018-003_a
1. Throttle body
2. Intake adapter
3. Loosen this clamp
3. From left side, disconnect the fuel hose from

fuel rail, refer to ELECTRONIC FUEL INJEC-
TION (EFI) subsection.
CAUTION The fuel hose may still be un-

der pressure.
vmr2015-018-002_a
1. Remove this heat shield
Intake Manifold Removal

1. Release fuel pressure. Refer to FUEL TANK
AND FUEL PUMP subsection.
2. From the right side of the vehicle, loosen the
lower clamp that retains the intake adapter to
the intake manifold.
vmr2015-018-004_a
1. Intake manifold
2. Fuel rail
3. Fuel rail disconnect
4. Disconnect fuel injector electrical connector.

5. Disconnect MAPTS connector.
122 vmr2015-018
vmr2015-018-005_a
1. Fuel injector connector

2. MAPTS connector
6. Remove intake manifold from engine and intake

adapter.
vmr2015-018-006_a
1. Remove 2 manifold retaining screws
Intake Manifold Inspection

Check intake manifold for cracks, warping at
flanges or any other damage. Replace if neces-
sary.
Intake Manifold Installation

Tighten intake manifold retaining screws to spec-
ified torque.
INTAKE MANIFOLD RETAINING SCREWS
20 N•m ± 2 N•m
Tightening torque
vmr2015-018 123
INTAKE MANIFOLD
See
ELECTRONIC FUEL
INJECTION (EFI)
0.7 ± 0.1 N•m

(6 ± 1 lbf•in)
10 ± 1 N•m
(89 ± 9 lbf•in)
10 ± 1 N•m
See (89 ± 9 lbf•in)
ELECTRONIC FUEL
INJECTION (EFI) Engine
oil
See
ELECTRONIC FUEL
INJECTION (EFI)
6 ± 0.7 N•m
(53 ± 6 lbf•in)
Engine
oil
Loctite
243
20 ± 2 N•m
(15 ± 1.5 lbf•ft)
vmr2015-031-001_a
vmr2016-032 83
PROCEDURES
INTAKE MANIFOLD
Intake Manifold Access
ing:
– Console
Removing the Intake Manifold

1. Release fuel pressure. Refer to FUEL TANK
2. Disconnect top of shift rod. vmr2015-031-002_a
1. Forward fuel rail disconnect

2. Rear fuel rail disconnect
4. Disconnect fuel injector electrical connectors.

5. Disconnect MAPTS connector.
vmr2012-015-006_a
SHIFT ROD DISCONNECT

1. Remove screw, nut, and bushing
3. Disconnect the fuel hoses from fuel rails, refer

to ELECTRONIC FUEL INJECTION (EFI) sub-
vmr2015-031-003_a
section.
1. Forward fuel injector connector
2. Rear fuel injector connector
CAUTION The fuel hose may still be un- 3. MAPTS connector
der pressure.
6. Disconnect throttle body from intake manifold
and air intake silencer. Refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
NOTE: Do not disconnect throttle cable need-
lessly.
7. Remove wiring harness support from engine.
84 vmr2016-032
vmr2012-015-005_a
1. Remove
8. Remove intake manifold from engine.
vmr2015-031-004_a
1. Manifold retaining screws (4x)
Inspecting the Intake Manifold

Check intake manifold for cracks, warping at
flanges or any other damage. Replace if neces-
sary.
Installing the Intake Manifold

Tighten intake manifold retaining screws to spec-
ified torque one cylinder at a time.
TIGHTENING TORQUE
Intake manifold 20 N•m ± 2 N•m
retaining screws (15 lbf•ft ± 1 lbf•ft)
Enable fuel pump using B.U.D.S.
vmr2016-032 85
Subsection 08 (TOP END)
TOP END
SERVICE TOOLS
DIAL INDICATOR ADAPTER ......................................................... 529 036 159 ......................................... 129
ENGINE LEAK DOWN TEST KIT ................................................... 529 035 661 ......................................... 129
PISTON CIRCLIP INSTALLER........................................................ 529 036 083 ......................................... 146
TDC DIAL INDICATOR .................................................................. 414 104 700 ......................................... 129
VALVE GUIDE INSTALLER ............................................................ 529 036 269 ......................................... 141
VALVE GUIDE REMOVER (6 MM) ................................................ 529 036 074 ......................................... 141
VALVE SPRING COMPRESSOR CUP............................................ 529 036 270 ......................................... 137
VALVE SPRING COMPRESSOR .................................................... 529 035 724 ......................................... 137
SERVICE TOOLS – OTHER SUPPLIER

SNAP-ON PLIERS.......................................................................... YA 8230 ......................................... 139
SERVICE PRODUCTS
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ......................................... 141
vmr2015-019 125
CYLINDER HEAD
7 ± 0,8 N•m
(62 ± 7 lbf•in)
Engine oil
12 ± 1 N•m
(106 ± 9 lbf•in)
Engine oil
See tightening NEW

procedure
Engine oil Engine oil
10 ± 1 N•m 11 ± 1 N•m
(89 ± 9 lbf•in) (97 ± 9 lbf•in)
Loctite 243
See IGNITION SYSTEM
Engine oil
12 ± 1 N•m
(106 ± 9 lbf•in)
NEW
Loctite 648
Engine oil
10 ± 1 N•m NEW
(89 ± 9 lbf•in)

vmr2015-019-001_a
126 vmr2015-019
CYLINDER AND PISTON
Engine oil
NEW
NEW
Engine oil
NEW
Engine oil
Engine oil

vmr2015-019-002_a
vmr2015-019 127
GENERAL
When diagnosing an engine problem, always per-
form a cylinder leak test.
NOTE: Even though the following procedures do
not require the engine removal, many illustrations
show the engine out of the vehicle for more clar-
ity.
IMPORTANT: Note position of parts on disas-
sembly. This may help to find the root cause of
a problem. A component that is not replaced
should be reinstalled in the same position as
originally mounted. vmr2015-019-003_a
1. Spark plug cable

2. Spark plug
INSPECTION
Remove valve cover. Refer to procedure in this
subsection.
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.
WARNING
Prevent burning yourself on hot engine parts.
Preparation
Disconnect battery.
WARNING
Always respect this order for disassembly; vmr2015-019-004_a
disconnect BLACK (-) cable first. 1. Valve cover screws
2. Valve cover
Remove radiator cap.
Rotate crankshaft until piston is at TDC ignition.
WARNING To turn crankshaft, there are two possible proce-
To prevent burning yourself only remove dures.
the radiator cap by wearing the appropriate First Procedure
safety equipment.
Turn the drive pulley.
Unplug spark plug cable. Second Procedure
Clean spark plug area and remove spark plug from 1. Remove plug screw with O-ring from magneto
cylinder head. cover.
128 vmr2015-019
NOTICE Do not scratch or damage piston/

cylinder surface.
NOTE: At TDC ignition the marks on the camshaft
timing gear have to be parallel to cylinder head
base as per following illustration.
vmr2015-019-005_a
1. Plug screw
2. O-ring
3. Magneto cover
2. Turn crankshaft.
REQUIRED TOOL
13 mm socket vmr2015-019-007_a
1. Marks on camshaft timing gear

NOTICE Turn only clockwise to avoid loosen- 2. Cylinder head base
ing of the MAG side screw of the crankshaft.

Leak Test
Set the piston to precisely TDC ignition. For REQUIRED TOOL
proper procedure refer to CRANKSHAFT LOCK-
ING PROCEDURE in the BOTTOM END subsec-
tion. ENGINE LEAK DOWN TEST
KIT (P/N 529 035 661)
NOTE: If engine is removed from vehicle a dial in-
dicator can be used.
REQUIRED TOOL Connect leak tester to adequate air supply.
TDC DIAL INDICATOR Set needle of measuring gauge to zero.
(P/N 414 104 700) NOTE: All testers have specific instructions on
DIAL INDICATOR ADAPTER
gauge operation and required pressure.
(P/N 529 036 159) Install gauge adapter into previously cleaned spark
plug hole.
Supply combustion chamber with air pressure.
vmr2015-019-006_a
1. TDC dial indicator

2. Dial indicator adapter
NOTE: If a dial indicator is not available, use a

screwdriver or another similarly suitable tool.
vmr2015-019 129
Reassembly
Reverse the preparation procedure. Ensure to
respect torque values and use of appropriate
products/lubricants. Refer to exploded views in
other subsections of this manual as required.
PROCEDURES
VALVE COVER
Valve Cover Access
ing.
vmr2015-019-101_a
1. Leak tester
2. Leak tester installed in spark plug bore
3. Air supply hose
Note the amount or percentage of leakage (de-

pending on tester).
LEAKAGE ENGINE
PERCENTAGE CONDITION
0% to 15% Excellent condition
16% to 25% Good condition
Fair condition; reduced
26% to 40%
engine performance
Poor condition, diagnose
41% and higher
and repair engine vmr2015-019-100_a
1. Seat
2. Console
NOTE: To make sure there is no false reading due 3. RH side panel
to a valves not perfectly seated, tap each valve ad- 4. RH side panel extension
5. RH inner fender panel
justment screw (on the rocker) using a soft ham-
mer.
Valve Cover Removal
Diagnosis Remove:
Listen for air leaks. – Valve cover screws
– Air escaping in intake port/throttle body means – Valve cover
leaking intake valve(s). – Gasket.
– Air escaping in exhaust port means leaking ex-
haust valve(s).
– Air bubbles in the coolant (radiator) means leak-
ing cylinder head gasket.
– Air/coolant escaping from cylinder/head means
damaged gasket(s) and/or loosened screws.
– Air escaping into crankcase area means exces-
sively worn cylinder and/or broken piston rings.
– Air/oil escaping from crankcase means dam-
aged gasket and/or loosened screws (refer to
BOTTOM END subsection).
NOTE: For all the checkpoints mentioned above,
see the appropriate engine section to diagnose
and repair the engine.
130 vmr2015-019
vmr2015-019-004_a
1. Valve cover screws

2. Valve cover
vmr2015-020-008_b
3. Gasket
1. Pan head screw
2. Camshaft retaining plate
Valve Cover Inspection 3. Cylinder head
Check the gasket on the valve cover if it is brittle,
Remove rocker arm shafts.
cracked or hard. If so, replace the gasket.
Valve Cover Installation

cedure.
Tighten valve cover retaining screws to specified
torque in a criss-cross sequence.
VALVE COVER RETAINING SCREWS
7 N•m ± 0.8 N•m
Tightening torque
ROCKER ARM
Rocker Arm Removal
Remove valve cover.
Refer to TIMING CHAIN subsection and remove
the following parts:
vmr2006-043-016_a
– Timing chain tensioner 1. Rocker arm shaft
– Camshaft timing gear. 2. Rocker arm (exhaust side)
3. Rocker arm (intake side)
Remove: 4. Adjustment screw
5. Lock nut
– Pan head screw
– Camshaft retaining plate. Remove:
– Rocker arm assembly (exhaust side and intake
side) with adjustment screws and lock nuts
– Thrust washers.
vmr2015-019 131
Measure rocker arm bore diameter. If diameter

is out of specification, change the rocker arm as-
sembly.
ROCKER ARM BORE DIAMETER
12.036 mm to 12.050 mm
NEW
(.4739 in to .4744 in)
Check adjustment screws for free movement,

cracks and/or excessive play.
tmr2013-068-012_a
1. Rocker arm (exhaust side)

3. Thrust washers
NOTICE Pay attention not to lose thrust

washers or drop them into the timing chain
compartment.
1 2 1 1
R400motr69A
3 1. Free movement of adjustment screw top
Rocker Arm Shaft Inspection

Check for scored friction surfaces; if so, replace
parts.
Measure rocker arm shaft diameter.
R400motr67A 4
1. 2 thrust washers
3. Cylinder head (spark plug side)
4. Big taper to spark plug side
Rocker Arm Inspection

R400motr70A A
Inspect each rocker arm for cracks and scored fric-
tion surfaces. If so, replace rocker arm assembly. A. Measure rocker arm shaft diameter here
Check the rocker arm rollers for free movement, ROCKER ARM SHAFT DIAMETER
wear and excessive radial play. Replace rocker
arm assembly if necessary. 12.00 mm to 12.018 mm
NEW
(.4724 in to .4731 in)
2 1 SERVICE LIMIT 11.990 mm (.472 in)
Any area worn excessively will require parts re-

placement.
Rocker Arm Installation

NOTE: Use the same procedure for exhaust and
intake rocker arm.
A Apply engine oil on rocker arm shaft.
R400motr68A
Insert a rocker arm shaft with the chamfered edge
1. Rocker arm (exhaust side) first through rocker arm pin bore.
2. Roller
A. Bore for rocker arm shaft
132 vmr2015-019
Install a thrust washer at timing chain side, then

the proper rocker arm (exhaust side or intake
side).
Push in rocker arm shaft until its chamfer reaches
the end of rocker arm bore.
vmr2015-020-008_b

2. Pan head screw
3. Cylinder head
Remove rocker arms (see ROCKER ARM in this

vmr2006-043-016_b subsection).
1. Rocker arm shaft Remove the camshaft.
2. Thrust washer (timing chain side)
3. Thrust washer (spark plug side) NOTE: For removal rotate camshaft so that
Place the other thrust washer and push rocker intake/exhaust lobe shows to upper side of cylin-
arm shaft to end position. der head.
Install the camshaft retaining plate.
Tighten pan head screw to specification.
PAN HEAD SCREW
10 N•m ± 1 N•m
Tightening torque
Adjust valve clearance, refer to PERIODIC MAIN-

TENANCE PROCEDURE.
CAMSHAFT
Camshaft Removal
tmr2013-068-013_a
Remove valve cover (see VALVE COVER in this 1. Camshaft retaining plate
subsection). 2. Area for camshaft lobes
3. Camshaft
the following parts: Camshaft Inspection
– Timing chain tensioner Check each lobe and bearing journal for:
– Camshaft timing gear. – scoring
Remove the camshaft retaining plate. – scuffing
– cracks
– signs of wear.
vmr2015-019 133
Using a micrometer to measure: NOTICE The camshafts are not identical in

– camshaft lobe height design. Do not invert the camshafts during
– camshaft journal. assembly. Any mix-up of the components will
lead to engine damage.
Place the camshaft retaining plate in the slot of the
camshaft.
vmr2015-032-002_a
A. Camshaft lobe (exhaust valves)

tmr2013-068-013_b
B. Camshaft lobe (intake valves)
C. Camshaft journal (timing chain side) 1. Direction of movement
D. Camshaft journal (spark plug side) 2. Camshaft retaining plate
3. Slot retaining camshaft
CAMSHAFT LOBE (EXHAUST)
Tighten pan head screw to specification.
32.890 mm to 33.090 mm
NEW PAN HEAD SCREW
(1.295 in to 1.303 in)
SERVICE LIMIT 32.840 mm (1.293 in) 10 N•m ± 1 N•m
Tightening torque
CAMSHAFT LOBE (INTAKE)
For other parts, refer to proper installation proce-
32.950 mm to 33.150 mm dure.
NEW
(1.297 in to 1.305 in)
SERVICE LIMIT 32.900 mm (1.295 in) CYLINDER HEAD
CAMSHAFT JOURNAL Cylinder Head Access
(TIMING CHAIN SIDE) Refer to BODY subsection and remove the follow-
34.959 mm to 34.975 mm ing.
NEW
(1.3763 in to 1.377 in)
SERVICE LIMIT 34.950 mm (1.376 in)
CAMSHAFT JOURNAL
(SPARK PLUG SIDE)
21.959 mm to 21.980 mm
NEW
(.8645 in to .8654 in)
Measure camshaft bearing in cylinder head. Refer

to CYLINDER HEAD INSPECTION in this subsec-
tion.
Camshaft Installation
134 vmr2015-019
tmr2011-013-011_a
1. Cylinder head screws M10

vmr2015-019-100_a
Pull up cylinder head.
1. Seat
2. Console Remove timing chain guide (fixed).
3. RH side panel
4. RH side panel extension Remove and discard the cylinder head gasket.
5. RH inner fender panel
Cylinder Head Removal

Drain engine coolant. Refer to ENGINE
COOLANT REPLACEMENT in the PERIODIC
Disconnect the coolant hose from the thermostat
housing.
NOTE: Before removing cylinder head, blow out
remaining coolant using air pressure. During cylin-
der head removal, the remaining coolant in cylin-
der head could overflow into the engine and the
engine oil will be contaminated.
Refer to EXHAUST SYSTEM subsection and dis-
connect exhaust pipe from cylinder head.
Refer to INTAKE MANIFOLD and disconnect the
intake manifold from the cylinder head. vmr2015-019-008_a
1. Cylinder head
Disconnect spark plug wire. 2. Timing chain
3. Chain guide (fixed)
Disconnect CTS connector, located at the cylinder 4. Cylinder head gasket
head.
Remove the valve cover and its gasket (see VALVE Cylinder Head Inspection
COVER in this subsection). Inspect timing chain guide (fixed) for wear, cracks
Refer to TIMING CHAIN subsection and remove or other damages. Replace if necessary.
the following parts: Check for cracks between valve seats, if so, re-
– Timing chain tensioner place cylinder head.
– Camshaft timing gear. Check mating surface between cylinder and cylin-
First remove the M6 cylinder head screws, then der head for contamination. If so, clean both sur-
the M10 cylinder head screws. faces.
Clean oil support through the cylinder head from
contamination.
vmr2015-019 135
tmr2013-068-016_a
1. Oil port to lubricate camshaft lobes intake/exhaust

2. Oil supply to camshaft bearing journal (timing chain side) vmr2015-019-018_a
3. Oil supply to camshaft bearing journal (spark plug side)
1. Timing chain guide (tensioner side) mounted in crankcase
2. Timing chain guide (fixed) between cylinder and cylinder head
Cylinder Head Camshaft Bearing Inspection
Measure camshaft bearing in cylinder head. Install a NEW cylinder head gasket.
Install cylinder head screws.
NOTICE Check for proper lengths of the
cylinder head screws.
tmr2013-068-017_a
A. Camshaft bearing (timing chain side)

B. Camshaft bearing (spark plug side)
CAMSHAFT BEARING
(TIMING CHAIN SIDE)
35.000 mm to 35.025 mm
NEW
(1.378 in to 1.3789 in)
vmr2015-019-009_a
CAMSHAFT BEARING 1. Location no. 1
(SPARK PLUG SIDE) 2. Location no. 2
22.000 mm to 22.021 mm CYLINDER HEAD SCREW IDENTIFICATION

NEW
(.8661 in to .867 in)
Location no. 1 M10 x 140
Location no. 2 M6 x 85
Cylinder Head Installation Tighten M10 cylinder head screws FIRST as per
The installation is the reverse of the removal pro- following specifications.
Ensure dowel pins are in place.
NOTICE Timing chain guide (fixed) has to be
fixed between cylinder and cylinder head.
136 vmr2015-019
VALVE SPRINGS
Valve Spring Removal
Refer to following procedures in this subsection
to remove:
– CAMSHAFT
– CYLINDER HEAD.
Compress valve spring.
REQUIRED TOOL
VALVE SPRING COMPRESSOR

(P/N 529 035 724)
vmr2015-019-019_a VALVE SPRING COMPRESSOR

TIGHTENING SEQUENCE - M10 CYLINDER HEAD SCREWS CUP (P/N 529 036 270)
M10 CYLINDER HEAD SCREWS
20 N•m ± 1 N•m
WARNING
Tightening step 1 Always wear safety glasses when disassem-
torque bling valve springs. Be careful when unlock-
step 2 180° ± 5°
ing valves. Components could fly away be-
cause of the strong spring preload.
Tighten M6 cylinder head screws as per following
specification.
R400motr79A
LOCATE VALVE SPRING COMPRESSOR IN CENTER OF THE

vmr2015-019-019_b VALVE
1. M6 Screws
Remove valve cotters.
M6 CYLINDER HEAD SCREWS
10 N•m ± 1 N•m
Tightening torque
Check timing chain guide (tensioner side) for

movement.
Refer to applicable subsection for installation de-
tails of remaining removed parts.
vmr2015-019 137
VALVE SPRING FREE LENGTH

NEW 40.41 mm (1.591 in)
Replace valve springs if not within specifications.
Valve Spring Installation

Colored area of the valve spring must be placed
on bottom side.
tmr2013-068-018_a
To ease installation of cotters, apply oil or grease
1. Valve spring compressor
2. Valve spring compressor cup on them so that they remain in place while relea-
3. Valve cotter sing the spring.
Remove tools and withdraw valve spring retainer NOTE: Valve cotter must be properly engaged in
and valve spring. valve stem grooves.
tmr2013-068-021_a
tmr2013-068-019_a
1. Valve spring retainer 1. Colored area position of the valve spring

2. Valve spring 2. Valve cotter
After spring is installed, ensure it is properly

Valve Spring Inspection locked by tapping on valve stem end with a soft
Check valve spring for visible damage. If so, re- hammer so that valve opens and closes a few
place valve spring. times.
Check valve spring for free length and straight- NOTICE An improperly locked valve spring
ness. will cause engine damage.
VALVES
Valve Removal
Remove valve spring, see VALVE SPRING in this
subsection.
Push valve stem, then pull valves (intake and ex-
haust) out of valve guide.
tmr2013-068-020_a
A. Valve spring length
138 vmr2015-019
mmr2009-115-072_a
tmr2013-068-022_a
1. Intake valves 36.5 mm (1.437 in) VALVE OUT OF ROUND

2. Exhaust valves 31 mm (1.22 in) (INTAKE AND EXHAUST VALVES)
Remove valve stem seal and discard it. NEW 0.005 mm (.0002 in)
REQUIRED TOOL SERVICE LIMIT 0.060 mm (.0024 in)
SNAP-ON PLIERS (P/N YA 8230) Valve Stem

Measure valve stem in three places using a mi-
crometer.
Replace valve if valve stem is out of specification
or has other damages such as wear or friction sur-
face.
tmr2013-068-023 R400motr83A
A. Valve stem diameter

Valve Inspection
Whenever valves are removed always inspect VALVE STEM DIAMETER
valve guides. Refer to VALVE GUIDES in this EXHAUST VALVE
subsection.
5.461 mm to 5.476 mm
NEW
Valve Stem Seal (.215 in to .2156 in)
Always install NEW seals whenever valves are re- SERVICE LIMIT 5.440 mm (.2142 in)
moved.
INTAKE VALVE
Valve 5.472 mm to 5.486 mm
NEW
Inspect valve surface, check for abnormal stem (.2154 in to .216 in)
wear and bending. If out of specification, replace 5.450 mm (.2146 in)
SERVICE LIMIT
by a new one.
vmr2015-019 139
Valve Face and Seat
A B
2
3
R400motr84A
V01C1HA
1. Valve seat A. Valve face contact width

2. Exhaust valve contaminated area B. Valve seat contact width
3. Valve face (contact surface to valve seat)
Check valve face and seat for burning or pittings Valve Installation
and replace valve or cylinder head if there are The installation is the reverse of the removal pro-
signs of damage. cedure. However, pay attention to the following.
Ensure to seat valves properly. Apply some lap- Install a NEW valve stem seal. Make sure thrust
ping compound to valve face and work valve on washer is installed before installing seal.
its seat with a lapping tool (see VALVE GUIDES in
this subsection). Apply engine oil on valve stem and install it.
Measure valve face contact width. NOTICE Be careful when valve stem is
NOTE: The location of contact area should be in passed through sealing lips of valve stem
center of valve seat. seal.
Measure valve seat width using a caliper. 1 2
VALVE SEAT CONTACT WIDTH
EXHAUST VALVE
1.25 mm to 1.55 mm
NEW
(.049 in to .061 in)
INTAKE VALVE
1.05 mm to 1.35 mm R400motr85A
NEW
(.041 in to .053 in) 1. Thrust washer
2. Sealing lips of valve stem seal
For proper valve spring installation refer to VALVE
If valve seat contact width is too wide or has dark SPRINGS in this subsection.
spots, replace the cylinder head.
NOTICE An improperly locked valve spring
will cause engine damage.
VALVE GUIDES
Valve Guide Inspection
Always replace valve stem seals whenever valve
guides are removed.
140 vmr2015-019
Measure valve guide in three places using a small Clean the valve guide bore before reinstalling the
bore gauge. valve guide into cylinder head.
NOTE: Clean valve guide to remove carbon de- NOTE: Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
posits before measuring. (P/N 293 800 070) on valve guide prior to install it
Replace valve guide if it is out of specification or into the cylinder head.
has other damages such as wear or friction sur- Install valve guide.
face.
REQUIRED TOOL
VALVE GUIDE DIAMETER
(INTAKE AND EXHAUST VALVES) VALVE GUIDE INSTALLER
(P/N 529 036 269)
5.506 mm to 5.518 mm
NEW
(.2168 in to .2172 in)
NOTICE Valve guide installer is used for in-
SERVICE LIMIT 5.568 mm (.2192 in) take and exhaust valve guides. Choose proper
side for installation.
Valve Guide Removal
to remove:
– Cylinder head
– Valve springs
– Valves
– Valve stem seals
– Thrust washers.
NOTE: Clean valve guide area from contamination
before removal.
Drive the valve guide out of cylinder head. tmr2013-068-026_a
1. Valve guide installer

REQUIRED TOOL 2. Mark "EX" - exhaust valve guide installer
3. Mark "IN" - intake valve guide installer
Hammer A. 14.5 mm (.571 in)
B. 13.3 mm (.524 in)
VALVE GUIDE REMOVER (6
MM) (P/N 529 036 074)
tmr2013-068-025_a
1. Valve guide installer

tmr2013-068-024_a
2. Valve guide
1. Valve guide remover
2. Valve guide NOTICE Push valve guide in the cold cylinder
head as per following illustration.
Valve Guide Installation
vmr2015-019 141
CYLINDER
Cylinder Removal
the following parts:
– Timing chain tensioner
– Camshaft timing gear.
Remove the cylinder head (see CYLINDER HEAD
in this subsection).
Pull cylinder.
Discard cylinder base gaskets.
tmr2013-068-025_b
1. Thrust surface of cylinder head

2. Valve guide
A. Measurement from thrust surface to valve guide top
VALVE GUIDE (MEASUREMENT “A”)

13.1 mm to 13.5 mm
INTAKE
(.5157 in to .5315 in)
14.3 mm to 14.7 mm
EXHAUST
(.563 in to .579 in)
Apply some lapping compound to valve face and

work valve on its seat with a lapping tool. vmr2015-019-010_a
1. Cylinder
2. Piston assembly
3. Cylinder base gasket
4. Camshaft timing chain
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 at 3 recommended posi-
tions.
tmr2013-068-027_a 3
1. Valve seat C
3. Turn valve while pushing against cylinder head 1
A. Valve seat angle 45°
NOTE: Ensure to seat valves properly. Apply A

B
marking paste to ease checking contact pattern.
Repeat procedure until valve seat/valve face fits
together. 2
R400motr91A
A. First measurement (from cylinder bottom)

B. Second measurement
C. Third measurement
142 vmr2015-019
CYLINDER TAPER MEASUREMENTS – On the piston rings

– On the piston ring compressor.
MEASUREMENT SPECIFICATION
Compress piston rings.
A 5 mm (.197 in)
Apply engine oil on the band of the tool.
B 58 mm (2.283 in)
REQUIRED TOOL
C 52 mm (2.047 in)
Piston ring compressor with band width of
CYLINDER TAPER SPECIFICATION 15 mm to 20 mm (.59 in to .79 in)
NEW (MAXIMUM) 0.038 mm (.0015 in) NOTE: The cylinder can not be pushed fully over
SERVICE LIMIT 0.090 mm (.0035 in) the piston unless the piston is located at TDC.
Put timing chain through the chain pit then put the
Distance between measurements should not ex- cylinder in place.
ceed the service limit mentioned above. Other-
wise, replace cylinder and piston rings.
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.
B vmr2015-019-012_a
1. Piston ring compressor

A 2. Piston
3. Cylinder
NOTICE Chain guide has to be fixed between

cylinder and cylinder head.
R400motr92A
Install cylinder head and the other parts in accor-
A. Perpendicular to crankshaft axis
B. Parallel to crankshaft axis dance with the proper installation procedures.
CYLINDER OUT OF ROUND PISTON

NEW (MAXIMUM) 0.015 mm (.0006 in)
Piston Removal
to remove:
Cylinder Installation – Cylinder head
the installation is the reverse of the removal pro- – Cylinder.
cedure. However, pay attention to the following. Place a rag under piston and in the area of timing
NOTICE Always replace cylinder base gasket chain compartment.
before installing the cylinder.
WARNING
NOTE: Make sure piston rings are properly Piston circlips are spring loaded.
spaced, refer to PISTON RINGS in this sub-
section.
Remove one piston circlip and discard it.
Apply engine oil:
– In the bottom area of the cylinder bore
vmr2015-019 143
A
R400motr96A
1. Measuring perpendicularly (90°) to piston pin

vmr2015-019-013_a A. 8 mm (.315 in)
1. Piston circlip
The measured dimension should be as described
NOTE: The removal of both piston circlips is not in the following tables. If not, replace piston.
necessary to remove piston pin.
PISTON MEASUREMENT
Push piston pin out of piston.
93.950 mm to 93.966 mm
NEW
(3.6988 in to 3.6994 in)
Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston dimen-
sion.
vmr2015-019-014_a
1. Piston pin
2. Piston
Detach piston from connecting rod.
Piston Inspection
F00B08A
Inspect piston for scoring, cracking or other dam-
ages. Replace piston and piston rings if neces- 1. Micrometer set to the piston dimension
sary. With the micrometer set to the dimension, adjust
Using a micrometer, measure piston at 8 mm a cylinder bore gauge to the micrometer dimen-
(.315 in) perpendicularly (90°) to piston pin. sion and set the indicator to 0 (zero).
144 vmr2015-019
Connecting Rod/Piston Pin Clearance

Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other
2 1 damages.
Measure piston pin. See the following illustration
for the proper measurement positions.
F00B09A
1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge
R400motr30A A
A. Piston pin diameter
PISTON PIN DIAMETER

19.996 mm to 20.000 mm
NEW
(.7872 in to .7874 in)
Replace piston pin if diameter is out of specifica-

tions.
Measure inside diameter of connecting rod small
1 end bushing.
F00B0AA
TYPICAL
1. Indicator set to 0 (zero)
Position the dial bore gauge 20 mm (.787 in) above

cylinder base, measuring perpendicularly (90°) to
piston pin axis.
Read the measurement on the cylinder bore
2 1
gauge. The result is the exact piston/cylinder wall
clearance.
PISTON/CYLINDER CLEARANCE
R1004motr11A
0.027 mm to 0.057 mm
NEW
(.0011 in to .0022 in) 1. Bore gauge
2. Connecting rod
CONNECTING ROD SMALL END DIAMETER
NOTE: Make sure used piston is not worn.
20.010 mm to 20.020 mm
If clearance exceeds specified tolerance, replace NEW
(.7878 in to .7882 in)
piston by a new one and measure piston/cylinder
clearance again.
NOTE: Make sure the cylinder bore gauge indica- Replace connecting rod if diameter of connecting
tor is set exactly at the same position as with the rod small end is out of specifications. Refer to
micrometer, otherwise the reading will be false. BOTTOM END subsection for removal procedure.
vmr2015-019 145
Compare measurements to obtain the connecting

rod/piston pin clearance.
CONNECTING ROD/
PISTON PIN CLEARANCE
Piston Installation
Apply engine oil on the piston pin. mmr2011-075-041_a
Insert piston pin into piston and connecting rod. TYPICAL

1. Circlip
Install piston with the punched arrow on piston 2. Sleeve
dome must point towards exhaust side of the en- 3. Installer handle
gine.
2. Push piston circlip installer handle until circlip
reaches end position in the sleeve.
vmr2015-019-011_a
vmr2015-019-015_a
TYPICAL
1. Piston 1. Circlip
2. Mark on piston must show to exhaust side 2. Sleeve
3. Installer handle
Install NEW piston circlip as per following proce-
dure: 3. Align sleeve with piston pin axis and push in-
staller handle until circlip engages in piston.
REQUIRED TOOL
PISTON CIRCLIP INSTALLER
(P/N 529 036 083)
NOTICE Always replace disassembled piston

circlip(s) by NEW ones. Place a rag on cylinder
base to avoid dropping the circlip inside the en-
gine.
1. Place circlip in sleeve and push piston circlip in-
staller handle until circlip reaches the mid posi-
tion in the sleeve.
vmr2015-019-016_a
1. Hold piston while pushing circlip in place

2. Sleeve
3. Installer handle
4. Direction to push circlip
NOTE: Take care that the hook of the piston circlip

is positioned properly.
146 vmr2015-019
1
2
R400motr103A
1. Piston
2. Feeler gauge
Ring End Gap

R400motr102A RING END GAP
CORRECT POSITION OF THE PISTON CIRCLIP UPPER COMPRESSION RING
0.20 mm to 0.35 mm
PISTON RINGS NEW
(.008 in to .014 in)
Ring Removal SERVICE LIMIT 0.60 mm (.024 in)
Remove the piston (see PISTON in this subsec- LOWER COMPRESSION RING
tion).
0.35 mm to 0.55 mm
NEW
(.014 in to .022 in)
Ring Inspection
Ring/Piston Groove Clearance
OIL SCRAPER RING
Using a feeler gauge measure each ring/piston
groove clearance. If the clearance is too large, the NEW
0.20 mm to 0.70 mm
piston and the piston rings should be replaced. (.008 in to .028 in)
RING/PISTON GROOVE CLEARANCE SERVICE LIMIT 1.00 mm (.039 in)
UPPER COMPRESSION RING To measure the ring end gap place the ring
0.03 mm to 0.07 mm in the cylinder in the area of 8 mm to 16 mm
NEW (5/16 in to 5/8 in) from top of cylinder.
(.0012 in to .0028 in)
SERVICE LIMIT 0.150 mm (.0059 in) NOTE: In order to correctly position the ring in the
cylinder, use piston as a pusher.
LOWER COMPRESSION RING
Using a feeler gauge, check ring end gap. Replace
0.02 mm to 0.06 mm ring if gap exceeds above described specified tol-
NEW
(.0008 in to .0024 in) erance.
Ring Installation
OIL SCRAPER RING
The installation is the reverse the removal proce-
0.01 mm to 0.18 mm dure. However, pay attention to the following.
NEW
(.0004 in to .0071 in)
NOTE: Use a ring expander to prevent breakage
SERVICE LIMIT 0.250 mm (.0098 in) during installation. The oil ring must be installed
by hand.
NOTE: First install spring and then rings of oil
scraper ring.
Install the oil scraper ring first, then the lower
compression ring with the word “N and TOP “
facing up, then the upper compression ring with
the word “N and TOP“ facing up.
vmr2015-019 147
vmr2015-019-017_a
1. Upper compression ring

2. Lower compression ring
3. Oil scraper ring
NOTICE Ensure that top and second rings are

not interchanged.
Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120° apart and do
not align the gaps with the piston pin bore or the
thrust side axis.
A
A A
A31C2OA
1. DO NOT align ring gap with piston thrust side axis

2. DO NOT align ring gap with piston pin bore axis
A. 120°
148 vmr2015-019
TOP END
SERVICE TOOLS
CRANKSHAFT LOCKING BOLT..................................................... 529 035 617 ......................................... 106
ENGINE LEAK DOWN TEST KIT ................................................... 529 035 661 ........................................... 92
PISTON CIRCLIP INSTALLER........................................................ 529 035 921 ......................................... 109
TDC DIAL INDICATOR .................................................................. 414 104 700 ........................................... 92
VALVE GUIDE INSTALLER ............................................................ 529 036 140 ......................................... 104
VALVE GUIDE REMOVER 5 MM .................................................. 529 035 924 ......................................... 104
VALVE SPRING COMPRESSOR CUP............................................ 529 035 764 ......................................... 100
VALVE SPRING COMPRESSOR .................................................... 529 035 724 ......................................... 100

SNAP-ON PLIERS.......................................................................... YA 8230 ......................................... 102
SERVICE PRODUCTS
vmr2016-033 87
CYLINDER HEAD NO. 1

7 ± 0.8 Nm
(62 ± 7 lbfin)
12 ± 1 Nm
(106 ± 9 lbfin)
Engine oil
NEW
See tightening
procedure Engine oil
10 ± 1 Nm 20 ± 2 Nm
Engine oil (89 ± 9 lbfin) (15 ± 1.5 lbfft)
See
IGNITION
SYSTEM
Engine oil
NEW
12 ± 1 Nm
(106 ± 9 lbfin)
NEW
NEW = Component must be replaced

when removed Engine oil
10 ± 1 Nm
(89 ± 9 lbfin) Loctite 648
tmr2011-013-002_b
88 vmr2016-033
CYLINDER HEAD NO. 2
Engine oil
7 ± 0.8 Nm
(62 ± 7 lbfin)
12 ± 1 Nm
(106 ± 9 lbfin)
See tightening
procedure
20 ± 2 Nm
(5 ± 1.5 lbfft)
See
IGNITION SYSTEM Engine oil
Engine oil
NEW
NEW
10 ± 1 Nm
(89 ± 9 lbfin)
Engine oil
Loctite 648
NEW
Engine oil 10 ± 1 Nm
(89 ± 9 lbfin)
NEW = Component must be replaced when removed
tmr2011-013-003_a
vmr2016-033 89
CYLINDERS AND PISTONS
Engine oil
Engine oil
Engine oil
NEW
NEW
Engine oil NEW
NEW
NEW
Engine
oil
vmr2006-043-003_d
90 vmr2016-033
GENERAL WARNING
Special reference are made in the text for proce- Always respect this order for disassembly;
dures which are different for cylinder no. 1 and disconnect BLACK (-) cable first.
cylinder no. 2.
2. Remove radiator cap.
WARNING
To prevent burning yourself only remove
the radiator cap by wearing the appropriate
safety equipment.
3. Unplug spark plug cable.

4. Clean spark plug area and remove spark plug
from cylinder head.
Vmr2012-015-002_a
1. Cylinder 1 (front)
2. Cylinder 2 (rear)
When diagnosing an engine problem, always per-

form a cylinder leak test.
NOTE: Even though the following procedures do
not require the engine removal, many illustrations
show the engine out of the vehicle for more clar-
ity.
IMPORTANT: Note position of parts upon disas- tmr2011-013-005_a
1. Spark plug cable

sembly. This may help to find the root cause of a 2. Spark plug
problem. A component that is not replaced should
be reinstalled in the same position as originally 5. Remove VALVE COVER. See procedure in this
mounted. subsection.
6. Rotate crankshaft until piston is at ignition TDC.
INSPECTION 7. Turn crankshaft using one of the following two
procedures.
LEAK TEST
First Procedure
Before performing the cylinder leak test, verify the
Turn the drive pulley.
following:
– Clamp(s) tightness Second Procedure
– Radiator and hoses. 1. Remove plug screw with O-ring from magneto
NOTE: For best accuracy, the leak test should be cover.
done with the engine at normal operating temper- 2. Use a 14 mm Allen key and turn crankshaft.
ature.
NOTICE Turn only clockwise to avoid loosen-
WARNING ing of magneto flywheel Allen screw.
Prevent burning yourself on hot engine parts. 3. Set the piston to precisely ignition TDC.
Preparing the Leak Test

1. Disconnect battery.
vmr2016-033 91
REQUIRED TOOL NOTE: All testers have specific instructions on

gauge operation and required pressure.
TDC DIAL INDICATOR
(P/N 414 104 700) 4. Install gauge adapter into previously cleaned
spark plug hole.
5. Supply combustion chamber with air pressure.
tmr2011-013-007_a
1. TDC dial indicator
NOTE: If a dial gauge is not available, use a screw-

driver or another similarly suitable tool.
vmr2015-019-101_a
NOTICE Do not scratch or damage pis-
TYPICAL
ton/cylinder surface. 1. Leak tester
2. Leak tester installed in spark plug bore
NOTE: At ignition TDC the marks on the camshaft 3. Air supply hose
timing gear have to be parallel to cylinder head 6. Note the amount or percentage of leakage (de-
base as per following illustration. pending on tester).
LEAKAGE ENGINE
PERCENTAGE CONDITION
0% to 15% Excellent condition
16% to 25% Good condition
Fair condition; reduced
26% to 40%
engine performance
Poor condition, diagnose
41% and higher
and repair engine
NOTE: To make sure there is no false reading due

to a valves not perfectly seated, tap each valve
adjustment screw (on the rocker arm) using a soft
tmr2011-013-008_a
hammer.
1. Marks on camshaft timing gear
2. Cylinder head base
Diagnosis
Leak Test Listen for air leaks.
1. Install gauge adapter into spark plug hole. – Air escaping in intake port/throttle body means
leaking intake valve(s).
REQUIRED TOOL
– Air escaping in exhaust port means leaking ex-
haust valve(s).
ENGINE LEAK DOWN TEST
KIT (P/N 529 035 661) – Air bubbles in the coolant (radiator) means leak-
ing cylinder head gasket.
– Air/coolant escaping from cylinder/head means
2. Connect to adequate air supply. damaged gasket(s) and/or loosened screws.
3. Set needle of measuring gauge to zero.
92 vmr2016-033
– Air escaping into crankcase area means exces- Removing the Valve Cover
sively worn cylinder and/or broken piston rings. Remove:
– Air/oil escaping from crankcase means dam- – Valve cover screws
aged gasket and/or loosened screws (refer to
– Valve cover
BOTTOM END subsection).
– Gasket.
NOTE: For all checkpoints mentioned above, see
appropriate engine section to diagnose and repair
the engine.
Reassembly
Reverse the preparation procedure. Ensure to
respect torque values and use of appropriate
products/lubricants. Refer to exploded views in
other subsections of this manual as required.
PROCEDURES
VALVE COVER
Valve Cover Access
vmr2016-033-001_a
Front Cylinder
TYPICAL — FRONT CYLINDER SHOWN
Refer to BODY subsection and remove the follow- 1. Valve cover screws
2. Valve cover
ing. 3. Gasket
Inspecting the Valve Cover

Check the gasket on the valve cover if it is brittle,
cracked or hard. If so, replace the gasket.
Installing the Valve Cover

Tighten valve cover retaining screws to specified
torque in a criss-cross sequence.
TIGHTENING TORQUE
Valve cover retaining 7 N•m ± 0.8 N•m
vmr2015-019-100_a
1. Seat ROCKER ARM

2. Console
3.
4.
RH side panel
RH side panel extension
Removing the Rocker Arm
5. RH inner fender panel 1. Remove VALVE COVER. See procedure in this
Rear Cylinder subsection.
Refer to BODY and remove: 2. Refer to TIMING CHAIN subsection and re-
move following parts:
– Seat
– Timing chain tensioner
– Console
– RH side panel and extension(s)
– LH side panel and extension(s). 3. Remove pan head screw and camshaft retain-
ing plate.
Refer to EXHAUST SYSTEM and remove exhaust
pipe.
vmr2016-033 93
tmr2011-013-010_a

vmr2016-033-002_a
3. Thrust washers
TYPICAL NOTICE Pay attention not to lose thrust
2. Pan head screw washers or drop them into the timing chain
compartment.
4. Remove rocker arm shafts.
1 2 1
R400motr67A 4
1. 2 thrust washers
3. Cylinder head (spark plug side)
4. Big taper to spark plug side
Inspecting the Rocker Arm

Inspect each rocker arm for cracks and scored fric-
vmr2006-043-016_a tion surfaces. If so, replace rocker arm assembly.
1. Rocker arm shaft Check the rocker arm rollers for free movement,
3. Rocker arm (intake side) wear and excessive radial play. Replace rocker
4. Adjustment screw arm assembly if necessary.
5. Lock nut
5. Remove rocker arm assembly (exhaust side

and intake side) with adjustment screws and
lock nuts.
6. Remove thrust washers.
94 vmr2016-033
2 1 ROCKER ARM SHAFT DIAMETER

12.000 mm to 12.018 mm
NEW
(.4724 in to .4731 in)
Any area worn excessively will require parts re-

placement.
A Installing the Rocker Arm
R400motr68A
NOTE: Use the same procedure for exhaust and
1. Rocker arm (exhaust side) intake rocker arm.
2. Roller
A. Bore for rocker arm shaft 1. Apply engine oil on rocker arm shaft.
Measure rocker arm bore diameter. If diameter 2. Insert a rocker arm shaft with the chamfered
is out of specification, change the rocker arm as- edge first through rocker arm pin bore.
sembly. 3. Install a thrust washer at timing chain side, then
the proper rocker arm (exhaust side or intake
ROCKER ARM BORE DIAMETER side).
12.036 mm to 12.050 mm 4. Push in rocker arm shaft until its chamfer
NEW
(.4739 in to .4744 in) reaches 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 Inspection vmr2006-043-016_b
Check for scored friction surfaces; if so, replace 1. Rocker arm shaft
2. Thrust washer (timing chain side)
parts. 3. Thrust washer (spark plug side)
Measure rocker arm shaft diameter.
5. Place the other thrust washer and push rocker
arm shaft to end position.
6. Install the camshaft retaining plate.
7. Adjust valve clearance, refer to PERIODIC
R400motr70A A CAMSHAFT
A. Measure rocker arm shaft diameter here
NOTE: The engine is equipped with two different
camshafts.
vmr2016-033 95
vmr2015-032-001_a
1. Intake cam
2. Exhaust cam
3. Camshaft of cylinder 1
4. Camshaft of cylinder 2 vmr2016-033-002_a
5. Flat spot 1. Camshaft retaining plate
2. Pan head screw
3. Cylinder head
Removing the Camshaft
The removal procedure is the same for both 4. Remove rocker arms (see ROCKER ARM in
camshafts. this subsection).
NOTICE Each camshaft is different in design. 5. Remove the camshaft.
Thus, it is important not to mix up any parts of NOTE: For removal rotate camshaft so that
the camshaft assembly with that of the other intake/exhaust lobe shows to upper side of cylin-
cylinder. Keep parts as a group. der head.
1. Remove valve cover (see VALVE COVER in this
subsection).
2. Refer to the TIMING CHAIN subsection to re-
move the following parts:
– Chain tensioner
3. Remove the camshaft retaining plate.
tmr2011-013-014_a

2. Area for camshaft lobes
3. Camshaft
Inspecting the Camshaft

Inspecting the Camshaft Lobe
Check each lobe for scoring, scuffing, cracks or
other signs of wear.
Measure camshaft lobe height using a microme-
ter.
96 vmr2016-033
vmr2015-032-002_a vmr2015-032-002_a
A. Camshaft lobe (exhaust valves) A. Camshaft lobe (exhaust valves)

B. Camshaft lobe (intake valves) B. Camshaft lobe (intake valves)
C. Camshaft journal (timing chain side) C. Camshaft journal (timing chain side)
D. Camshaft journal (spark plug side) D. Camshaft journal (spark plug side)
CAMSHAFT LOBE (INTAKE) CAMSHAFT JOURNAL

(TIMING CHAIN SIDE)
31.830 mm to 32.030 mm
NEW
(1.2531 in to 1.261 in) 34.959 mm to 34.975 mm
NEW
(1.3763 in to 1.377 in)
CAMSHAFT LOBE (EXHAUST)
CAMSHAFT JOURNAL
31.730 mm to 31.930 mm (SPARK PLUG SIDE)
NEW
(1.2492 in to 1.2571 in)
21.959 mm to 21.980 mm
SERVICE LIMIT 31.710 mm (1.2484 in) NEW
(.8645 in to .8654 in)
Measure camshaft bearing in cylinder head. Refer SERVICE LIMIT 21.950 mm (.8642 in)
to CYLINDER HEAD INSPECTION in this subsec-
tion. Installing the Camshaft
Inspecting the Camshaft Journal Reverse the removal procedure. Pay attention to
Check each journal for scoring, scuffing, cracks or the following details.
other signs of wear. NOTICE The camshafts are not identical in
Measure camshaft journal using a micrometer. design. Do not invert the camshafts during
assembly. Any mix-up of the components will
lead to engine damage.
Place the camshaft retaining plate in the slot of the
camshaft.
vmr2016-033 97
10. First remove the M6 cylinder head screws,

then the cylinder head screws M10.
tmr2011-013-014_b
1. Direction of movement
2. Camshaft retaining plate tmr2011-013-011_a
3. Slot retaining camshaft
For other parts, refer to proper installation proce-
dure. 11. Pull up cylinder head.
12. Remove timing chain guide (fixed).
CYLINDER HEAD 13. Remove and discard the cylinder head gasket.
Cylinder Head Access
Refer to VALVE COVER in this subsection.
Removing the Cylinder Head

1. The removal procedure is the same for both 4
cylinder heads. 2
2. Drain coolant (refer to PERIODIC MAINTE-
NANCE PROCEDURES subsection).
3. Disconnect the coolant hose from the thermo-
stat housing.
NOTE: Before removing cylinder head, blow out
remaining coolant by air pressure. During cylin-
1
der head removal, the remaining coolant in cylin-
der head could overflow into the engine and a little
quantity of coolant could drop into the engine. In R400motr72A 3
this case, the engine oil will be contaminated. 1. Cylinder head
4. Refer to EXHAUST SYSTEM subsection and 2. Timing chain
3. Chain guide (fixed)
disconnect exhaust system head pipe from 4. Cylinder head gasket
cylinder head.
5. Disconnect spark plug wire. Inspecting the Cylinder Head
6. Disconnect temperature sensor connector, lo- Inspect timing chain guide (fixed) for wear, cracks
cated at rear cylinder head. or other damages. Replace if necessary.
7. Remove the intake manifold. Refer to INTAKE Check for cracks between valve seats, if so, re-
MANIFOLD subsection. place cylinder head.
8. Remove the valve cover and its gasket (see Check mating surface between cylinder and cylin-
VALVE COVER in this subsection). der head for contamination. If so, clean both sur-
faces.
move the following parts: Clean oil support through the cylinder head from
contamination.
– Chain tensioner
98 vmr2016-033
Reverse the removal procedure. Pay attention to

the following details.
1 Ensure dowel pins are in place.
NOTICE Timing chain guide (fixed) has to be
fixed between cylinder and cylinder head.
2 3
R400motr73A
1. Oil port to lubricate camshaft lobes intake/exhaust

2. Oil supply to camshaft bearing journal (timing chain side)
3. Oil supply to camshaft bearing journal (spark plug side)
Inspecting the Cylinder Head Camshaft

Bearing
Measure camshaft bearing in cylinder head.
vmr2016-033-002_b
1. Timing chain guide (tensioner side) mounted in crankcase

B 2. Timing chain guide (fixed) between cylinder and cylinder head
Install a NEW cylinder head gasket.

Install cylinder head screws in correct position.
A NOTICE Cylinder head screws have different
sizes and lengths.
R400motr77A
A. Camshaft bearing (timing chain side)

B. Camshaft bearing (spark plug side)
CAMSHAFT BEARING
(TIMING CHAIN SIDE)
35.000 mm to 35.025 mm
NEW
(1.378 in to 1.3789 in)
CAMSHAFT BEARING
(SPARK PLUG SIDE)
22.000 mm to 22.021 mm
NEW
(.8661 in to .867 in)
Installing the Cylinder Head

NOTE: Front and rear cylinder heads are not iden-
tical. Never interchange cylinder heads.
vmr2016-033 99
tmr2011-013-011_d
1. M6 Screws
TIGHTENING TORQUE
M6 cylinder head 10 N•m ± 1 N•m
Check timing chain guide (tensioner side) for

movement.
vmr2015-032-003_a Refer to applicable subsection for installation de-
1. Location no. 1 tails of remaining removed parts.
2. Location no. 2
CYLINDER HEAD SCREW IDENTIFICATION VALVE SPRINGS

Location no. 1 M10 x 140 Removing the Valve Spring
Location no. 2 M6 x 85 1. Refer to following procedures in this subsection
to remove:
Tighten M10 cylinder head screws FIRST as per – CAMSHAFT
following specifications.
– CYLINDER HEAD.
NOTE: Always perform one step on all M10 cylin-
2. Remove valve spring.
der head screws before going to the next step.
REQUIRED TOOL

(P/N 529 035 724)

CUP (P/N 529 035 764)
WARNING
Always wear safety glasses when disassem-
bling valve springs. Be careful when unlock-
ing valves. Components could fly away be-
cause of the strong spring preload.
tmr2011-013-011_c
TIGHTENING SEQUENCE - M10 CYLINDER HEAD SCREWS
TIGHTENING TORQUE
20 N•m ± 1 N•m
M10 cylinder STEP A
head screws
STEP B 180° +/- 5°
Tighten M6 cylinder head screws as per following

specification.
100 vmr2016-033
Inspecting the Valve Spring

Check valve spring for visible damage. If so, re-
place valve spring.
Check valve spring for free length and straight-
ness.
R400motr79A
LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF

THE VALVE
3. Remove valve cotters.

R400motr80A A
1 3 2 A. Valve spring length
VALVE SPRING FREE LENGTH

NOMINAL NEW 40.81 mm (1.607 in)
Replace valve springs if not within specifications.
Installing the Valve Spring

Colored area of the valve spring must be placed
on top.
R400motr78A
1. Valve spring compressor clamp on them so that they remain in place while relea-
2. Valve spring compressor cup
3. Valve cotter sing the spring.
4. Remove tools and withdraw valve spring re- NOTE: Valve cotter must be properly engaged in
tainer and valve spring. valve stem grooves.
R400motr81A
1. Position of the valve spring

tmr2011-013-015_a 2. Valve cotter
1. Valve spring retainer
2. Valve spring
vmr2016-033 101

locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
times.
NOTICE An improperly locked valve spring
VALVES
Removing the Valve
1. Remove valve spring, see VALVE SPRING in
this subsection.
2. Push valve stem, then pull valves (intake and
exhaust) out of valve guide.
vmr2006-043-023
Inspecting the Valve

Whenever valves are removed always inspect
valve guides. Refer to VALVE GUIDES in this
subsection.
Valve Stem Seal
Always install NEW seals whenever valves are re-
moved.
Inspecting the Valve
Inspect valve surface, check for abnormal stem
wear and bending. If out of specification, replace
by a new one.
vmr2006-043-021_a
1. Intake valves 31 mm
2. Exhaust valves 27 mm
3. Remove valve stem seal and discard it.

REQUIRED TOOL
SNAP-ON PLIERS (P/N YA 8230)
mmr2009-115-072_a
VALVE OUT OF ROUND

(INTAKE AND EXHAUST VALVES)
NEW 0.005 mm (.0002 in)
Inspecting the Valve Stem

Measure valve stem in three places using a mi-
crometer.
102 vmr2016-033
Replace valve if valve stem is out of specification Ensure to seat valves properly. Apply some lap-
or has other damages such as wear or friction sur- ping compound to valve face and work valve on
face. its seat with a lapping tool (see VALVE GUIDES in
this subsection).
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.
VALVE SEAT CONTACT WIDTH
EXHAUST VALVE
A 1.25 mm to 1.55 mm
NEW
(.049 in to .061 in)
R400motr83A INTAKE VALVE
A. Valve stem diameter 1.05 mm to 1.35 mm
NEW
(.041 in to .053 in)
VALVE STEM DIAMETER
EXHAUST VALVE
4.956 mm to 4.970 mm If valve seat contact width is too wide or has dark
NEW spots, replace the cylinder head.
(.1951 in to .1957 in)
INTAKE VALVE
4.966 mm to 4.980 mm
NEW
(.1955 in to .1961 in)
Inspecting the Valve Face and Seat
vmr2016-033-003_a
2 A. Valve seat contact width
3
Installing the Valve
1 the following details.
Install a NEW valve stem seal. Make sure thrust
R400motr84A washer is installed before installing seal.
1. Valve seat Apply engine oil on valve stem and install it.
2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seat) NOTICE Be careful when valve stem is
Check valve face and seat for burning or pitting passed through sealing lips of valve stem
and replace valve or cylinder head if there are seal.
signs of damage.
vmr2016-033 103
1 2 REQUIRED TOOL
VALVE GUIDE
REMOVER 5 MM
(P/N 529 035 924)
Hammer
R400motr85A
1. Thrust washer
2. Sealing lips of valve stem seal 1
on them so that they remain in place while relea-
sing the spring.
locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
times. R400motr86A
NOTICE An improperly locked valve spring 1. Valve guide remover

2. Valve guide
Installing the Valve Guide
VALVE GUIDES For installation, reverse the removal procedure.
Inspecting the Valve Guide Pay attention to the following details.
Always replace valve stem seals whenever valve Clean the valve guide bore before reinstalling the
guides are removed. valve guide into cylinder head.
Measure valve guide in three places using a small Install valve guide.
bore gauge. REQUIRED TOOL
NOTE: Clean valve guide to remove carbon de-
VALVE GUIDE INSTALLER
posits before measuring. (P/N 529 036 140)
Replace valve guide if it is out of specification or
has other damages such as wear or friction sur-
face.
VALVE GUIDE DIAMETER (INTAKE AND 1
EXHAUST VALVES)
4.998 mm to 5.018 mm
NEW
(.1968 in to .1976 in)
Removing the Valve Guide

1. Remove cylinder head (see CYLINDER 2
HEAD in this subsection). R400motr87A
2. Remove valves (see VALVES in this subsec- 1. Valve guide installer

tion). 2. Valve guide
NOTE: Clean valve guide area from contamination NOTE: Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
before removal. (P/N 293 800 070) on valve guide prior to install it
3. Drive valve guide out of cylinder head using into the cylinder head.
specified tool.
104 vmr2016-033
NOTICE Push valve guide in the cold cylinder 2. Remove the cylinder head (see CYLINDER
head as per following illustration. HEAD in this subsection).
3. Pull cylinder.
4. Discard cylinder base gaskets.
2 1
A
1
R400motr87B 2
1. Thrust surface of cylinder head
3
2. Valve guide
A. Measurement from thrust surface to valve guide top
R400motr90A
VALVE GUIDE (MEASUREMENT A)

1. Cylinder
14.00 mm to 14.40 mm 2. Piston assembly
NEW 3. Cylinder base gasket
(.5512 in to .5669 in) 4. Camshaft timing chain
Apply some lapping compound to valve face and Inspecting the Cylinder
work valve on its seat with a lapping tool. Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder. If so, re-
3 A place cylinder.
2 Cylinder Taper
1
Measure cylinder bore at recommended posi-
tions.
R400motr89A A
B
1. Valve seat
3. Turn valve while pushing against cylinder head
A. Valve seat angle 45°
R400motr91B
NOTE: Ensure to seat valves properly. Apply
marking paste to ease checking contact pattern. A. First measurement (from cylinder bottom)
B. Second measurement
Repeat procedure until valve seat/valve face fits C. Third measurement
together.
CYLINDER
Removing the Cylinder
– Chain tensioner
vmr2016-033 105
CYLINDER TAPER MEASUREMENTS – On the piston rings

– On the piston ring compressor.
MEASUREMENT SPECIFICATION
Compress piston rings.
A 5 mm (.197 in)
REQUIRED TOOL
B 63 mm (2.48 in)
Piston ring compressor with band width of
C 37 mm (1.46 in)
15 mm to 20 mm (.59 in to .79 in)
CYLINDER TAPER SPECIFICATION First mount cylinder 2.
NEW (MAXIMUM) 0.038 mm (.0015 in) NOTE: The cylinder can not be pushed fully over
SERVICE LIMIT 0.090 mm (.0035 in) the piston unless the piston is located at TDC.
Then remove the CRANKSHAFT LOCKING BOLT
Distance between measurements should not ex- (P/N 529 035 617).
ceed the service limit. Otherwise, replace cylin-
der and piston rings. Crank the engine further and position piston 1 at
TDC.
Cylinder Out of Round Mount cylinder 1.
Measure cylinder diameter in piston axis direction Put timing chain through the chain passage, then
from top of cylinder. Take another measurement slide cylinder over piston.
90° from first one and compare.
NOTE: Take the same measuring points like de-
scribed in CYLINDER TAPER above.
B
A
R400motr92A
vmr2016-033-004_a
A. Perpendicular to crankshaft axis 1. Piston ring compressor
B. Parallel to crankshaft axis 2. Cylinder
CYLINDER OUT OF ROUND NOTICE Chain guide has to be fixed between

NEW (MAXIMUM) 0.015 mm (.0006 in) cylinder and cylinder head.
SERVICE LIMIT 0.020 mm (.0008 in) NOTE: After both cylinders are installed, turn
crankshaft until piston of cylinder 2 is at TDC and
Installing the Cylinder lock crankshaft. Refer to CRANKSHAFT in the
BOTTOM END subsection.
the following details. Install cylinder head and the other parts in accor-
dance with the proper installation procedures.
NOTICE Always replace cylinder base gasket
before installing the cylinder. PISTON
NOTE: Make sure piston rings are properly Removing the Piston
spaced, refer to PISTON RINGS in this sub-
1. Refer to following procedures in this subsection
section.
and remove following parts:
Apply engine oil: – Cylinder head
– In the bottom area of the cylinder bore – Cylinder.
106 vmr2016-033
2. Place a rag under piston and in the area of tim-

ing chain compartment.
WARNING 1
Piston circlips are spring loaded.
3. Remove one piston circlip and discard it.
A
R400motr96A
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
83.950 mm to 83.966 mm
NEW
(3.3051 in to 3.3057 in)
Piston/Cylinder Clearance
vmr2016-033-005_a
1. Piston circlip
Adjust and lock a micrometer to the piston dimen-
sion.
NOTE: The removal of both piston circlips is not
necessary to remove piston pin. 1
4. Push piston pin out of piston.
2
F00B08A
1. Micrometer set to the piston dimension
R400motr95A
With the micrometer set to the dimension, adjust
1. Piston a cylinder bore gauge to the micrometer dimen-
2. Piston pin sion and set the indicator to 0 (zero).
5. Detach piston from connecting rod.
Inspecting the Piston

Inspect piston for scoring, cracking or other dam-
ages. Replace piston and piston rings if neces-
sary.
Using a micrometer, measure piston at 8 mm
(.315 in) perpendicularly (90°) to piston pin.
vmr2016-033 107

Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other
2 1 damages.
Measure piston pin. See the following illustration
for the proper measurement positions.
F00B09A
1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge
R400motr30A A
A. Piston pin diameter
PISTON PIN DIAMETER

19.996 mm to 20.000 mm
NEW
(.7872 in to .7874 in)
Replace piston pin if diameter is out of specifica-

tions.
Measure inside diameter of connecting rod small
1
end bushing.
F00B0AA
TYPICAL
1. Indicator set to 0 (zero)
Position the dial bore gauge 20 mm (.787 in) above

cylinder base, measuring perpendicularly (90°) to
piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall 2 1
clearance.
PISTON/CYLINDER CLEARANCE
0.057 mm to 0.087 mm R1004motr11A
NEW
(.0022 in to .0034 in)
1. Bore gauge
2. Connecting rod
CONNECTING ROD SMALL END DIAMETER
NOTE: Make sure used piston is not worn.
20.010 mm to 20.020 mm
If clearance exceeds specified tolerance, replace NEW
(.7878 in to .7882 in)
piston by a new one and measure piston/cylinder
clearance again. SERVICE LIMIT 20.060 mm (.7898 in)
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
108 vmr2016-033
Replace connecting rod if diameter of connecting NOTICE Always replace disassembled piston
rod small end is out of specifications. Refer to circlip(s) by NEW ones. Place a rag on cylinder
BOTTOM END subsection for removal proce- base to avoid dropping the circlip inside the en-
dure. gine.
Compare measurements to obtain the connecting Place circlip in sleeve as per following illustration.
rod/piston pin clearance.
CONNECTING ROD/
PISTON PIN CLEARANCE 3
Installing the Piston

Reverse the removal procedure. Pay attention to 1
the following details. 2
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
For each cylinder, install piston with the punched
arrow on piston dome pointing towards the rear
side of the engine. R400motr100A
Front cylinder: Mark on top of piston must show 1. Circlip

to intake side. 2. Sleeve
3. Assembly jig from piston clip installer
Rear cylinder: Mark on top of piston must show
to exhaust side. Push taper side of assembly jig until circlip
reaches middle of sleeve.
Align sleeve with piston pin axis and push assem-
bly jig until circlip engages in piston.
tmr2015-019-007_a
1. Piston of cylinder 1
vmr2007-036-008_a
2. Mark on piston must show to intake side of cylinder 1
3. Piston of cylinder 2 1. Hold piston while pushing circlip in place
4. Mark on piston must show to exhaust side of cylinder 2 2. Sleeve
3. Assembly jig
Use the piston appropriate circlip installer to as- 4. Direction to push circlip
semble the NEW piston circlip as per following NOTE: Take care that the hook of the piston circlip
procedure: is positioned properly.
REQUIRED TOOL
PISTON CIRCLIP
INSTALLER (P/N 529
035 921)
vmr2016-033 109
1
2
R400motr103A
1. Piston
2. Feeler gauge
Ring End Gap

RING END GAP
vmr2016-033-006
UPPER COMPRESSION RING
CORRECT POSITION OF THE PISTON CIRCLIP
0.10 mm to 0.30 mm
NEW
(.004 in to .012 in)
PISTON RINGS
Removing the Piston Rings
LOWER COMPRESSION RING
Remove the piston (see PISTON in this subsec-
tion). 0.35 mm to 0.55 mm
NEW
(.014 in to .022 in)
Inspecting the Piston Rings SERVICE LIMIT 0.85 mm (.033 in)
Ring/Piston Groove Clearance OIL SCRAPER RING
Using a feeler gauge measure each ring/piston 0.20 mm to 0.70 mm
groove clearance. If the clearance is too large, the NEW
(.008 in to .028 in)
piston and the piston rings should be replaced.
RING/PISTON GROOVE CLEARANCE
To measure the ring end gap place the ring
UPPER COMPRESSION RING
in the cylinder in the area of 8 mm to 16 mm
0.025 mm to 0.070 mm (5/16 in to 5/8 in) from top of cylinder.
NEW
(.001 in to .0028 in)
NOTE: In order to correctly position the ring in the
SERVICE LIMIT 0.100 mm (.0039 in) cylinder, use piston as a pusher.
LOWER COMPRESSION RING Using a feeler gauge, check ring end gap. Replace
ring if gap exceeds specified tolerance.
0.020 mm to 0.060 mm
NEW
(.0008 in to .0024 in)
Installing the Piston Rings
SERVICE LIMIT 0.150 mm (.0059 in) For installation, reverse the removal procedure.
OIL SCRAPER RING Pay attention to the following details.
0.010 mm to 0.180 mm NOTE: First install spring and then rings of oil
NEW scraper ring.
(.0004 in to .0071 in)
SERVICE LIMIT 0.250 mm (.0098 in) NOTE: Use a ring expander to prevent breakage
during installation. The oil ring must be installed
by hand.
Install the oil scraper ring first, then the lower
compression ring with the word “N and TOP “
facing up, then the upper compression ring with
the word “N and TOP“ facing up.
110 vmr2016-033
3
vmr2007-036-009_a
1. Upper compression ring

2. Lower compression ring
3. Oil scraper ring
NOTICE Ensure that top and second rings are

not interchanged.
Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120° apart and do
not align the gaps with the piston pin bore or the
thrust side axis.
A
A A
A31C2OA
1. DO NOT align ring gap with piston thrust side axis

2. DO NOT align ring gap with piston pin bore axis
A. 120°
vmr2016-033 111
Subsection 09 (TIMING CHAIN)
TIMING CHAIN
SERVICE TOOLS
CAMSHAFT TIMING TOOL........................................................... 529 036 268 ................................. 154–155
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ................................. 155, 157
vmr2015-020 149
TIMING CHAIN
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
Loctite 243
Engine oil
6 ± 0,7 N•m
(53 ± 6 lbf•in)
0,1 N•m
(0,89 lbf•in)
4,5 ± 0,5 N•m

(40 ± 4 lbf•in)
vmr2015-020-001_a
150 vmr2015-020
GENERAL
originally mounted.
TROUBLESHOOTING
UNUSUAL ENGINE NOISE OR VIBRATION
1. IMPROPER VALVE CLEARANCE ADJUSTMENT
AND/OR WORN OUT ROCKER ARM(S)
- Readjust valve clearance and/or replace defective vmr2015-020-002_a
part(s), refer to TOP END subsection. 1. Timing chain tensioner
2. DEFECTIVE CHAIN TENSIONER
- Replace chain tensioner.
Timing Chain Tensioner Access
Refer to BODY subsection and remove the RH in-
3. WORN OUT TIMING CHAIN GUIDE(S) ner fender panel.
- Replace timing chain guide(s).
4. STRETCHED TIMING CHAIN OR WORN OUT Timing Chain Tensioner Removal
TIMING GEARS 1. Make sure the piston is set to TDC ignition. Re-
- Replace timing chain and timing gears. fer to CRANKSHAFT LOCKING PROCEDURE in
the BOTTOM END subsection.
5. LOOSE TIMING GEAR RETAINING SCREWS
2. Carefully unscrew chain tensioner plug and re-
- Retighten screws to recommended torque.
lease spring tension.
6. INCORRECT CAMSHAFT TIMING
- Replace damaged components and readjust CAUTION Tensioner is spring loaded.
camshaft timing.
3. Remove:
ENGINE LACKS ACCELERATION OR – O-ring
POWER – Spring
1. INCORRECT CAMSHAFT TIMING – Chain tensioner plunger.
- Replace damaged components and readjust
camshaft timing.
PROCEDURES
TIMING CHAIN TENSIONER
Timing Chain Tensioner Location
The timing chain tensioner is located in the cylin-
der.
vmr2015-020-003_a
1. Chain tensioner plug

2. O-ring
3. Spring
4. Chain tensioner plunger
4. Remove:
– Chain tensioner housing retaining screws
vmr2015-020 151
– Chain tensioner housing

– O-ring.
vmr2015-020-005_a
MOVE GEAR BACK AND FORTH
2. Apply engine oil on the plunger before installa-

vmr2015-020-004_a tion.
1. Screws
2. Chain tensioner housing 3. Slightly turn the camshaft timing gear in order
3. O-ring to get the timing chain play on the tensioner
side.
Timing Chain Tensioner Inspection
4. Slightly screw the plunger in until the timing
Check the chain tensioner housing and plug for chain allows no more back and forth movement
cracks or other damages. Replace if necessary. of the camshaft timing gear.
Check chain tensioner plunger for free movement 5. Screw the plunger in an additional 1/8 turn to
and/or scoring. reach the required specified torque.
Check if O-rings are brittle, cracked or hard. Re- TIMING CHAIN TENSIONER ADJUSTMENT
place if necessary. (TORQUE)
Check spring condition. Replace if bent, broken or 0.1 N•m (.9 lbf•in)
worn.
NOTICE Improper adjustment of the timing
Timing Chain Tensioner Installation
chain will lead to severe engine damage.
1. The installation is the reverse of the removal
procedure. However, pay attention to the fol- 6. Place the O-ring on plug.
lowing. 7. Fit the spring on one side into the slot of the
NOTE: Before installing the chain tensioner make plug.
sure, that the camshaft timing gear can be moved
back and forth.
152 vmr2015-020
vmr2015-020-006_a
tmr2013-069-006_a
Step 1: Compress spring
1. Plug
Step 2: Screw in plug
2. Slot
3. Spring
4. Spring end 9. Remove the crankshaft locking bolt and install
5. O-Ring all other removed parts.
Fit the spring on the other side into the plunger.
NOTE: Turn spring only clockwise in order to fit
the spring end into the notch of the plunger to
avoid loosening the plunger during spring installa-
tion. Do not preload the spring.
vmr2015-021-045_a
1. Crankshaft locking bolt
10. Finally, tighten the chain tensioner plug to

specification.
tmr2013-069-007_a
FOR CLARITY PARTS ARE REMOVED FROM CYLINDER CHAIN TENSIONER PLUG
1. Plunger
2. Notch 4.5 N•m ± 0.5 N•m
3. Spring Tightening torque
4. Spring end
5. Plug with O-ring
8. Then compress the spring and screw the plug CAMSHAFT TIMING GEAR
in.
Camshaft Timing Gear Removal
NOTE: To avoid overstressed timing chain, the
Remove the valve cover, refer to TOP END sub-
plug must engage into threads within the first full
section.
turn.
Turn crankshaft to TDC ignition and lock crank-
shaft, refer to CRANKSHAFT LOCKING PROCE-
DURE in the BOTTOM END subsection.
Unscrew timing chain tensioner. Refer to TIMING
CHAIN TENSIONER in this subsection.
vmr2015-020 153
Remove:
– Camshaft timing gear retaining screws
vmr2015-020-005_b
vmr2015-020-008_a
1. Camshaft timing gear retaining screws
2. Camshaft timing gear 1. Mating surface on camshaft
2. Threads for camshaft screws
NOTE: Secure timing chain with a piece of wire.
2. Crankshaft must be locked at TDC position
Camshaft Timing Gear Inspection before installing the timing chain, refer to
CRANKSHAFT LOCKING PROCEDURE in the
Check camshaft timing gear for wear or deteriora- BOTTOM END subsection.
tion.
3. Install the camshaft timing tool on the cylinder
If gear is worn or damaged, replace it as a set with head.
the timing chain.
For crankshaft gear, refer to BOTTOM END sub- REQUIRED TOOL
section, see CRANKSHAFT. CAMSHAFT TIMING TOOL
(P/N 529 036 268)
Camshaft Timing Gear Installation
The installation is the reverse of the removal pro- NOTE: Align tube of camshaft adjustment tool
cedure. However, pay attention to the following. properly with machined radius on cylinder head.
1. Clean mating surface and threads of camshaft
prior installing camshaft timing gear.
vmr2015-020-009_a
CAMSHAFT TIMING TOOL INSTALLED

1. Tube (camshaft adjustment tool)
2. Machined radius (camshaft adjustment tool)
3. Cylinder head
154 vmr2015-020
4. Set camshaft to TDC ignition position by align- 7. Install and tighten camshaft timing gear retain-
ing the camshaft flange flat spot with the tool ing screws to specified torque.
lever.
NOTE: In addition, to ensure proper camshaft tim-
ing, press camshaft adjustment tool lever down-
wards.
vmr2015-020-012_a
1. Camshaft timing gear

2. Timing gear retaining screws
CAMSHAFT TIMING GEAR RETAINING SCREWS

vmr2015-020-010_a
LOCTITE 243 (BLUE)
PRESS TOOL LEVER DOWN Service product
1. Lever (P/N 293 800 060)
2. Flat spot
3. Camshaft 10 N•m ± 1 N•m
Tightening torque
NOTICE Crankshaft and camshaft must
be locked at TDC ignition position to place 8. Remove the CAMSHAFT TIMING TOOL (P/N 529
camshaft timing gear and timing chain in the 036 268).
proper position.
5. Place camshaft timing gear along with the tim- TIMING CHAIN
ing chain on the camshaft. Timing Chain Removal
NOTE: The printed marks on the camshaft timing Remove engine from vehicle, refer to ENGINE RE-
gear must be parallel to the cylinder head base. MOVAL/INSTALLATION subsection.
Refer to MAGNETO AND STARTER SYSTEM sub-
section and remove following parts:
– Magneto cover
– Rotor.
Refer to TOP END subsection and remove the
valve cover.
Refer to GEARBOX AND 4X4 COUPLING UNIT
subsection and remove the output shaft.
NOTE: Mark the operating direction of the timing
chain and check for excessive radial play before
removal. Refer to TIMING CHAIN INSPECTION.
vmr2015-020-011_a
– Chain tensioner
1. Timing chain
2. Camshaft timing gear – Camshaft timing gear.
3. Printed marks on camshaft timing gear
6. Install and adjust timing chain tensioner, refer to

TIMING CHAIN TENSIONER in this subsection.
vmr2015-020 155
Check timing chain guides for wear, cracks or de-

forming. Replace as required.
NOTE: Check also the timing chain guide (ten-
sioner side).
Timing Chain Installation

Install timing chain with camshaft timing gear.
NOTE: Ensure to carry out proper valve timing, re-
fer to CAMSHAFT TIMING GEAR in this subsec-
tion.
vmr2015-020-013_a NOTICE Improper valve timing will damage
1. Timing chain guide (tensioner side) engine components.
2. Timing chain
Carefully pull the timing chain downwards and TIMING CHAIN GUIDE
sideways, then out of the crankcase. (TENSIONER SIDE)
Timing Chain Inspection Timing Chain Guide Removal
Check timing chain on camshaft timing gear for (Tensioner Side)
excessive radial play. Refer to procedures in this subsection and re-
move:
– Camshaft timing gear
– Timing chain.
Remove:
– Bearing screw
– Timing chain guide (tensioner side).
vmr2015-020-005_c
CHECKING TIMING CHAIN RADIAL PLAY
Check chain condition for wear and teeth condi-

tion.
vmr2015-020-015_a
1. Bearing screw
2. Timing chain guide (tensioner side)
Timing Chain Guide Inspection

vmr2006-044-018_a
(Tensioner Side)
1. Timing chain Check timing chain guide for wear, cracks or de-
forming. Replace if necessary.
If chain is excessively worn or damaged, replace
it as a set (camshaft timing gear and timing chain).
156 vmr2015-020
Timing Chain Guide Installation

(Tensioner Side)
cedure.
TIMING CHAIN GUIDE BEARING SCREW
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
10 N•m ± 1 N•m
Tightening torque
vmr2015-020 157
TIMING CHAIN
SERVICE TOOLS
CAMSHAFT TIMING TOOL ........................................................... 529 036 268 ......................................... 117
CRANKSHAFT TDC POSITION TOOL ........................................... 529 036 201 ................................. 117, 121
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ................................. 118, 123
vmr2016-034 113
4,5 ± 0,5 N•m

(40 ± 4 lbf•in)
0,1 N•m
(0.89 lbf•in)
Engine oil
6 ± 0,7 N•m
10 ± 1 N•m (53 ± 6 lbf•in)
(89 ± 9 lbf•in) Loctite 243
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
6 ± 0,7 N•m
(53 ± 6 lbf•in)
Loctite 243
0,1 N•m
(0.89 lbf•in)
Engine oil
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
4,5 ± 0,5 N•m
(40 ± 4 lbf•in)
vmr2015-033-010_a
114 vmr2016-034
TROUBLESHOOTING Timing Chain Tensioner Access

For the front cylinder chain tensioner, refer to
UNUSUAL ENGINE NOISE OR VIBRATION BODY subsection and remove the following:
1. IMPROPER VALVE CLEARANCE ADJUSTMENT – Seat
AND/OR WORN OUT ROCKER ARM(S) – RH side panel and extension.
- Readjust valve clearance and/or replace defective
part(s), refer to TOP END subsection. For the rear cylinder chain tensioner, refer to
BODY subsection and remove the following:
2. DEFECTIVE CHAIN TENSIONER – Seat
- Replace chain tensioner. – LH side panel and extension.
3. WORN OUT TIMING CHAIN GUIDE(S) For the rear cylinder chain tensioner, also remove
- Replace timing chain guide(s). the outer exhaust system heat shield. Refer to
EXHAUST SYSTEM subsection.
4. STRETCHED TIMING CHAIN OR WORN OUT
TIMING GEARS
- Replace timing chain and timing gears.
5. LOOSE TIMING GEAR RETAINING SCREWS
- Retighten screws to recommended torque.
camshaft timing.
ENGINE LACKS ACCELERATION OR

POWER
camshaft timing. vmr2015-033-100_a
1. Heat shield to remove

PROCEDURES
Removing the Timing Chain Tensioner
TIMING CHAIN TENSIONERS 1. Make sure the applicable piston is set to TDC ig-
nition. Refer to CAMSHAFT TIMING GEARS in
Timing Chain Tensioner Location this subsection.
The timing chain tensioner is located on the back 2. Carefully remove chain tensioner screw plug
of each cylinder head. and release spring tension.
CAUTION Tensioner is spring loaded.

3. Remove:
– O-ring
– Spring
– Chain tensioner plunger.
tmr2011-045-005_a
1. Timing chain tensioner
vmr2016-034 115
Installing the Timing Chain Tensioner

NOTE: Before installing the chain tensioner, make
sure the camshaft timing gear can be moved back
and forth.
vmr2006-043-004_a
1. Chain tensioner screw plug

2. O-ring
3. Spring
4. Chain tensioner plunger
4. Remove:
– Chain tensioner housing retaining screws
– Chain tensioner housing
– O-ring.
tmr2011-045-003_a
MOVE GEAR BACK AND FORTH
1. Apply engine oil on the chain tensioner plunger

before installation.
2. Slightly turn the camshaft timing gear in order
to move the timing chain excess play to the ten-
sioner side.
3. Slightly screw in the plunger until the timing
chain does not allow back and forth movement
of the camshaft timing gear.
4. Screw the plunger in an additional 1/8 turn to
obtain the required specified torque.
TIMING CHAIN TENSIONER ADJUSTMENT
(TIGHTENING TORQUE)
vmr2006-043-005_a 0.1 N•m (.9 lbf•in)
1. Screws
2. Chain tensioner housing
3. O-ring NOTICE Improper adjustment of the timing
chain will lead to severe engine damage.
Inspecting the Timing Chain Tensioner 5. Insert the spring on one side into the slot of the
Check chain tensioner housing and screw plug for chain tensioner screw plug, and on the other
cracks or other damages. Replace if necessary. side, into the plunger.
Check chain tensioner plunger for freedom of NOTE: Turn spring only clockwise in order to fit
movement and/or scoring. the spring end into the notch of the plunger to
Ensure O-rings are not brittle, cracked or hard. Re- avoid loosening the plunger during spring installa-
place if necessary. tion. Do not preload the spring.
Check spring condition. Replace if bent, broken or NOTE: Do not forget to place the O-ring on chain
worn. tensioner screw plug.
116 vmr2016-034
6. Then compress the spring and screw the plug Installing the Camshaft Timing Gear
in. For installation, reverse the removal procedure.
NOTE: To avoid overstressing the timing chain, Pay attention to the following details.
the chain tensioner screw plug must engage in 1. Clean camshaft mating surface and threads
the tensioner bore threads within the first full prior to installing camshaft timing gear.
turn.
7. Remove locking tool and install all other re-
moved parts.
8. Tighten the chain tensioner screw plug.
CAMSHAFT TIMING GEARS

Removing the Camshaft Timing Gear
1. Remove valve cover, refer to TOP END subsec-
tion.
2. Set applicable piston to TDC ignition and lock
magneto flywheel. Refer to CAMSHAFT TIM-
ING in this subsection.
3. Remove timing chain tensioner. Refer to TIM- tmr2011-045-004_a
ING CHAIN TENSIONERS in this subsection. 1. Camshaft mating surface

2. Camshaft screw threads
4. Remove camshaft timing gear retaining
screws. 2. Set applicable piston to TDC ignition position
and install the crankshaft position tool, refer to
CAMSHAFT TIMING in this subsection.
REQUIRED TOOL
CRANKSHAFT TDC
POSITION TOOL
(P/N 529 036 201)
3. Install camshaft timing tool on the cylinder

head.
REQUIRED TOOL
CAMSHAFT TIMING TOOL

(P/N 529 036 268)
NOTE: Properly align tube of camshaft timing tool

tmr2011-045-003_b
with machined radius on cylinder head.
TYPICAL
1. Camshaft timing gear retaining screws
5. Remove the camshaft timing gear.

NOTE: Secure timing chain with a piece of wire.
Inspecting the Camshaft Timing Gear

Check camshaft timing gear for wear or deteriora-
tion.
If timing gear is worn or damaged, replace it as a
set with the timing chain.
For crankshaft gear inspection, refer to CRANK-
SHAFT in the BOTTOM END subsection.
vmr2016-034 117
vmr2015-033-001_a vmr2015-033-003_a
CAMSHAFT TIMING TOOL INSTALLED 1. Timing chain

1. Tube (camshaft timing tool) 2. Camshaft timing gear
2. Machined radius (camshaft timing tool) 3. Printed marks on camshaft timing gear
3. Cylinder head
6. Install and adjust timing chain tensioner, refer to
4. Set camshaft to TDC ignition position by align- TIMING CHAIN TENSIONER in this subsection.
ing the flat portion on the camshaft flange with
the tool lever. 7. Install and tighten camshaft timing gear retain-
ing screws to specified torque.
NOTE: In addition, to ensure proper camshaft tim-
ing, press camshaft timing tool lever downwards.
vmr2015-033-004_a

vmr2015-033-002_a 2. Timing gear retaining screws
PRESS TOOL LEVER DOWN
1. Lever SERVICE PRODUCT
2. Flat portion
3. Camshaft Camshaft timing gear LOCTITE 243 (BLUE)
retaining screws (P/N 293 800 060)
NOTICE Crankshaft and camshaft must
be locked at TDC ignition position to place TIGHTENING TORQUE
camshaft timing gear and timing chain in the
proper position. Camshaft timing gear 10 N•m ± 1 N•m
5. Place camshaft timing gear and timing chain on
the camshaft. 8. Remove the camshaft timing tool.
NOTE: The printed marks on the camshaft timing
gear must be parallel to the cylinder head base. Camshaft Timing
NOTE: If a piston (cylinder 1 or 2) is set to TDC
ignition, the camshaft timing gear of the opposite
cylinder must be in the following position.
118 vmr2016-034
tmr2011-045-011_a
vmr2015-033-006_a
TYPICAL
1. Cylinder head base 1. CPS
2. Marks on timing gear of the opposite cylinder 2. Screw
Camshaft Timing Piston No. 2 (rear) 5. Set rear piston no. 2 to TDC ignition by turning
1. Remove spark plugs of both cylinders. the crankshaft clockwise.
2. Remove valve covers of both cylinders. REQUIRED TOOL
3. Remove the screw plug and O-ring from mag- Allen key 14 mm
neto cover.
vmr2015-033-007_a
vmr2015-033-005_a
TURN CRANKSHAFT CLOCKWISE TO PISTON NO. 2 TDC
1. Screw plug 1. Allen key 14 mm
2. O-ring
5.1 The rear piston is at TDC when it's index
4. Remove the crankshaft position sensor (CPS). mark on the magneto flywheel is aligned
with the notch in the magneto cover.
vmr2016-034 119
3. To set front piston no. 1 to TDC ignition turn

crankshaft 280° counterclockwise.
REQUIRED TOOL
Allen key 14 mm
vmr2007-037-008_b
PISTON NO. 2 AT TDC

1. Piston no. 2 identifier
2. Index mark on magneto flywheel
3. Notch on magneto cover
4. CPS bore in magneto cover
5.2 Confirm printed marks on the camshaft

timing gear are parallel with cylinder head vmr2015-033-007_b
base, in the lowest position. In this posi- TURN COUNTERCLOCKWISE 280° TO NUMBER 1 PISTON TDC
1. Allen key 14 mm
tion the piston is set to TDC ignition.
NOTE: If marks on camshaft timing gear are 3.1 The front piston is at TDC when it's index
not as specified, turn crankshaft 360°. mark on the magneto flywheel is aligned
with the notch in the magneto cover.
tmr2011-045-003_c
TYPICAL - PISTON AT TDC IGNITION vmr2007-036-006_b

1. Printed marks on camshaft timing gear CYLINDER 1 AT TDC
2. Cylinder head base 1. Number 1 piston identifier
2. Index mark “1” on magneto flywheel
6. Install the crankshaft TDC position tool to lock 3. Notch on magneto cover
4. Crankshaft position sensor bore
crankshaft in position. Refer to CRANKSHAFT
TDC POSITION TOOL in this subsection. 3.2 Confirm printed marks on the camshaft
Camshaft Timing Piston No. 1 (front) timing gear are parallel with cylinder head
base, in the lowest position. In this posi-
1. Set rear piston no. 2 to TDC ignition, see tion the piston is set to TDC ignition.
CAMSHAFT TIMING PISTON NO. 2 (REAR) in
this subsection.
2. Remove crankshaft TDC position tool.
120 vmr2016-034
vmr2015-033-008_a
MAGNETO COVER
1. Crankshaft TDC position tool installed in CPS bore
tmr2011-045-003_c
TYPICAL - PISTON AT TDC IGNITION NOTICE Tool must be fully inserted.

4. Insert the crankshaft TDC position tool to lock

crankshaft in position. Refer to CRANKSHAFT
TDC POSITION TOOL INSTALLATION in this
subsection.
Crankshaft TDC Position Tool Installation
NOTICE Never use crankshaft TDC position
tool to remove or tighten drive CVT screw or
rotor retaining screw. Damage to the teeth of
the trigger wheel on the rotor will occur.
Install tool in magneto cover CPS bore.
REQUIRED TOOL
vmr2015-033-009_a
CRANKSHAFT TDC 1. Magneto cover
POSITION TOOL 2. TDC position tool
(P/N 529 036 201)
NOTE: Make sure to match the teeth on the

TIMING CHAIN
crankshaft TDC position tool with the magneto Timing Chain Location
rotor.
The engine is equipped with two timing chains.
– MAG side timing chain is located behind the
magneto cover.
– PTO side timing chain is located behind the PTO
cover.
Removing the Timing Chain (MAG

Side)
1. Refer to MAGNETO AND STARTER subsection
– Magneto cover
tmr2011-045-020_a
1. Crankshaft TDC position tool teeth (end view)

– Rotor
– Sprag clutch gear.
vmr2016-034 121
2. Refer to TOP END subsection and remove the

following part:
– Valve cover.
3. Refer to following procedures in this subsection
– Chain tensioner
4. Remove timing chain guide (tensioner side) and
lower timing chain guide.
tmr2011-045-015_a
1. Timing chain
2. Lower timing chain guide

removal. Refer to TIMING CHAIN INSPECTION.
5. Carefully pull the timing chain sideward and
down from the crankcase.
Inspecting the Timing Chain

Inspection is the same for both timing chains.
Vmr2012-016-005_a
Check timing chain on camshaft timing gear for
1. Timing chain
2. Lower timing chain guide excessive radial play.

removal. Refer to TIMING CHAIN INSPECTION .
5. Carefully pull the timing chain downwards and
sideways, then out of the crankcase.
Removing the Timing Chain (PTO

Side)
1. Refer to BOTTOM END subsection and remove
following parts:
– PTO cover
– Breather gear
– Intermediate gear.
2. Refer to TOP END subsection and remove fol-
lowing part: tmr2011-045-003_d
CHECKING TIMING CHAIN RADIAL PLAY

– Valve cover.
3. Refer to applicable procedures in this subsec- Check chain condition for wear and teeth condi-
tion and remove following parts: tion.
– Chain tensioner
4. Remove timing chain guide (tensioner side) and
lower timing chain guide.
122 vmr2016-034
Inspecting the Timing Chain Guide

(Tensioner Side)
Check timing chain guide for wear, cracks or de-
formation. Replace if necessary.
Installing the Timing Chain Guide

vmr2006-044-018_a
(Tensioner Side)
1. Timing chain
If chain is excessively worn or damaged, replace cedure.
it as a set (camshaft timing gear and timing chain).
SERVICE PRODUCT
Check timing chain guides for wear, cracks or de-
formation. Replace as required. Timing chain guide LOCTITE 243 (BLUE)
bearing screw (P/N 293 800 060)
NOTE: Check also the timing chain guide (ten-
sioner side). TIGHTENING TORQUE
Installing the Timing Chain Timing chain guide 10 N•m ± 1 N•m

bearing screw (89 lbf•in ± 9 lbf•in)
The installation is essentially the reverse of the re-
moval procedure however, pay attention to the fol-
lowing details.
NOTE: Installation is the same for both timing
chains.
Install timing chain with camshaft timing gear.
NOTE: Ensure to carry out proper valve timing, re-
fer to CAMSHAFT TIMING GEARS in this subsec-
tion.
NOTICE Improper valve timing will damage
engine components.
TIMING CHAIN GUIDE

(TENSIONER SIDE)
tmr2011-045-019_a

2. Bearing screw
Removing the Timing Chain Guide

(Tensioner Side)
Refer to TIMING CHAIN in this subsection.
vmr2016-034 123
Subsection 10 (BOTTOM END)
BOTTOM END
SERVICE TOOLS
BEARING INSTALLER (GEARBOX) ............................................... 529 035 762 ......................................... 172
BEARING INSTALLER (GEARBOX) ............................................... 529 035 763 ......................................... 171
CRANKCASE SUPPORT (MAG SIDE) ........................................... 529 035 916 ................................. 169–170
CRANKCASE SUPPORT PTO ........................................................ 529 035 754 ................................. 169–170
CRANKSHAFT LOCKING BOLT..................................................... 529 035 617 ................................. 176, 180
DIAL INDICATOR ADAPTER ......................................................... 529 036 159 ......................................... 175
HANDLE ........................................................................................ 420 877 650 ................. 162, 169, 171–172
OIL SEAL INSTALLER ................................................................... 529 036 069 ......................................... 169
OUTPUT SHAFT SEAL INSTALLER .............................................. 529 035 941 ......................................... 162
PLAIN BEARING REMOVER/INSTALLER ..................................... 529 035 917 ................................. 169–170
TDC DIAL INDICATOR .................................................................. 414 104 700 ......................................... 175
SERVICE PRODUCTS
LOCTITE 5910 ............................................................................... 293 800 081 ......................................... 173
vmr2015-021 159
CRANKCASE
25 ± 3 N•m
Loctite 243 (18 ± 2 lbf•ft)
Petamo Grease
NEW
10 ± 1 N•m 10 ± 1 N•m
(89 ± 9 lbf•in) (89 ± 9 lbf•in)
NEW
Multi Purpose
Loctite 5910 Grease BP LS3
10 ± 1 N•m
(89 ± 9 lbf•in)
25 ± 3 N•m
(18 ± 2 lbf•ft)
25 ± 3 N•m
(18 ± 2 lbf•ft)
Loctite 5910
Engine oil
10 ± 1 N•m
(89 ± 9 lbf•in)
NEW
Loctite 5910 Engine oil
25 ± 3 N•m
(18 ± 2 lbf•ft) 12 ± 1 N•m
(106 ± 9 lbf•in)
10 ± 1 N•m Loctite 243
Engine oil
NEW
Engine oil
Multi Purpose Grease BP LS3
NEW
Engine oil
Petamo Grease
NEW

vmr2015-021-001_a
160 vmr2015-021
CRANKSHAFT/BALANCER SHAFT
Engine oil
Engine oil
Engine oil See tightening

procedure
NEW
35 ± 4 N•m
(26 ± 3 lbf•ft)
Loctite 243
Engine oil

vmr2015-021-002_a
vmr2015-021 161
GENERAL
This section includes the procedures pertaining
to the crankcase, crankshaft and balancer shaft.
For the gearbox, follow the procedure for the
CRANKCASE then refer to GEARBOX AND 4X4
COUPLING UNIT subsection.
During assembly / installation, use the 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
vmr2015-021-003_a
must strictly be adhered to. 1. Output shaft oil seal
Locking devices when removed (e.g.: locking 2. Bearing flange
tabs, elastic stop nuts, self-locking fasteners,
etc.) must be installed or replaced with new Drain engine oil, refer to ENGINE OIL CHANGE
ones where specified. If the efficiency of a in the PERIODIC MAINTENANCE PROCEDURES
locking device is impaired, it must be re- subsection.
newed. Disconnect the rear propeller shaft from output
shaft, refer to REAR DRIVE subsection.
PROCEDURES Using a small screwdriver, remove the output
IMPORTANT: Note position of parts on disas- shaft oil seal from bearing flange.
sembly. This may help to find the root cause of NOTICE Avoid scratching the bearing flange
a problem. A component that is not replaced or output shaft during oil seal removal.
originally mounted. Check oil seal seating surface for grooves. Re-
place bearing flange if necessary.
OUTPUT SHAFT OIL SEAL Check bearing behind oil seal for contamination
and/or metal shavings. Replace if necessary.
Output Shaft Oil Seal Removal
Replace oil seal if brittle, hard or otherwise dam- Output Shaft Oil Seal Installation
aged.
REQUIRED TOOL
NOTE: The output shaft oil seal can be removed
and installed without removing the engine from
OUTPUT SHAFT SEAL
vehicle.
HANDLE (P/N 420 877 650)
162 vmr2015-021
Counter Shaft Oil Seal Installation

Using a suitable tube with the proper diameter to
install the oil seal.
Install all removed parts.
SHIFT SHAFT OIL SEAL

Shift Shaft Oil Seal Removal
Replace oil seal if brittle, hard or otherwise dam-
aged.
NOTE: The shift shaft oil seal can be removed
without removing the engine from vehicle.
vmr2015-021-004_a
1. Outputshaftseal installer
2. Handle
Install all remaining removed parts. Refer to appli-

cable subsections.
COUNTER SHAFT OIL SEAL

Counter Shaft Oil Seal Removal
aged.
NOTE: The counter shaft oil seal can be removed
without removing the engine from vehicle.
Remove the driven pulley. Refer to CONTINU- vmr2015-021-007_a
OUSLY VARIABLE TRANSMISSION subsection. 1. Shift shaft oil seal
2. Shift shaft
Scribe a mark on the end of shift shaft and on

shifting plate.
Unscrew shifting plate bolt then remove shifting
plate.
vmr2015-021-005_a
1. Counter shaft oil seal

2. Counter shaft
3. Crankcase, PTO side
Using a small screwdriver, remove the counter

shaft oil seal.
NOTICE Avoid scratching the crankcase or vmr2015-024-012_a
counter shaft during oil seal removal. 1. Index mark
Using a small screwdriver, remove the shift shaft

oil seal.
vmr2015-021 163
NOTICE Avoid scratching the crankcase or CRANKCASE

shift shaft during oil seal removal.
Crankcase Disassembly
Shift Shaft Oil Seal Installation NOTE: Oil pump removal from crankcase MAG
Using a suitable tube, with the proper diameter, side is not necessary, but recommended to see
install the seal. condition of oil pump, refer to LUBRICATION
SYSTEM subsection.
Align the previously scribed marks and install the
shift plate. Remove:
Tighten shift plate screw to specification. – Engine from vehicle, refer to ENGINE RE-
MOVAL AND INSTALLATION subsection
SHIFT PLATE – Magneto cover and rotor, refer to MAGNETO
9 N•m ± 1 N•m AND STARTER subsection
Tightening torque
(80 lbf•in ± 9 lbf•in) – Output shaft, refer to GEARBOX AND 4X4
UNIT subsection
CRANKSHAFT OIL SEAL – Cylinder head and cylinder, refer to TOP END
subsection
Crankshaft Oil Seal Removal – Drive and driven pulley, refer to CONTINU-
Replace oil seal if brittle, hard or otherwise dam- OUSLY VARIABLE TRANSMISSION subsection
aged. – Oil pressure switch, refer to LUBRICATION
NOTE: The crankshaft oil seal can be removed SYSTEM subsection.
without removing the engine from vehicle. Measure axial clearance between the crankshaft
and crankcase PTO with a feeler gauge.
vmr2015-021-008_a
1. Crankshaft oil seal

2. Crankshaft, PTO side
Remove the drive pulley. Refer to CONTINU-

OUSLY VARIABLE TRANSMISSION subsection. vmr2015-021-010_a
1. Feeler gauge
Using a small screwdriver, remove the crankshaft
oil seal. CRANKSHAFT AXIAL CLEARANCE
NOTICE Avoid scratching the crankcase or 0.1 mm to 0.4 mm
NEW
crankshaft during oil seal removal. (.004 in to .016 in)
Crankshaft Oil Seal Installation
Using a suitable tube with the proper diameter to If measurement is out of specification, in-
install the seal. spect butting faces of crankshaft and crankcase
(MAG/PTO side) for excessive wear.
Remove:
– Timing chain
164 vmr2015-021
– Intermediate gear of oil pump

– Drive gear of water pump.
vmr2015-021-012_a
1. 2x screws M8 x 85
2. 1x screw M6 x 16
vmr2015-021-011_a
1. Timing chain Place the crankcase on a wood stand, MAG side

2. Intermediate gear, oil pump
3. Drive gear, water pump upwards.
Remove crankshaft locking bolt. Split crankcase with 2 screwdrivers.
vmr2015-021-045_a vmr2015-021-013_a

POSITION FOR BIG FLAT SCREWDRIVER
Remove crankcase retaining screws:
1. Start removing the M6 screws
2. Then remove the M8 screws.
vmr2015-021 165
vmr2015-021-014_a vmr2015-021-018_a
POSITION FOR BIG FLAT SCREWDRIVER CRANKCASE MAG SIDE
1. Oil orifices
Crankcase Cleaning
Clean all metal components in a solvent.
clogged.
vmr2015-021-035_a
CRANKCASE MAG SIDE

1. Oil orifices
vmr2015-021-015_a
CRANKCASE MAG SIDE

1. Oil orifices
vmr2015-021-016_a
CRANKCASE MAG SIDE vmr2015-021-017_a

1. Oil orifices
CRANKCASE PTO SIDE
1. Oil orifices
2. Engine blow by bore
166 vmr2015-021
vmr2015-021-053_a
MAGNETO COVER vmr2015-021-019_a

1. Oil orifices
MAG PLAIN BEARING
1. Plain bearing
2. Oil bore
A. Plain bearing inside diameter
vmr2015-021-052_a
MAGNETO COVER
1. Oil orifices
vmr2015-021-020_a
Clean crankcase mating surfaces using a com- PTO PLAIN BEARING
bination of LOCTITE CHISEL (GASKET REMOVER) 1. Plain bearing
(P/N 413 708 500) and a brass brush. First brush 2. Oil bore
in one direction then make the final brushing A. Plain bearing inside diameter
perpendicularly (90°) to the first pass. PLAIN BEARING INSIDE DIAMETER (MAG/PTO)
NOTICE Do not wipe with rags. Use a new SERVICE LIMIT 42.100 mm (1.6575 in)
clean hand towel only.
Ball and Needle Bearings
Crankcase Inspection
Check ball bearings and needle bearings for ex-
NOTE: To check some parts, it is recommended cessive play and smooth operation. Replace if
to remove all components from crankcase. necessary.
Crankshaft Plain Bearing
Check MAG and PTO plain bearings for scoring or
other damages.
Measure plain bearing inside diameter.
Compare measurements to MAG/PTO main
journal diameters of crankshaft, refer to CRANK-
SHAFT in this subsection.
Replace if the measurement is out of specifica-
tion.
vmr2015-021 167
vmr2015-021-021_a
CRANKCASE MAG
1. Balancer shaft ball bearing
2. Counter shaft needle bearing
3. Bevel gear needle bearing vmr2015-021-023_a
CRANKCASE PTO
Balancer Shaft Oil Seal

aged.
vmr2015-021-022_a
CRANKCASE PTO
2. Counter shaft ball bearing
3. Bevel gear ball bearing
vmr2015-021-024_a
CRANKCASE PTO
1. Balancer shaft oil seal
Balancer Shaft Oil Seal Replacement

Procedure
Balancer Shaft Oil Seal Removal
Remove balancer shaft ball bearing, refer to
BEARING REPLACEMENT PROCEDURE in this
subsection.
The oil seal is removed easily with a flat screw-
driver.
168 vmr2015-021
NOTICE Always support crankcase properly

when ball bearings, needle bearings or plain
bearings are removed or installed; otherwise,
crankcase could be damaged.
Unless otherwise instructed, never use hammer
to install ball bearings, needle bearings or plain
bearings. Use press machine only.
NOTICE Ball bearings have to be installed
with closed bearing cage to the engine out-
side.
Crankshaft Plain Bearing Removal
NOTE: Always use a press for removal or installa-
vmr2015-021-025_a
tion of plain bearing halves.
CRANKCASE PTO
1. Balancer shaft oil seal Carefully press the plain bearings out from the
NOTICE Avoid scoring bearing seat or oil crankcase half from inside towards the outside.
seal bore in crankcase. NOTE: Use proper crankcase support when re-
moving plain bearings.
Balancer Shaft Oil Seal Installation
REQUIRED TOOL
NOTICE Oil seal must be installed with seal-
ing lip towards balancer shaft. PLAIN BEARING
REMOVER/INSTALLER
REQUIRED TOOL (P/N 529 035 917)
OIL SEAL INSTALLER (P/N 529 CRANKCASE SUPPORT (MAG

036 069) SIDE) (P/N 529 035 916)
HANDLE (P/N 420 877 650)

CRANKCASE SUPPORT PTO
(P/N 529 035 754)
vmr2015-021-026_a
CRANKCASE, PTO SIDE

1. Balancer shaft oil seal vmr2015-021-027_a
2. Oil seal installer
3. Handle CRANKCASE MAG SIDE
1. Crankcase support MAG
Bearing Replacement Procedure

NOTICE Clean oil, outside and inside, from
crankcase.
vmr2015-021 169
REQUIRED TOOL
PLAIN BEARING
REMOVER/INSTALLER
(P/N 529 035 917)
CRANKCASE SUPPORT (MAG

SIDE) (P/N 529 035 916)
CRANKCASE SUPPORT PTO

(P/N 529 035 754)
Use an O-ring (Ø 42 mm (1.65 in) x

vmr2015-021-028_a 1 mm to 1.5 mm (.04 in to .06 in) thickness)
CRANKCASE PTO SIDE to hold plain bearings in place during installation.
1. Crankcase support PTO
The O-ring will disappear in the groove of the
plain bearing remover/installer.
vmr2015-021-029_a
PRESS PLAIN BEARINGS OUTSIDE

1. Plain bearing remover/installer vmr2015-021-027_a
2. Plain bearing CRANKCASE MAG SIDE

3. Crankcase (PTO side shown) 1. Crankcase support MAG
Crankshaft Plain Bearing Installation

NOTICE Unless otherwise instructed, never
use hammer to install plain bearings. Use
press only.
NOTE: Use proper crankcase support when in-
stalling plain bearings. Damage to crankcase may
occur if this procedure is not performed correctly.
Carefully press in the plain bearings in the same di-
rection as during disassembly, from the crankcase
inside towards the outside.
Install plain bearings in a cold crankcase.
NOTE: Do not lubricate plain bearings and/or
crankcase for installation. vmr2015-021-028_a
CRANKCASE PTO SIDE

1. Crankcase support PTO
Mark position of plain bearing oil bore on plain

bearing remover/installer.
170 vmr2015-021
Mark position of oil bore on crankcase half.

Align mark on plain bearing remover/installer with
mark on crankcase half.
vmr2015-021-020_b
CRANKCASE PTO
1. Oil bore
2. Partition
Bevel Gear Needle Bearing Removal

vmr2015-021-030_a
Remove bevel gear needle bearing using a punch.
PRESS PLAIN BEARINGS INSIDE
1. Oil bore position marked on plain bearing remover/installer
2. Plain bearing oil bore
3. Oil bore position marked on crankcase
NOTICE Misalignment of the plain bearing

and crankcase oil bores will prevent proper oil
supply to plain bearings.
Carefully press in the plain bearings from inside
the crankcase towards the outside.
NOTICE The partition of the plain bearings in
crankcase half MAG side must be positioned
near to oil bore in counterclockwise direction.
vmr2015-021-031_a
1. Bevel gear needle bearing

2. Punch
Bevel Gear Needle Bearing Installation

REQUIRED TOOL
BEARING INSTALLER
(GEARBOX) (P/N 529 035 763)
HANDLE (P/N 420 877 650)
vmr2015-021-019_b
CRANKCASE MAG
1. Oil bore
2. Partition
NOTICE The partition of the plain bearings

in crankcase half PTO side must be positioned
near to oil bore in counterclockwise direction.
vmr2015-021 171
vmr2015-021-032_a vmr2015-021-034_a
1. Bevel gear needle bearing 1. Counter shaft needle bearing

2. Needle bearing installer 2. Needle bearing installer
3. Handle 3. Handle
Counter Shaft Needle Bearing Removal Starter Drive Needle Bearing Replacement
Remove counter shaft needle bearing, using a For starter drive needle bearing replacement refer
punch. to MAGNETO AND STARTER subsection.
Balancer Shaft (PTO side) and Bevel Gear Ball
Bearing Removal
To remove ball bearings use a blind hole bearing
puller.
vmr2015-021-033_a
1. Counter shaft needle bearing

2. Hole in crankcase MAG side
Counter Shaft Needle Bearing Installation

REQUIRED TOOL
BEARING INSTALLER vmr2015-021-022_b

(GEARBOX) (P/N 529 035 762) CRANKCASE PTO
HANDLE (P/N 420 877 650)
REQUIRED TOOL
BLIND HOLE BEARING

PULLER SET (P/N 529 036 117)
Balancer Shaft (PTO side) and Bevel Gear Ball

Bearing Installation
Use a suitable installer for installing ball bearings.
172 vmr2015-021
Balancer Shaft (MAG side) Ball Bearing Crankcase Assembly

Removal The assembly is the reverse of the disassembly
procedure. However, pay attention to the follow-
ing.
faces.
IMPORTANT: When beginning the application of
the crankcase 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 polycarbonate plate and apply some sealant
on it. Use a soft rubber roller 50 mm to 75 mm
(2 in to 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
vmr2015-021-019_c
ready, apply the sealant on crankcase mating sur-
CRANKCASE MAG
1. Balancer shaft ball bearing faces.
Removed ball bearing with a suitable pusher from sealant as described here to get a uniform appli-
outside in. cation without lumps. If you do not use the roller
Balancer Shaft (MAG side) Ball Bearing method, you may use your finger to uniformly dis-
Installation tribute the sealant (using a finger will not affect
the adhesion). Do not apply in excess as it will
Use a suitable installer.
spread out inside crankcase.
Counter Shaft (PTO side) Ball Bearing
Removal
Remove screw.
Push ball bearing from outside in with a punch.
F12R17A
First tighten crankcase M8 retaining screws as per

following sequence:
vmr2015-021-037_a
1. Screw
CRANKCASE M8 RETAINING SCREWS
2. Counter shaft ball bearing
25 N•m ± 3 N•m
Tightening torque
Counter Shaft (PTO side) Ball Bearing (18 lbf•ft ± 2 lbf•ft)
Installation
Use a suitable installer.
NOTE: Install ball bearing with closed bearing
cage towards outside of engine.
vmr2015-021 173
vmr2015-021-045_a
vmr2015-021-012_b
Then tighten crankcase M6 retaining screws as Align the dot of crankshaft gear with the balancer
per following sequence. shaft gear dot then remove balancer shaft.
CRANKCASE M6 RETAINING SCREWS

10 N•m ± 1 N•m
Tightening torque
vmr2015-021-038_a
1. Crankshaft
2. Balancer shaft
3. Dots on crankshaft gear and balancer shaft gear
vmr2015-021-012_c
Balancer Shaft Inspection
M6 SCREWS TIGHTENING SEQUENCE Check balancer shaft and replace if damaged.
Check ball bearings on MAG and PTO side for
BALANCER SHAFT excessive play and smooth operation. Replace if
necessary.
Balancer Shaft Removal
Inspect the balancer shaft gear for chipped, worn
Split crankcase, refer to CRANKCASE in this sub-
or broken teeth. Replace balancer shaft if neces-
section.
sary.
Remove the crankshaft locking bolt.
NOTE: If any imperfection is detected, check also
the crankshaft gear, refer to CRANKSHAFT in this
subsection.
Balancer Shaft Installation

174 vmr2015-021
Align the dot on crankshaft gear with the balancer

shaft gear dot.
vmr2015-019-005_a
1. Plug screw
2. O-ring
3. Magneto cover
Set piston to TDC ignition by turning the crank-

vmr2015-021-039_a
shaft.
1. Mark on crankshaft gear
2. Mark on balancer shaft gear REQUIRED TOOL
13 mm socket
CRANKSHAFT
Crankshaft Locking Procedure
Disconnect spark plug cable and remove the spark
plug.
REQUIRED TOOL
TDC DIAL INDICATOR
(P/N 414 104 700)
DIAL INDICATOR ADAPTER
(P/N 529 036 159)
vmr2015-021-042_a
1. Wrench with 13 mm socket
TDC ignition
NOTICE Never use the mark on the magneto
to find the TDC. Only use the crankshaft locking
tool to locate the TDC.
Remove valve cover and verify if the printed
marks on the camshaft timing gear are parallel
with the cylinder head edge. If so, the engine is
at TDC ignition position.
vmr2015-021-040_a
1. Dial gauge NOTE: If printed marks on camshaft timing gear

2. Dial indicator adapter are not as specified, turn crankshaft 360°.
Remove the plug screw and O-ring from magneto NOTE: In this position the piston is set to TDC
cover. ignition.
vmr2015-021 175
vmr2015-020-005_d vmr2015-021-044_a
TYPICAL - PISTON AT TDC IGNITION 1. Screwdriver

Lock crankshaft.
Remove: REQUIRED TOOL
– Screw
CRANKSHAFT LOCKING BOLT
– Sealing ring. (P/N 529 035 617)
vmr2015-021-043_a
vmr2015-021-045_a
1. Screw
2. Sealing ring 1. Crankshaft locking bolt
3. Output shaft on front side of vehicle
Use a screwdriver to check if groove in crankshaft Crankshaft Removal

is aligned with the hole. Remove:
– Balancer shaft, see BALANCER SHAFT in this
subsection
– Crankshaft.
176 vmr2015-021
vmr2015-021-048_a
1. Crankshaft
vmr2015-021-046_a
2. Feeler gauge
1. Crankshaft
2. Crankcase PTO CONNECTING ROD BIG END AXIAL PLAY
Crankshaft Inspection and 0.100 mm to 0.452 mm
NEW
Disassembly (.004 in to .018 in)
Replace crankshaft if the gears are worn or other- SERVICE LIMIT 0.500 mm (.02 in)
wise damaged.
Refer to TOP END subsection.
Connecting Rod Big End Radial Play
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 rod from crankshaft.
NOTICE Connecting rod screws are not
reusable. Always discard screws and replace
by NEW ones. It is recommended to install
new plain bearings when reinstalling connect-
ing rods.
vmr2015-021-047_a
1. Balancer gear
2. Crankshaft timing gear
Connecting Rod Big End Axial Play

Using a feeler gauge, measure distance between
butting face of connecting rod and crankshaft 1
counterweight. If the distance exceeds specified
tolerance, replace the crankshaft. R400motr31A
1. Connecting rod screw
Measure crankpin. Compare to inside diameter of

connecting rod big end.
vmr2015-021 177
If the crank pin diameter is out of specification,

replace crankshaft.
CONNECTING ROD BIG END DIAMETER
1
If connecting rod big end diameter is out of spec-

ification, replace plain bearings and recheck.
CONNECTING ROD BIG END RADIAL PLAY
2
If connecting rod big end radial clearance is out of

specification, replace plain bearings and recheck.
Crankshaft Radial Play MAG/PTO Side
Measure crankshaft MAG/PTO side. Compare to
inside diameter of MAG/PTO plain bearings, refer
to CRANKCASE in this subsection.
R400motr32A
1. Micrometer
2. Crankpin area for plain bearings
CRANK PIN DIAMETER

40.001 mm to 40.025 mm
NEW
(1.5748 in to 1.5758 in)

replace crankshaft.
vmr2015-021-049_a
To measure the connecting rod big end diameter, 1. Micrometer
use the OLD screws. 2. Crankshaft, MAG side main bearing journal
Install the OLD plain bearings as they were
mounted initially.
Carry out the tightening procedure described in
CRANKSHAFT ASSEMBLY in this subsection. 2
R400motr35A
R400motr33A 1. Micrometer
2. Crankshaft area for PTO plain bearing
A. Connecting rod big end plain bearing
178 vmr2015-021
CRANKSHAFT MAG/PTO DIAMETER NOTICE Strictly adhere following instruc-

tions:
42.016 mm to 42.040 mm
NEW – Do not apply any thread locker.
(1.6542 in to 1.6551 in)
– The running direction of the big end bear-
SERVICE LIMIT 42.000 mm (1.6535 in) ings and of the piston pins must not change.
CRANKSHAFT MAG RADIAL PLAY – Always perform each step on both connect-
ing rod screws before going to the next step.
– Failure to strictly follow procedure may
cause connecting rod screws to loosen and
Crankshaft Assembly lead to severe engine damage.
The assembly is the reverse of the disassembly REQUIRED TOOL
procedure. However, pay attention to the follow-
ing. Torque wrench
Clean the split surface on both sides (cracked Angle torque wrench
area) carefully with compressed air.
Use NEW bearings, when connecting rod big end
diameter is out of specification.
Put plain bearings correctly in place.
vmr2015-021-050_a
1. Angle torque wrench
CONNECTING RODS SCREWS TIGHTENING

SEQUENCE
Step
Tighten to 1/2 of specified torque
1
Step Tighten to 20 N•m ± 2 N•m
R400motr36A 2 (15 lbf•ft ± 1 lbf•ft)
1. Half plain bearing of connecting rod big end Step Torque by an additional 60 ± 5° turn using
2. Split surface of the connecting rod 3 an angle torque wrench
3. Nose of bearing in line with connecting rod groove
Oil the plain bearing surface of the connecting rod Crankshaft Installation
and crank pin before installation.
NOTICE Lower cap and rod must match to- cedure. However, pay attention to following.
gether since there is a cracked surface. Install crankshaft first then balancer shaft.
Oil NEW connecting rod screws.
NOTICE Always use NEW connecting rod
screws for the final assembly. They are not
reusable.
Thread screws in connecting rod, then tighten as
per following procedure.
vmr2015-021 179
vmr2015-021-051_a
1. Crankshaft
2. Balancer shaft
Align the marks of crankshaft and balancer shaft.
vmr2015-021-039_a
1. Mark on crankshaft gear

2. Mark on balancer shaft gear
After reinstalling of crankcase MAG, measure ax-

ial clearance of crankshaft with a feeler gauge be-
tween PTO crankcase and crankshaft thrust sur-
face.
Install the CRANKSHAFT LOCKING BOLT (P/N 529
035 617) to keep the crankshaft in TDC position
before installing the camshaft timing chain (refer
to CRANKSHAFT LOCKING PROCEDURE in this
subsection).
NOTICE Make sure the woodruff key on
crankshaft MAG is present and correctly in
place.
180 vmr2015-021
BOTTOM END
SERVICE TOOLS
CRANKCASE SUPPORT MAG/PTO .............................................. 529 036 031 ......................................... 139
CRANKSHAFT LOCKING BOLT..................................................... 529 035 617 ......................................... 142
DRIVE SHAFT OIL SEAL INSTALLER ........................................... 529 036 028 ................................. 131–132
DRIVE SHAFT OIL SEAL PROTECTOR......................................... 529 036 029 ......................................... 130
PLAIN BEARING REMOVER/INSTALLER ..................................... 529 035 917 ......................................... 139
PLAIN BEARING REMOVER/INSTALLER ..................................... 529 036 032 ......................................... 134
PTO COVER OIL SEAL INSTALLER .............................................. 529 036 033 ......................................... 133
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 131
LOCTITE 5910 ............................................................................... 293 800 081 ......................................... 130
vmr2016-035 125
ENGINE DRIVE SHAFT
Engine oil
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 767
(antiseize lubricant)
Petamo
grease
Loctite
5910
Engine oil
Loctite
10 ± 1 N•m 5910
(89 ± 9 lbf•in)
Loctite
243 Engine oil
Petamo
grease
tmr2011-014-001_b
126 vmr2016-035
CRANKCASE AND PTO COVER
Engine oil
NEW
See tightening sequence

Loctite 243 25 ± 3 N•m
(18 ± 2 lbf•ft)
6 ± 0,7 N•m 10 ± 1 N•m

(53 ± 6 lbf•in) (89 ± 9 lbf•in)
NEW
Engine oil
25 ± 3 N•m
(18 ± 2 lbf•ft)
Engine oil
See
tightening 10 ± 1 N•m
sequence (89 ± 9 lbf•in)
12 ± 1 N•m
Engine oil
Petamo Grease
NEW
10 ± 1 N•m
(89 ± 9 lbf•in)
vmr2015-034-001_b
vmr2016-035 127
CRANKSHAFT
NEW
SeeSee torquing
tightening
NEW procedure
procedureinside
Engine
oil
See torquing
See tightening
procedure
procedure
inside
Engine oil
vmr2013-018-001_b
128 vmr2016-035
PROCEDURES
originally mounted.
ENGINE DRIVE SHAFT

NOTE: The engine drive shaft transmits the
power from the gearbox to the front differential
tmr2011-014-007_a
and is located inside the crankcase.
1. Bearing cover front drive side
2. Circlip
Removing the Engine Drive Shaft 3. Drive shaft
Remove the engine. Refer to ENGINE REMOVAL Removing the Engine Drive Shaft
AND INSTALLATION subsection.
Split crankcase, refer to CRANKCASE in this sub-
Removing the Rear Bearing Cover section.
Detach gearbox from engine, refer to GEARBOX Remove engine drive shaft from the crankcase.
AND 4X4 COUPLING UNIT subsection.
At rear of engine, remove the bearing cover and
its O-ring.
tmr2011-014-008_a
1. Crankcase MAG side

2. Engine drive shaft
tmr2011-014-006_a
Inspecting the Engine Drive Shaft
1. Bearing cover screws Replace oil seals and/or O-ring (bearing cover
2. O-ring
3. Bearing cover gearbox side gearbox side) if they are brittle, hard or damaged.
Check drive shaft bearings for contamination
Removing the Front Bearing Cover and/or metal shavings. Check if bearings turn
Remove the bearing cover at the front of the en- freely and smoothly. Replace if necessary.
gine.
NOTICE Check ends of the circlip for sharp
edges or burrs before removing the drive shaft,
to avoid damaging the oil seal.
vmr2016-035 129
tmr2011-014-009_a
1. Bearing cover
2. Drive shaft bearing
Check drive shaft for cracks, bend, pitting or other F12R17A
visible damages.
Check drive shaft splines for wear or damages. Do not apply in excess as it will spread out inside
crankcase.
Check oil seal running surface of the drive shaft
for scratches. Replace if necessary. NOTE: It is recommended to apply this specific
sealant as described here to get a uniform appli-
Installing the Engine Drive Shaft cation without lumps. If you do not use the roller
The installation is the reverse of removal proce- method, you may use your finger to uniformly dis-
dure however, pay attention to the following de- tribute the sealant (using a finger will not affect
tails. the adhesion).
Clean all metal components in solvent. Installing the Rear Bearing Cover
Clean crankcase surfaces and bearing covers us- For bearing cover installation on gearbox side, pro-
ing a combination of LOCTITE CHISEL (GASKET RE- tect the oil seal to avoid damaging the sealing lip.
MOVER) (P/N 413 708 500) and a brass brush. First REQUIRED TOOL
brush in one direction then make the final brush-
ing perpendicularly (90°) to the first pass. DRIVE SHAFT OIL SEAL
NOTICE Do not wipe with rags. Use a new PROTECTOR (P/N 529 036 029)
Use a suitable installer for installing bearings.
faces.
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 mm - 75 mm
(2 in - 3 in), available in arts products suppliers for
printing, and roll the sealant to get a thin uniform tmr2011-014-010_a
coat on the plate (spread as necessary). When 1. Drive shaft
ready, apply the sealant on bearing cover sur- 2. Bearing cover gearbox side
3. O-ring
faces. 4. Protection sleeve
TIGHTENING TORQUE
Rear bearing cover 10 N•m ± 1 N•m
130 vmr2016-035
Installing the Front Bearing Cover
tmr2013-018-005_a
1. Bearing cover
2. Oil seal
vmr2015-034-002_a
FRONT OF ENGINE 5. Install drive shaft oil seal using the following
1. Water pump cover tool.
2. Oil seal front side
3. Drive shaft
REQUIRED TOOL
TIGHTENING TORQUE
DRIVE SHAFT OIL SEAL
LOCTITE 243 (BLUE) INSTALLER (P/N 529 036 028)
Service product
(P/N 293 800 060)
Front bearing cover 10 N•m ± 1 N•m
Installing the Engine Drive Shaft

Finally check for axial play of the drive shaft.
FRONT OIL SEAL

(ENGINE DRIVE SHAFT)
Replacing the Front Oil Seal
(Engine Drive Shaft)
NOTE: The front oil seal can be replaced with the
engine installed.
1. Remove front propeller shaft. vmr2013-018-002_a
2. Remove adapter sleeve between propeller 1. Bearing cover

2. Oil seal
shaft and front engine drive shaft. 3. Oil seal installer
3. Remove the front bearing cover, refer to EN-
GINE DRIVE SHAFT REMOVAL/INSTALLATION 6. Reinstall remaining parts in the reverse order of
in this subsection. removal.
4. Remove drive shaft seal from bearing cover.
REAR OIL SEAL
(ENGINE DRIVE SHAFT)
Replacing the Rear Oil Seal
(Engine Drive Shaft)
1. Remove gearbox from the engine, refer to
GEARBOX AND 4X4 COUPLING UNIT subsec-
tion.
vmr2016-035 131
2. Remove rear bearing cover, refer to ENGINE

DRIVE SHAFT REMOVAL/INSTALLATION in
this subsection.
3. Remove O-ring from bearing cover.
vmr2013-018-002_a
1. Bearing cover
2. Oil seal
6. Install O-ring in rear bearing cover.

vmr2013-018-003_a
1. Bearing cover
2. O-ring
4. Remove drive shaft seal from bearing cover.
vmr2013-018-004_a
1. O-ring
2. Bearing cover
tmr2013-018-005_a
1. Bearing cover
7. Reinstall remaining parts in the reverse order of
2. Oil seal removal.
5. Install drive shaft oil seal using the following
tool. PTO COVER OIL SEAL
REQUIRED TOOL NOTE: To replace oil seal it is not necessary to
remove engine from vehicle.
DRIVE SHAFT OIL SEAL
INSTALLER (P/N 529 036 028) Removing the PTO Oil Seal
1. Refer to CONTINUOUSLY VARIABLE TRANS-
MISSION (CVT) subsection and remove the fol-
lowing parts:
– CVT cover
– Drive pulley
– Driven pulley
– CVT air guide.
2. Remove oil seal using a small flat screwdriver.
132 vmr2016-035
NOTICE Avoid scoring surfaces with tool. PTO COVER

Removing the PTO Cover
MISSION (CVT) subsection to remove the fol-
lowing parts:
– CVT cover
– Drive pulley
– Driven pulley
– CVT air guide.
2. Disconnect vent hose.
3. Remove PTO cover screws and pull on PTO
cover to remove it.
vmr2015-034-003_a
1. PTO cover
2. Oil seal
Inspecting the PTO Oil Seal

Check oil seal running surface of crankshaft PTO
side for grooves. Replace if necessary.
Installing the PTO Oil Seal

cedure however, pay attention to the following de-
tails.
NOTICE Oil seal must be installed with seal-
ing lip toward the engine.
Push oil seal in place using the following tool.
REQUIRED TOOL
PTO COVER OIL SEAL

vmr2006-044-003_a
1. PTO cover
2. PTO cover screws
3. Vent hose nipple
Inspecting the PTO Cover

1. Check the PTO cover for cracks or other dam-
age.
2. Replace PTO cover if damaged.
3. Clean oil breather bore in PTO cover from con-
taminations with a parts cleaner then use pres-
vmr2015-034-004_a surized air to dry it.
1. PTO cover
3. Oil seal
vmr2016-035 133
WARNING Replacing the Plain Bearing

Always wear skin and eye protection. Chem-
(PTO Cover)
icals can cause skin rash, skin burns and se- Removing the Plain Bearing
vere eye injury.
4. Check surface of sealing sleeve for wear or use a hammer to install plain bearings. Always
other damages. Replace PTO cover if dam- use a press.
aged. 1. Carefully remove the PTO oil seal with a screw-
driver, without damaging the PTO cover.
2. Press out the plain bearings from the outside
towards the inside.
REQUIRED TOOL
PLAIN BEARING
REMOVER/INSTALLER
(P/N 529 036 032)
NOTE: The PTO cover has to be supported from

below on a suitable support with straight surface
tmr2011-014-013_a
in order to prevent damage of the sealing surface.
1. Oil breather bore
2. Surface of sealing sleeve
5. Check plain bearings for scoring or other dam-

ages.
NOTE: Measure plain bearing inside diameter
(PTO cover) and compare to crankshaft bearing
journal diameter (PTO cover bearing). Refer to
CRANKSHAFT in this subsection. Replace if the
measurement is out of specification.
vmr2006-044-007_a
1. PTO cover
2. Plain bearing remover/installer
Installing the Plain Bearing

NOTE: Do not lubricate plain bearings or PTO
tmr2011-014-013_b cover for installation.
1. Plain bearing
2. Oil bore Install plain bearings in a cold PTO cover.
A. Measure plain bearing inside diameter
REQUIRED TOOL
PLAIN BEARING INSIDE DIAMETER PLAIN BEARING
(PTO COVER) REMOVER/INSTALLER
SERVICE LIMIT 34.120 mm (1.3433 in) (P/N 529 036 032)
1. Mark position of oil bore on PTO cover and on

plain bearing remover/installer.
2. Align mark on plain bearing remover/installer
with mark on PTO cover.
134 vmr2016-035
Tighten PTO cover screws following the sequence

illustrated.
vmr2006-044-008_a
1. Mark position of oil bore on PTO cover

2. Mark position of oil bore on plain bearing remover/installer
NOTICE Misalignment of plain bearing and

PTO cover oil bores will prevent proper oil
supply to plain bearings.
3. Carefully press in the plain bearings in the same
direction as during disassembly, from the out-
side towards the inside.
NOTE: Support PTO cover using a suitable sup- vmr2006-044-003_b
TIGHTENING SEQUENCE
port with a straight surface to prevent damage of
the sealing surface. TIGHTENING TORQUE
NOTICE The joining surfaces of the plain 10 N•m ± 1 N•m
bearings must be positioned near the oil bore PTO cover screws
in a counterclockwise direction.
DRIVE GEARS
Drive Gears Location
The engine is equipped with a breather gear which
prevents engine oil from seeping out through the
breathing system into the air intake system.
The drive gears are located on the engine PTO
side behind the PTO cover.
tmr2011-014-013_c
1. Plain bearing joint

2. PTO cover (inside surface)
3. Oil bore
Installing the PTO Cover

For installation, reverse the removal procedure
however, pay attention to the following details.
NOTE: At installation, replace PTO cover gasket
and oil seal.
vmr2016-035 135
tmr2011-014-014_a tmr2011-014-016_a
1. Breather gear 1. Thrust washer

2. Intermediate gear 2. Water pump drive gear
3. Water pump drive gear 3. Needle pin
4. Oil pump drive gear
Inspecting the Drive Gears

Removing the Drive Gears
1. Remove PTO cover, refer to PTO COVER in this Intermediate Gear/Oil Pump Drive Gear/Water
subsection. Pump Drive Gear
2. Withdraw intermediate gear and breather gear. Inspect gears for wear or other damage. Replace
if damaged.
3. Remove oil pump drive gear, refer to OIL PUMP
in the LUBRICATION SYSTEM subsection. Breather Gear
4. To remove water pump drive gear, pull the shaft Check if oil seal is brittle, hard or damaged. Re-
assembly slightly out and turn it about one tooth place if necessary.
until it stays out.
5. Then push water pump drive gear in.
tmr2011-014-017_a
1. Breather gear
2. Oil seal
Inspect gear for wear or other damage.

tmr2011-014-015_a
Step 1: Push gear in

Check ball bearing for excessive play and smooth
1. Water pump drive gear operation. Replace breather gear assembly if nec-
2. Intermediate shaft essary.
6. Remove needle pin and pull water pump drive Installing the Drive Gears
gear out.
The installation is essentially the reverse of the re-
7. Remove thrust washer from intermediate moval procedure however, pay attention to the fol-
shaft. lowing.
Adequately oil the ball bearing of the breather
gear.
136 vmr2016-035
CRANKCASE – Oil cooler

– Oil pump drive gear.
Disassembling the Crankcase
NOTE: Oil pump removal from crankcase is not
1. Refer to PERIODIC MAINTENANCE PROCE- necessary, but recommended to see condition of
DURES subsection and carry out the following: oil pump. Refer to LUBRICATION SYSTEM sub-
1.1 Drain cooling system. section.
1.2 Drain engine oil. 12. Remove electric starter.
1.3 Drain gearbox oil.
2. Lock crankshaft. Refer to CRANKSHAFT
LOCKING PROCEDURE in the this subsec-
tion.
MISSION (CVT) subsection and remove the fol-
lowing parts:
– CVT cover
– Drive pulley
– Driven pulley
– CVT air guide.
4. Remove engine from vehicle. Refer to ENGINE vmr2016-035-001_a
REMOVAL AND INSTALLATION subsection. 1. Electric starter
2. Screw
5. Remove gearbox from engine.
6. Refer to MAGNETO AND STARTER subsection NOTE: Before splitting the crankcase, measure
and remove the following parts: crankshaft axial play. Refer to CRANKSHAFT in
– Magneto cover this subsection.
– Rotor with sprag clutch gear 13. Remove crankcase retaining screws.
– Starter drive gears.
7. Refer to applicable procedures in this subsec-
tion and remove the following parts:
– PTO cover
– Drive gears
– Bearing covers of engine drive shaft.
8. Refer to TIMING CHAIN subsection and re-
– Chain tensioners
– Camshaft timing gears
– Timing chains
– Timing chain guides.
9. Refer to TOP END subsection and remove the
following parts: vmr2016-035-002_a
1. Four screws M8 x 65
– Front cylinder head 2. 12 screws M6 x 75
– Rear cylinder head 3. One screw M6 x 25
– Cylinders. 14. Carefully split crankcase halves using a screw-

10. Refer to COOLING SYSTEM subsection and driver and a soft hammer.
remove the following parts:
– Water pump housing.
11. Refer to LUBRICATION SYSTEM subsection
and remove the following parts:
– Oil filter
vmr2016-035 137
vmr2016-035-003
NOTE: During disassembly, do not damage the vmr2006-042-017_a

sealing surfaces of the crankcase halves. 1. Engine oil strainer
2. Retaining plate
15. Pull crankshaft out of crankcase. 3. Screws
16. Remove the water pump intermediate shaft.
Cleaning the Crankcase
WARNING
Use safety goggles to avoid eye injuries.
Clean crankcase using a part cleaner.

Dry crankcase using compressed air.
Blow low pressure filtered air through the oil sup-
ply lines.
Inspecting the Crankcase

Check crankcase halves for cracks or other dam-
age. Replace if damaged.
Check MAG and PTO plain bearings for scoring or
vmr2006-044-023_b other damages.
17. Remove engine oil strainer.

NOTE: Oil strainer removal for inspection and
cleaning is recommended. Refer to LUBRICA-
TION SYSTEM subsection.
tmr2011-014-024_a
1. Plain bearing
138 vmr2016-035
Measure plain bearing inside diameter and com- NOTE: During disassembly, make sure not to
pare to PTO/MAG main journal diameters of crank- damage the sealing surfaces of the crankcase
shaft, refer to CRANKSHAFT in this subsection. halves.
Replace if the measurements are out of specifi-
cation.
tmr2011-014-025_a
PRESS PLAIN BEARINGS OUTSIDE

1. Crankcase half
vmr2006-044-025_a 2. Plain bearing remover/installer
3. Crankcase support sleeve (P/N 529 036 031)
1. Plain bearing
2. Oil bore
A. Measure plain bearing inside diameter
Installing the Plain Bearing
MAIN BEARING INSIDE DIAMETER (PTO/MAG)
use a hammer to install plain bearings. Aways
SERVICE LIMIT 42.100 mm (1.6575 in) use a press.
During reassembly, make sure not to damage the
Replacing the Plain Bearing (Main)
sealing surfaces of the crankcase halves.
Removing the Plain Bearing NOTE: Place the proper crankcase support sleeve
NOTICE Always properly support crankcase under crankcase halves before installing the plain
halves when removing plain bearings. Dam- bearings, refer to PLAIN BEARING REMOVAL
age to crankcase halves may occur if this pro- PROCEDURE in this subsection.
cedure is not performed correctly. Install plain bearings in a cold crankcase.
NOTE: Always use a press for removal of plain NOTE: Do not lubricate plain bearings and/or
bearings. crankcase for installation.
Carefully press the plain bearings out from the REQUIRED TOOL
crankcase half from the inside towards the out-
side. PLAIN BEARING
REMOVER/INSTALLER
NOTE: Place an appropriate support under (P/N 529 035 917)
crankcase halves before removing plain bear-
ings.
NOTE: Use an O-ring (Ø 42 x 1 mm to 1.5 mm
REQUIRED TOOLS (.04 in to .06 in) thickness) to hold plain bear-
ings in place during installation. The O-ring will
CRANKCASE SUPPORT MAG/PTO disappear in the groove of the plain bearing re-
(P/N 529 036 031) mover/installer.
1. Mark position of plain bearing oil bore on plain
PLAIN BEARING bearing remover/installer.
REMOVER/INSTALLER 2. Mark position of oil bore on crankcase half.
(P/N 529 035 917)
3. Align mark on plain bearing remover/installer
with mark on crankcase half.
vmr2016-035 139
tmr2011-014-028_a
1. Plain bearing joint

2. Oil bore
tmr2011-014-026_a
3. Crankcase half PTO (inside surface)
1. Oil bore position marked on plain bearing remover/installer
2. Plain bearing oil bore
3. Oil bore position marked on crankcase Assembling the Crankcase
NOTICE Misalignment of the plain bearing The assembly of crankcase is essentially the re-
and crankcase oil bores will prevent proper oil verse of removal procedure. However, pay atten-
supply to plain bearings. tion to the following details.
4. Carefully press in the plain bearings from inside clogged.
the crankcase towards the outside.
NOTICE The joint of the plain bearings in Install a NEW crankcase gasket.
crankcase half MAG side must be positioned
near the oil bore in a clockwise direction. Oil the plain bearings before mounting the crank-
shaft.
Reinstall crankshaft, see procedure in this subsec-
tion
Properly reinstall engine oil strainer and screws.
Refer to LUBRICATION SYSTEM subsection.
Reinstall water pump intermediate shaft and
gears, refer to WATER PUMP GEARS in the
COOLING SYSTEM subsection.
Tighten crankcase retaining screws as per follow-
ing sequence.
tmr2011-014-027_a
1. Crankcase half MAG (inside surface)

2. Partition
3. Oil bore
NOTICE The joint of the plain bearings in the

crankcase half PTO side must be positioned
near the oil bore in the counterclockwise di-
rection.
vmr2016-035-002_b
140 vmr2016-035
TIGHTENING TORQUE Crankshaft Locking Procedure

25 N•m ± 3 N•m NOTE: When the crankshaft is locked, the rear
M8 crankcase screws piston no. 2 is at TDC (top dead center). The
crankshaft cannot be locked with front piston no.
1 at TDC.
NOTICE To see if the rear piston no. 2 is
at TDC ignition, refer to CAMSHAFT TIMING
GEAR in the TIMING CHAIN subsection.
1. Remove spark plug cables and spark plugs from
both cylinders.
2. Remove screw plug and O-ring from magneto
cover.
vmr2016-035-002_c
TIGHTENING TORQUE
10 N•m ± 1 N•m
M6 crankcase screws
CRANKSHAFT
vmr2015-033-005_a
1. Plug screw
2. O-ring
3. Remove crankshaft position sensor.
vmr2015-033-006_a
1. Crankshaft position sensor

2. Screw
vmr2006-044-035_b
1. Crankcase MAG 4. Remove screw plug and discard sealing ring.

2. Crankshaft
vmr2016-035 141
vmr2015-034-005_a
1. Sealing ring
vmr2007-037-008_b
2. Plug screw
3. Crankcase PTO side, front side CYLINDER 2 AT TDC
1. Number 2 piston identifier
2. Index mark on magneto flywheel
5. Use a 14 mm Allen key to turn crankshaft until 3. Notch on magneto cover
the rear piston no. 2 is at TDC. 4. CPS bore in magneto cover
6. Use a screwdriver to check if the groove in the

crankshaft is aligned with the crankshaft locking
tool orifice.
vmr2015-033-007_a
1. Allen key 14 mm
NOTE: When the piston no. 2 is at TDC, the num- vmr2015-034-006_a
ber 2 piston index mark on the magneto flywheel 1. Screwdriver

and the notch on the magneto cover are aligned. 7. Lock crankshaft.
REQUIRED TOOL
CRANKSHAFT LOCKING
BOLT (P/N 529 035 617)
142 vmr2016-035
Measure axial play on PTO end of crankshaft using

a dial indicator.
CRANKSHAFT AXIAL PLAY
0.200 mm to 0.500 mm
NEW
(.008 in to .02 in)
If axial play is out of specification, replace

crankcase and/or crankshaft.
Connecting Rod Big End Axial Play
vmr2015-034-007_a
Using a feeler gauge, measure between face of
1. Crankshaft locking bolt connecting rods and crankshaft counterweight.
If the measurement exceeds specified tolerance,
8. Gradually insert the tool in the crankshaft replace the crankshaft.
groove. Make sure that the tool tip enters the
groove and does not jam on the crankshaft
balancer surface.
Crankshaft Removal
Refer to CRANKCASE.
Crankshaft Inspection
NOTE: Check each crankshaft bearing journal for
scoring, scuffing, cracks or other signs of wear.
NOTE: Replace crankshaft if the crankshaft tim-
ing gears are worn or otherwise damaged.
NOTICE Components out of specifications
must always be replaced. If this is not ob-
served, severe damage may be caused to the
engine.
vmr2006-044-037_a
1. Crankshaft
2. Connecting rods
3. Feeler gauge
CONNECTING ROD BIG END AXIAL PLAY

0.200 mm to 0.500 mm
NEW
(.008 in to .02 in)

vmr2006-044-036_a
Refer to TOP END subsection.
1. Crankshaft timing gears
Crankshaft Axial Play

NOTE: Axial play must be measured before split-
ting the crankcase.
vmr2016-035 143
Connecting Rod Big End Radial Play NOTE: To measure the connecting rod big end di-
NOTE: Prior to removing connecting rod from the ameter, use the OLD connecting rod screws.
crankshaft, mark big end halves together to en- 3. Install the OLD plain bearings as they were
sure a correct reinstallation (cracked surface fits mounted initially.
in only one position). 4. Carry out the tightening procedure described in
1. Remove connecting rods from crankshaft. CRANKSHAFT ASSEMBLY in this subsection.
NOTICE Connecting rod screws are not
reusable. Always discard screws and replace
with NEW ones. It is recommended to install
new plain bearings when reinstalling connect-
ing rods.
vmr2006-044-039_a
A. Connecting rod big end plain bearing
CONNECTING ROD BIG END DIAMETER

vmr2007-037-003_a
1. Connecting rod screws

If connecting rod big end diameter is out of spec-
2. Measure crankpin. Compare to inside diameter ification, replace plain bearings and recheck.
of connecting rod big end. CONNECTING ROD BIG END RADIAL
CLEARANCE
If connecting rod big end radial clearance is out of

specification, replace plain bearings and recheck.
Crankshaft Radial Play MAG/PTO Side

Measure crankshaft main bearing journals on
MAG and PTO sides. Compare to inside diam-
eter of MAG and PTO plain bearings, refer to
CRANKCASE in this subsection.
vmr2006-044-038_a
1. Micrometer
2. Crankpin
CRANK PIN DIAMETER

40.001 mm to 40.025 mm
NEW
(1.5748 in to 1.5758 in)

replace crankshaft.
144 vmr2016-035
Crankshaft Radial Play

(PTO Cover Bearing)
Measure crankshaft journal diameter (PTO cover
bearing). Compare to plain bearing inside diame-
ter (PTO cover). Refer to PTO COVER in this sub-
section.
vmr2006-044-040_a
1. Micrometer
2. Crankshaft MAG side main bearing journal
vmr2006-044-042_a
1. Micrometer
2. Crankshaft journal (PTO support bearing)
CRANKSHAFT JOURNAL DIAMETER

(PTO COVER BEARING)
34.004 mm to 34.020 mm
NEW
(1.3387 in to 1.3394 in)
CRANKSHAFT RADIAL PLAY

vmr2006-044-041_a (PTO COVER BEARING)
1. Micrometer SERVICE LIMIT 0.10 mm (.0039 in)
2. Crankshaft PTO side main bearing journal
CRANKSHAFT MAIN BEARING JOURNAL If crankshaft journal diameter is out of specifica-

DIAMETER (MAG/PTO SIDE) tion, replace crankshaft.
42.016 mm to 42.040 mm If crankshaft radial play (PTO cover bearing) is
NEW out of specification, replace plain bearings and
(1.6542 in to 1.6551 in)
recheck.
Assembling the Crankshaft
CRANKSHAFT RADIAL PLAY (MAG/PTO SIDE)
For assembly, reverse the disassembly procedure
SERVICE LIMIT 0.07 mm (.0028 in) however, pay attention to following details.
Clean the split surface on both sides (cracked
area) carefully with compressed air.
Insert plain bearings in the connecting rods as il-
lustrated.
vmr2016-035 145
3
2
R1004motr20A
1. Half plain bearing of connecting rod big end

2. Mating surface of the connecting rod
3. Joining surface of plain bearing in line with connecting rod
groove
Oil the plain bearing surface of the connecting rod

and crankshaft pin before installation.
NOTICE Lower cap and rod must match to- vmr2006-044-043_a
1. Angle torque wrench

gether since there is a cracked surface.
Oil NEW connecting rod screws. NEW connecting rods can be installed either way.
Thread screws in the connecting rods, then TIGHTENING TORQUE
tighten as per following procedure. Tighten to 1/2 of
Step A
specified torque
NOTICE Strictly adhere following instruc-
tions: Tighten to
– Always use NEW connecting rod screws at fi- Connecting rod Step B 20 N•m ± 2 N•m
nal assembly. They are not reusable.
– Do not apply any thread locker. Torque an additional
Step C 60 ± 5° turn using an
– The running direction of the big end bearings
angle torque wrench
and of the piston pins must not change.
– Always perform each step on both connecting
rod screws before going to the next step. Installing the Crankshaft
– Failure to strictly follow procedure may cause For installation of crankshaft in crankcase reverse
connecting rod screws to loosen and lead to se- the removal procedure. However, pay attention to
vere engine damage. the following details.
REQUIRED TOOLS Do not interchange the connecting rods of pistons
1 and 2 during installation.
Torque wrench
NOTICE Observe the correct installation po-
Angle torque wrench sition when fitting the crankshaft with the
connecting rods. The connecting rod MAG
side has to face cylinder no. 1.
146 vmr2016-035
vmr2006-044-035_a
1. Crankcase half MAG side

2. Connecting rod cylinder 1
3. Connecting rod cylinder 2
vmr2016-035 147
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
TRANSMISSION (CVT)
SERVICE TOOLS
CLUTCH PULLER .......................................................................... 529 035 746 ......................................... 187
DRIVE PULLEY HOLDER (CVT) .................................................... 529 006 400 ......................................... 186
DRIVEN CLUTCH HOLDER........................................................... 529 035 771 ......................................... 196
PULLER/LOCKING TOOL.............................................................. 529 036 098 ................................. 185, 202
SERVICE PRODUCTS
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ......................... 189, 197, 201
vmr2015-022 181
Loctite 767
Isoflex grease
Topas NB52
Pulley flange
cleaner
Isoflex grease
Topas NB52
Isoflex grease See tightening

Topas NB52 procedure
NEW
5 ± 0,6 N•m
(44 ± 5 lbf•in)
LH threads
100 ± 7 N•m
(74 ± 5 lbf•ft)
7 ± 0,8 N•m
(62 ± 7 lbf•in)
vmr2015-022-001_a
182 vmr2015-022
5 ± 1 N•m
(44 ± 9 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4.5 lbf•ft)
5 ± 1 N•m
(44 ± 9 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4.5 lbf•ft)
vmr2015-022-100_a
vmr2015-022 183
GENERAL
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle.
To perform the following instructions, it is not nec-
essary to remove engine from vehicle.
This CVT is lubrication free. Never lubricate any
components except drive pulley one-way clutch.
WARNING
Never touch CVT while engine is running.
Never drive vehicle when CVT cover is re-
moved.
vmr2015-022-002_a
WARNING 1. Bayonet cap

2. O-ring
Any drive pulley repairs must be performed
by an authorized Can-Am dealer. Subcompo- Let water drain from CVT cover.
nent installation and assembly tolerances re-
NOTICE If an appreciable amount of water or
quire strict adherence to procedures detailed.
any debris entered the CVT cover, CVT must be
cleaned and inspected.
NOTICE Never use any type of impact
Reinstall bayonet cap with O-ring.
wrench at drive pulley removal and instal-
lation. CVT Cover Removal
WARNING Disconnect CVT cooling air ducts.
The clutch assembly is a precisely balanced
unit. Never replace parts with used parts
from another clutch assembly.
NOTICE These pulleys have metric threads.

Do not use imperial thread puller. Always
tighten puller by hand to ensure that the drive
pulley has the same type of threads (metric vs
imperial) before tightening completely.
PROCEDURES
CVT COVER
CVT Cover Access vmr2015-012-014_a
CVT AIR INLET DUCT DISCONNECT

Refer to BODY subsection and remove the follow- 1. Loosen clamps
ing: 2. Remove CVT air inlet adapter
– LH side and extension panels
– LH footboard panel.
CVT Cover Draining

Turn bayonet cap 90° counterclockwise to open it.
Remove bayonet cap with O-ring.
184 vmr2015-022
vmr2015-022-003_a
vmr2015-012-015_a
CVT AIR OUTLET DUCT DISCONNECT CVT COVER TIGHTENING SEQUENCE

Step 1: Loosen clamps
Step 2: Remove CVT air outlet adapter CVT COVER RETAINING SCREWS
Remove: 7 N•m ± 0.8 N•m
Tightening torque
– Retaining screws (62 lbf•in ± 7 lbf•in)
– CVT cover
– Gasket. DRIVE BELT
Drive Belt Removal
NOTICE In case of a drive belt failure, the CVT
cover, air inlet and air outlet must be cleaned
and inspected for obstruction.
Remove CVT cover, refer to procedure in this sub-
section.
Open driven pulley.
REQUIRED TOOL
PULLER/LOCKING TOOL
(P/N 529 036 098)
Screw tool in the threaded hole of driven pulley

vmr2015-022-004_a and tighten to open the pulley.
1. Retaining screws
2. CVT cover
3. Gasket
NOTE: To support the cover remove the center

top screw last.
CVT Cover Installation

Install the center top screw of cover in first.
Install the other screws then torque them in a
crisscross sequence.
Tighten the CVT cover screws as per following se-
quence.
vmr2015-022-005_a
1. Puller/locking tool
2. Fixed sheave of driven pulley
vmr2015-022 185
Slide belt over the top edge of fixed sheave. DRIVE PULLEY
vmr2015-022-006_a
vmr2015-022-007_b
1. Drive pulley
Drive Belt Inspection 2. Driven pulley
3. Belt
For drive belt inspection refer to DRIVE BELT
INSPECTION in the PERIODIC MAINTENANCE Drive Pulley Removal
Remove drive belt, refer to procedure in this sub-
Drive Belt Installation section.
For installation, reverse the removal procedure. Prior to removing the drive pulley, mark sliding
Pay attention to following details. sheave and governor cup together to ensure cor-
rect reinstallation. There are 4 levers mounted
The maximum drive belt life span is obtained
out of 6 possible positions.
when the drive belt has the proper rotation direc-
tion. Install it so that the arrow printed on belt is
pointing towards the back of the vehicle.
vmr2015-022-008_a
1. Mark on drive pulley sliding sheave

2. Mark on governor cup
vmr2015-022-007_a
1. Arrow towards the back of the vehicle To block drive pulley, two methods can be used:
2. Drive pulley (front)
3. Driven pulley (rear) – Lock crankshaft. Refer to CRANKSHAFT
LOCKING PROCEDURE in the BOTTOM END
subsection.
– Block drive pulley.
REQUIRED TOOL
DRIVE PULLEY HOLDER (CVT)
(P/N 529 006 400)
186 vmr2015-022
Slowly release spring pressure and remove sliding

sheave.
Slowly release sliding sheave.
Remove fixed sheave.
REQUIRED TOOL
CLUTCH PULLER (P/N 529
035 746)
vmr2015-022-009_a
1. Drive pulley holder

2. Drive pulley sliding sheave
3. Area to place holding tool hook
Loosen drive pulley screw clockwise.

NOTICE Drive pulley screw has LH threads.
NOTE: Do not unscrew the drive pulley screw
completely. If governor cup is stuck, hit it using
a soft hammer. vmr2015-022-011_a
Remove service tool. 1. Drive pulley puller

2. Fixed sheave
Apply axial pressure with your hand on the sliding
sheave and governor cup. Drive Pulley Disassembly
Remove: Governor Cup
– Screw Carefully lift governor cup until slider shoes come
– Spring washer at their highest position into guides.
– Thrust washer.
CAUTION Sliding sheave of drive pulley is

spring loaded.
tmr2011-015-005_a
1. Governor cup
2. Slider shoes
3. Sliding sheave
4. Guides
vmr2015-022-010_a
Step 1: Push NOTE: The following procedure is not necessary

1. Drive pulley screw except if roller must be removed. Refer to DRIVE
2. Spring washer
3. Thrust washer PULLEY INSPECTION before proceeding.
4. Sliding sheave with governor cup
vmr2015-022 187
NOTE: Whenever removing a governor cup that

has the 2 boxes marked (punch marks), replace it
with a new one.
vmr2006-021-015_a
vmr2006-021-018 PUSHING OUT ROLLER SLEEVE

1. Punch
2. Vise
Remove slider shoess
NOTICE Always replace all rollers at the
same time. Partially worn rollers may cause
damage to the CVT system.
Remove roller sleeve and roller.
R400motr171A 1
1. Slider shoe
Put governor cup on a vise. Use protection plates vmr2015-022-012_a
on the vise jaws to avoid marks and/or damages 1. Roller sleeve

to the governor cup. 2. Roller
Push out roller sleeve with an appropriate punch Sliding Sheave

in the direction illustrated (against insertion arrow NOTE: This drive pulley is equipped with 4 levers.
marked on governor cup arm).
Unscrew lock nut and remove centrifugal lever
NOTE: Use a punch with a smaller diameter than pivot bolt.
the roller sleeve.
Remove centrifugal lever and both thrust wash-
NOTICE Do not clamp the governor cup in ers.
the vise to push out bearing sleeve. Governor
cup will be damaged.
188 vmr2015-022
1 2
R400motr167A 2 1
vmr2006-021-019_a
1. Lock nut 1. Spring

2. Centrifugal lever pivot bolt 2. Spring sleeves
3. Centrifugal lever
4. Thrust washers
Drive Pulley Cleaning
Fixed Sheave Clean pulley faces and shaft with fine steel wool
and dry cloth.
WARNING
Using a paper towel with the recommended
Always wear safety glasses to remove spring
cleaning solvent, clean:
sleeves.
– Crankshaft tapered end
Pull and rotate one-way clutch slowly until the half – Crankshaft threads
of spring sleeves are visible. – Taper inside of the fixed sheave of the drive pul-
ley
– Drive pulley screw threads.
REQUIRED SERVICE PRODUCT
PULLEY FLANGE CLEANER (P/N 413 711 809)
NOTICE To avoid damage, make sure cleaner

does not contact the crankshaft seal.
Remove all hardened oil deposits that have baked
on crankshaft and pulley tapered surfaces with
coarse or medium steel wool and/or sand paper
4 no. 600.
NOTICE Do not use any other type of abra-
sive.
Reclean mounting surfaces with paper towel and
cleaning solvent.
Wipe off the mounting surfaces with a clean, dry
R400motr166A 2 3 1 paper towel.
1. One-way clutch NOTICE Mounting surfaces must be free of
2. Fixed sheave
3. Spring sleeve area any oil, cleaner or towel residue.
4. Direction of removal
Hold both spring sleeves with fingers and carefully

remove them when the one-way clutch is disen-
gaged.
vmr2015-022 189
vmr2015-022-013_a
tmr2011-015-006_a
1. Taper
2. Threads 1. Sliding sheave
3. Crankshaft 2. Bushings
NOTICE Do not use acetone to clean bush-

ing.
Drive Pulley Inspection

Governor Cup
Check governor cup for cracks or other visible
vmr2015-022-014_a
damages. Replace if necessary.
1. Drive pulley screw threads
Roller and Slider Shoe
Check each roller for roundness of external diam-
eter.
NOTE: Whenever replacing rollers and slider
shoes, always replace all rollers and slider shoes
as a set.
Check slider shoes for visible wear and replace if
damaged.
Measure the roller diameter. If one roller is out of
specification, replace all rollers.
R400motr168A 1
1. Taper of fixed sheave
Only use petrol base cleaner when cleaning bush-

ings.
vmr2006-021-014_a
1. Roller
2. Slider shoe
A. Roller outer diameter
190 vmr2015-022
ROLLER OUTER DIAMETER – Centrifugal lever pivot bolts

– Lock nuts.
13.80 mm to 14.00 mm
NEW
(.543 in to .551 in)
ROLLER INNER DIAMETER
8.025 mm to 8.175 mm
NEW
(.316 in to .322 in)
Centrifugal Lever Pivot Bolt

Measure diameter of centrifugal lever pivot bolt,
replace if it is out of specification.
A
vmr2006-021-019_b
1. Lock nut
2. Centrifugal lever pivot bolt
4. Thrust washers
5. Contact surface to the roller
NOTICE Whenever replacing centrifugal

R400motr169A 1 levers, always replace all levers at the same
1. Centrifugal lever pivot bolt time. Otherwise, the drive pulley will be un-
A. Measure diameter here balanced (because of lever differences).
CENTRIFUGAL LEVER PIVOT BOLT DIAMETER Sliding Sheave
SERVICE LIMIT 6.000 mm (.236 in) Check sliding sheave for cracks and sliding con-
tact surface for excessive wear. Replace sliding
Centrifugal Lever sheave if necessary.
Check bushing diameter in the centrifugal lever for Measure centrifugal lever pivot bolt bores. Re-
wear. If a centrifugal lever must be replaced, replace sliding sheave if bores are out of specifica-
place all levers at the same time. tion or damaged.
tmr2011-015-007_a
2. Bushing
A. Bushing inner diameter
A
CENTRIFUGAL LEVER BORE DIAMETER
R400motr172A
A. Centrifugal lever pivot bolt bore diameter
Inspect and replace as necessary the following

items if their contact surfaces are heavy worn:
– Centrifugal lever
– Thrust washers
vmr2015-022 191
CENTRIFUGAL LEVER PIVOT BOLT BORE A

DIAMETER
6.113 mm to 6.171 mm
NEW
(.241 in to .243 in)
Measure bushing diameters of sliding sheave.

REQUIRED TOOL
Dial bore gauge
MEASURING POINT
At least 5 mm (1/4 in) from bushing edge
R400motr174A 1
1. Bushing on governor cup side
A
A. Bore diameter of bushing
SLIDING SHEAVE SMALL BUSHING

30.000 mm to 30.040 mm
NEW
(1.181 in to 1.183 in)
Replace sliding sheave if one of the bushings is

out of specification. Visually inspect coatings.
Fixed Sheave
R400motr173A 1
Check fixed sheave contact surface to the gover-
1. Bushing on fixed sheave side
nor cup for scoring and other damages. If so, re-
place fixed sheave.
SLIDING SHEAVE LARGE BUSHING
55.000 mm to 55.040 mm
NEW
(2.165 in to 2.167 in)
R400motr175A 1
1. Visually check here
192 vmr2015-022
Check for any marks on fixed sheave plate. Re-

place if necessary.
Check ring gear teeth for excessive wear or other
damage. Replace fixed sheave if necessary.
WARNING
Fixed sheave and ring gear are balanced to-
gether. Always replace both parts together
otherwise severe injury and/or damages may
occur.
Spring
Measure spring free length and squareness. If
spring is out of specification, replace by a new
one. vmr2008-127-053_a
A. Squareness
SPRING FREE LENGTH
One-Way Clutch
Check bearings for excessive play and smooth op-
eration. Replace one-way clutch if necessary.
NOTICE Be careful not to damage the inside
of one-way clutch during bearing removal.
3
vmr2008-127-052_a
A. Free length 1
R400motr176A 2
CLUTCH SPRING SQUARENESS
1. One-way clutch
SERVICE LIMIT 4 mm (.157 in) 2. Bearings
3. Drive pulley sliding sheave side
Measure length of spring sleeve and check if

edges on top of the spring sleeve are excessively
worn. If out of specifications, replace both spring
sleeves and springs at the same time.
SPRING SLEEVE LENGTH
9.2 mm to 9.4 mm
NEW
(.362 in to .37 in)
Drive Pulley Assembly

For assembly, reverse the disassembly proce-
dure. Pay attention to following details.
vmr2015-022 193
One-Way Clutch NOTICE Final position of roller sleeve has to

Lubricate spring sleeves, springs and between be flush with the contact surface of the slider
one-way clutch bearings using recommended shoes (no protrusion).
product.
REQUIRED SERVICE PRODUCTT
ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021)
Sliding Sheave
Install centrifugal lever and both thrust washers.
vmr2006-021-029_a
1. Top edge of roller sleeve

2. Mating surface of slider shoes
3. Vise
vmr2006-021-019_a
1. Lock nut
4. Thrust washers
vmr2008-127-051_a
1. Flush surfaces
Whenever replacing roller sleeves, punch a mark

in an empty telltale box. If each box is already
marked, replace governor cup with a new one.
NOTICE Centrifugal lever must move easily NOTICE Do not tap too hard. Severe damage
after installation. to the governor cup may appear.
Governor Cup
Rebuild governor cup with NEW roller sleeves,
thrust washers, rollers and slider shoes.
Push in roller sleeve with an appropriate punch in
the direction of the protruding arrow. Push until
roller sleeve aligns with the contact surface of the
slider shoe.
194 vmr2015-022

wrench at drive pulley removal and instal-
lation.
Clean mounting surfaces as described in DRIVE
PULLEY CLEANING in this subsection.
Install drive pulley on crankshaft extension.
Install:
– Thrust washer
– Spring washer with its concave side towards
vmr2006-021-017
drive pulley
– Drive pulley screw.
NOTICE Rollers must move easily after in-
stallation.
Carefully press slider shoes in the governor cup
arm so they bottom out evenly in the machined
portion of the governor cup arm.
NOTICE Slider shoes must be pressed in
evenly to ensure they are centered in the arm
and slide properly in the guides.
Align governor cup with sliding sheave using the
marks traced at disassembly.
1 2
vmr2015-022-015_a
1. Drive pulley screw

2. Spring washer
3. Thrust washer
WARNING
Never substitute spring washer and/or screw
with aftermarket parts. Always use BRP gen-
uine parts.
Lock the drive pulley as per removal procedure.

Tighten drive pulley screw counterclockwise to
specification.
DRIVE PULLEY SCREW
100 N•m ± 7 N•m
Tightening torque
NOTE: Drive pulley screw has LH threads.

R400motr164A

Drive Pulley Installation

NOTICE Do not apply antiseize or any lubri-
cant on crankshaft and drive pulley tapers.
vmr2015-022 195
WARNING
Driven pulley is spring loaded. Hold driven
clutch pulley tight and slowly remove the
driven pulley screw to release spring ten-
sion.
vmr2015-022-016_a
1. Drive pulley holder

2. Drive pulley removal/installation area
DRIVEN PULLEY
Driven Pulley Removal
Remove drive belt, refer to DRIVE BELT in this
subsection. vmr2015-022-019_a
Block driven pulley fixed sheave. 1. Driven pulley screw

2. Washer
REQUIRED TOOL 3. Driven pulley fixed sheave
DRIVEN CLUTCH HOLDER Remove:

(P/N 529 035 771) – Driven pulley
– Spring
– Cam
– Plate.
vmr2015-022-017_a
1. Driven clutch holder

2. Driven pulley fixed sheave
Unscrew the driven pulley screw. vmr2015-022-020_a
NOTE: Do not remove screw completely. 1. Fixed sheave of driven pulley

2. Sliding sheave of driven pulley
Apply axial pressure with your hand on driven pul- 3. Spring
4. Cam
ley and maintain during screw removal. 5. Plate
Remove: Remove distance sleeve including O-ring from
– Driven pulley screw counter shaft on engine PTO side.
– Washer. Replace O-ring if brittle, hard or damaged.
196 vmr2015-022
tmr2011-015-009_a
vmr2015-023-014_a
1. Distance sleeve 1. Ball bearing

2. O-ring 2. Shaft
3. Counter shaft 3. Fixed sheave of driven pulley
Use a soft hammer to push shaft with bearing out

Driven Pulley Disassembly of fixed sheave.
Fixed Sheave
Remove retaining ring and lift torque gear.
vmr2015-022-022_a
1. Soft hammer
2. Shaft
vmr2015-022-021_a
1. Retaining ring Remove shaft from ball bearing.

2. Torque gear
Driven Pulley Cleaning
NOTE: The following procedure is not necessary To remove a dust deposit from cam or shaft, use
except if ball bearing or shaft must be removed. a dry cloth.
Refer to INSPECTION before proceeding. Clean pulley faces and shaft with fine steel wool
Heat ball bearing area up to 100°C (212°F) before and dry cloth.
removing ball bearing. Clean driven pulley using the recommended prod-
uct
RECOMMENDED PRODUCT
Clean the CVT crankcase area from contamina-

tion.
Using a paper towel with cleaning solvent to clean
counter shaft end and the inside of the shaft.
vmr2015-022 197
NOTICE To avoid damage, make sure cleaner REQUIRED TOOL

does not contact the counter oil shaft seal.
Dial bore gauge
1
MEASURING POINT
BUSHINGS INNER DIAMETER

30.060 mm to 30.100 mm
NEW
(1.183 in to 1.185 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-
R400motr182A 2 ation. Replace if necessary.
1. Counter shaft supports
2. Sealing lip of counter shaft oil seal
Check shaft for heavy wear or visible damage. Re-
place if necessary.
Driven Pulley Inspection If the shaft is removed, measure bushing inner di-
ameter
Sliding Sheave
NOTE: This bushing cannot be replaced. Replace
Check sliding sheave for cracks and sliding con-
fixed sheave if bushing is out of specification. Vi-
sually inspect coatings.
sheave if necessary.
Check bushings for cracks, scratch and for free REQUIRED TOOL
movement when assembled to sliding sheave. Dial bore gauge
Using a dial bore gauge, measure bushing diam-
eters. Measuring point must be at least 5 mm MEASURING POINT
(1/4 in) from bushing edges. At least 5 mm (1/4 in) from bushing edge
Measure bushing inner diameter.
NOTE: Bushings cannot be replaced. Replace
sliding sheave if bushings are out of specification.
Visually inspect coatings.
tmr2011-015-010_a
1. Bushing
vmr2006-021-038_a 2. Fixed sheave
1. Bushings
2. Backside of sliding sheave
198 vmr2015-022
BUSHING INNER DIAMETER 1 3 2

30.060 mm to 30.100 mm
NEW
(1.183 in to 1.185 in)
Check torque gear for visible damage and cracks.

Measure for wear limit using a caliper.
R400motr186A
1. Caliper
2. Sliding sheave
3. Contact surface
A. Wear to be measured
WEAR ON CONTACT SURFACE

tmr2011-015-011_a
A. Measurement inside
B. Measurement outside Spring
WEAR ON TEETH (BOTH SIDES)
spring is out of specification, replace by a new
SERVICE LIMIT 7.500 mm (.295 in) one.
SPRING FREE LENGTH
Cam
Check cam for visible damage and measure for SERVICE LIMIT 164 mm (6.457 in)
wear using a caliper.
1
A
vmr2008-127-055_a
A. Free length
R400motr185A
CLUTCH SPRING SQUARENESS
1. Contact surfaces for power train
2. Caliper SERVICE LIMIT 3.8 mm (.15 in)
A. Width to be measured due to wear on contact surface
WIDTH ON TOP SURFACE

vmr2015-022 199
1
2
vmr2008-127-056_a
A. Squareness
R400motr188A
Driven Pulley Assembly 1. Shaft

2. Fixed sheave
For installation, reverse the removal procedure. 3. Press machine
Pay attention to following details. Install torque gear then secure it with retaining
Heat ball bearing area up to 100°C (212°F) before ring.
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.
vmr2015-022-021_b
1. Torque gear
2. Retaining ring
Driven Pulley Installation

vmr2015-022-023_a
1. Ball bearing
Place O-ring on counter shaft splines and move it
NOTICE Do not use a hammer, use a press with spacer in end position.
only.
NOTICE Chamfer on inside diameter of the
spacer must face engine side.
200 vmr2015-022
Place spring behind sliding sheave then align

driven pulley with cam.
vmr2015-022-024_a
1. O-ring
2. Distance sleeve
3. Chamfered area of distance sleeve
vmr2015-022-026_a
Clean: 1. Cam
– Threads of gearbox counter shaft 2. Spring
3. Driven pulley
– Driven pulley screw threads.
With your hand, push the driven pulley onto the
REQUIRED SERVICE PRODUCT
shaft to compress the spring.
NOTICE A cam not correctly engaged will
NOTICE Threads of gearbox counter shaft cause damage to the driven pulley and cam.
and driven pulley screw must be free of oil and Install the driven pulley screw and its washer.
grease. Lubricants in threads will create too
high preload to tightened driven pulley screw. NOTE: Tighten the screw with your hand suffi-
ciently for the cam to remain engaged.
Install cam retainer on counter shaft spline the
right way then install cam.
NOTE: Place cam retainer with printed mark “EN-
GINE SIDE” towards the engine.
vmr2015-022-027_a
Step 1: Push
1. Washer
2. Driven pulley screw
vmr2015-022-025_a Install drive belt. Refer to DRIVE BELT in this sub-

1. Cam retainer section.
2. Printed mark “ENGINE SIDE”
3. Counter shaft spline
Insert sliding sheave into fixed sheave.
vmr2015-022 201
REQUIRED TOOL
PULLER/LOCKING
TOOL
(P/N 529 036 098)
vmr2015-022-028_a
2. Sliding sheave
NOTE: If driven pulley sheaves cannot be opened

when the service tool is screwed in, the cam is not
correctly engaged in the sliding sheave.
Torque driven pulley screw to specification.
DRIVEN PULLEY SCREW TIGHTENING
PROCEDURE
Step 1 20 N•m ± 1 N•m (15 lbf•ft ± 1 lbf•ft)
Step 2 180° ± 5°
Check driven pulley end play.

SPECIFICATION
Driven pulley end play 0 mm (0 in)
202 vmr2015-022
TRANSMISSION (CVT)
SERVICE TOOLS
CLUTCH HOLDER......................................................................... 529 036 238 ......................... 154, 162, 167
CLUTCH PULLER .......................................................................... 529 035 746 ......................................... 154
PULLER/LOCKING TOOL .............................................................. 529 036 098 ................................. 153, 167
SERVICE PRODUCTS
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ................. 157, 163–164, 166
vmr2016-036 149
Loctite 767
Isoflex grease
Topas NB52
NEW Loctite 243

10 ± 1 N•m
(89 ± 9 lbf•in)
Pulley flange cleaner
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
Isoflex grease
Topas NB52
5 ± 0,6 N•m
(44 ± 5 lbf•in) Isoflex grease
Topas NB52 NEW
See tightening
procedure
NEW
NEW
120 ± 8 N•m
(89 ± 6 lbf•ft)
7 ± 0,8 N•m
(62 ± 7 lbf•in)

vmr2016-036-001_a
150 vmr2016-036
PRO Models
NEW
NEW
5 ± 1 N•m
(44 ± 9 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4.5 lbf•ft)
5 ± 1 N•m
(44 ± 9 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4.5 lbf•ft)

vmr2016-036-101_a
vmr2016-036 151
GENERAL 2. Let water drain from CVT cover.

NOTE: For a better understanding, the following 3. Reinstall drain reservoir.
illustrations are taken with engine out of vehicle. NOTICE If an appreciable amount of water or
To perform the following instructions, it is not nec- any debris entered the CVT cover, CVT must be
essary to remove engine. cleaned and inspected.
WARNING Removing the CVT Cover
Never touch CVT while engine is running. Remove CVT cover screws.
Never drive vehicle when CVT cover is re-
moved. NOTE: Do not use and impact tool to remove CVT
cover screws. To support the CVT cover remove
the top center screw last.
WARNING
Remove the CVT cover and its gasket.
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.
WARNING
The clutch assembly is a precisely balanced
unit. Never replace parts with used parts
from another clutch assembly.
PROCEDURES
CVT COVER
Vmr2012-018-004_a
CVT Cover Access 1. CVT cover screw
Refer to BODY subsection and remove the follow- 2. CVT cover
3. Gasket
ing:
– LH side and extension panels Installing the CVT Cover
– LH footboard panel. Install the top center screw of first.
Draining the CVT Cover NOTE: Do not use and impact tool to install CVT
cover screws.
If water is present in CVT cover, it can be drained
as follows: Tighten the CVT cover screws as per following se-
quence.
1. Remove drain reservoir from CVT cover.
Vmr2012-018-003_a
Vmr2012-018-003_b
CVT COVER TIGHTENING SEQUENCE
1. Drain reservoir
2. Spring clip
152 vmr2016-036
TIGHTENING TORQUE Inspecting the Drive Belt

7 N•m ± 0.8 N•m For drive belt inspection refer to DRIVE BELT
CVT cover screws INSPECTION in the PERIODIC MAINTENANCE
DRIVE BELT Installing the Drive Belt
Removing the Drive Belt For installation, reverse the removal procedure.
Pay attention to following details.
NOTICE In case of a drive belt failure, the The maximum drive belt life span is obtained
CVT, cover, drain reservoir and air outlet must when the drive belt has the proper rotation direc-
be cleaned and inspected for obstruction. tion. Install it so that the arrow printed on belt
1. Remove CVT COVER. is pointing towards front of the vehicle, viewed
from top.
2. Open driven pulley.
REQUIRED TOOL
PULLER/LOCKING TOOL
(P/N 529 036 098)
3. Screw tool in the threaded hole of driven pulley

and tighten to open the pulley.
vmr2007-051-006_a
1. Arrow printed on belt

2. Drive pulley (front)
3. Driven pulley (rear)
4. Rotation direction
DRIVE PULLEY
Removing the Drive Pulley
Vmr2012-018-005_a
1. Remove DRIVE BELT, see procedure in this
2. Fixed sheave of driven pulley subsection.
2. Prior to removing the drive pulley, mark sliding
4. Slide the belt over the top edge of fixed sheave
sheave and governor cup to ensure correct in-
to remove it.
dexation at reinstallation.
Vmr2012-018-006_a
vmr2016-036 153
CAUTION Sliding sheave of drive pulley is

spring loaded.
vmr2006-021-011_a

3. Lock the drive pulley. tmr2011-015-004_a
REQUIRED TOOL Step 1: Push

1. Thrust washer
2. Conical spring washer
CLUTCH HOLDER 3. Drive pulley screw
4. Sliding sheave with governor cup
(P/N 529 036 238)
8. Slowly release and remove sliding sheave.
9. Remove friction washer.
Vmr2012-018-008_a
tmr2013-019-003_a
1. Clutch holder 1. Friction washer

2. Drive pulley sliding sheave 2. One way clutch
3. Drive pulley fixed sheave
4. Loosen the drive pulley screw.
10. Screw clutch puller in fixed sheave to remove
NOTICE Never use any type of impact fixed pulley.
wrench for drive pulley removal. NOTICE Use only recommended tool.
NOTE: Do not unscrew the drive pulley screw
REQUIRED TOOL
completely. If governor cup is stuck, hit it using
a soft hammer. CLUTCH PULLER
5. Remove service tool. (P/N 529 035 746)
6. Apply axial pressure with your hand on the slid-
ing sheave and governor cup.
7. Remove drive pulley screw with its conical
spring washer and thrust washer.
154 vmr2016-036
Vmr2012-018-009_a
1. Drive pulley puller

2. Fixed sheave R400motr171A 1
1. Slider shoe
Disassembling the Drive Pulley
3. Place the governor cup on a vice to push out the
Governor Cup
roller sleeve in the direction illustrated (against
1. Carefully lift governor cup until slider shoes insertion arrow marked on governor cup arm).
move to their highest position in the guides. Use an appropriate punch (diameter of punch
must be smaller than the diameter of the sleeve
bore in the governor cup arm).
NOTICE Do not clamp the governor cup in
the vice to push out roller sleeve. Governor
cup will be damaged.
NOTE: Use protection plates to avoid marks
and/or damages to the governor cup.
NOTICE Always replace all rollers as a set.
Partly worn rollers may cause damage to the
CVT system.
tmr2011-015-005_a
1. Governor cup
2. Slider shoes
3. Sliding sheave
4. Guides
NOTE: The following steps are not necessary ex-

cept if roller must be removed. Refer to INSPEC-
TION before proceeding.
2. Remove slider shoes from governor cup arm.
Use a flat screwdriver if necessary.
vmr2006-021-015_a
1. Punch
2. Vice
vmr2016-036 155
Fixed Sheave
WARNING
Always wear safety glasses to remove spring
sleeves.
Pull and rotate one-way clutch slowly until the

spring sleeves are visible.
vmr2006-021-016_a
1. Removal direction
2. Assembly direction
NOTE: Whenever removing a governor cup which

already has two marked boxes, replace it by a new
one.
vmr2006-021-020_a
1. One-way clutch
2. Fixed sheave
3. Spring sleeve area
vmr2006-021-018
Sliding Sheave Hold both spring sleeves with fingers and carefully
remove them when the one-way clutch is disen-
Unscrew lock nut and remove centrifugal lever gaged.
pivot bolt. This drive pulley is equipped with 4
levers.
Remove centrifugal lever and both thrust wash-
ers.
Vmr2012-018-024_a
vmr2006-021-021_a
1. Lock nut
2. Centrifugal lever pivot bolt 1. Springs
3. Centrifugal lever 2. Spring sleeves
4. Thrust washers
156 vmr2016-036
Cleaning the Drive Pulley

Clean pulley faces and shaft with fine steel wool
and a dry cloth.
Using a paper towel with the recommended
cleaning solvent, clean:
– Crankshaft tapered end
– Taper inside the fixed sheave of the drive pulley
– Crankshaft threads
– Drive pulley screw threads.
REQUIRED PRODUCT
tmr2011-015-006_a
NOTICE Avoid contact between cleaner and 1. Sliding sheave
crankshaft seal as damage may occur. 2. Bushings
Remove all hardened oil deposits that have baked Inspecting the Drive Pulley
on the crankshaft and pulley tapered surfaces us-
ing coarse or medium steel wool, and/or sand pa- Bushings
per no. 600. For bushing inspection, refer to SLIDING SHEAVE
in this subsection.
NOTICE Do not use any other type of abra-
sive. Governor Cup
Reclean mounting surfaces with paper towel and Check governor cup for cracks or other visible
PULLEY FLANGE CLEANER (P/N 413 711 809). damage. Replace if necessary.
Wipe off the mounting surfaces with a clean, dry Roller and Slider Shoe
paper towel. Check each roller for roundness of external diam-
NOTICE Mounting surfaces must be free of eter.
any oil, cleaner or towel residue. Check if rollers move freely.
NOTICE Whenever replacing rollers and
slider shoes, always replace all rollers and
slider shoes as a set.
Check slider shoes for visible wear If chamfer is
not present anymore, replace ALL slider shoes.
NOTE: If necessary, use a screwdriver to remove
slider shoes.
vmr2015-121-002_a
1. Taper of fixed sheave
Only use petrol base cleaner when cleaning slid-

ing sheave bushings.
NOTICE Do not use acetone to clean bush-
ing.
vmr2016-036 157
tmr2011-015-007_a
2. Bushing
A. Bushing inner diameter
CENTRIFUGAL LEVER BORE DIAMETER

6.035 mm to 6.078 mm
NEW
vmr2016-036-002_a (.238 in to .239 in)
1. Roller 6.200 mm (.244 in)
2. Slider shoe
SERVICE LIMIT
3. Chamfer
A. Roller outer diameter Inspect and replace as necessary the following
items if their contact surfaces are heavy worn:
ROLLER OUTER DIAMETER
– Centrifugal lever
13.80 mm to 14.00 mm – Thrust washers
NEW
(.543 in to .551 in)
– Centrifugal lever pivot bolts
SERVICE LIMIT 13.20 mm (.519 in) – Lock nuts.
ROLLER INNER DIAMETER
8.025 mm to 8.175 mm
NEW
(.316 in to .322 in)
SERVICE LIMIT 9 mm (.354 in)
Centrifugal Lever Pivot Bolt

Measure diameter of centrifugal lever pivot bolt;
replace if out of specification.
Vmr2012-018-024_b
1. Lock nut
R610tran12A A 1 3. Centrifugal lever
4. Thrust washers
1. Centrifugal lever pivot bolt 5. Contact surface to the roller
A. Measure diameter here
WARNING
CENTRIFUGAL LEVER PIVOT BOLT DIAMETER Whenever replacing centrifugal levers, al-
6.078 mm to 6.100 mm ways replace all levers as a set. Otherwise,
NEW drive pulley unbalance will occur.
(.239 in to .24 in)
Sliding Sheave
Centrifugal Lever Check sliding sheave for cracks and sliding con-
Check bushing diameter in the centrifugal lever for tact surface for excessive wear. Replace sliding
wear. Replace centrifugal lever if necessary. sheave if necessary.
Measure centrifugal lever pivot bolt bores. Re-
place sliding sheave if bores are out of specifica-
tion or otherwise damaged.
158 vmr2016-036
SLIDING SHEAVE LARGE BUSHING

55.000 mm to 55.040 mm
NEW
(2.165 in to 2.167 in)
vmr2006-021-024_a
A. Centrifugal lever pivot bolt bore diameter
CENTRIFUGAL LEVER PIVOT BOLT BORE

DIAMETER
6.113 mm to 6.171 mm
NEW
(.241 in to .243 in)
SERVICE LIMIT 6.300 mm (.248 in) R610tran11A 1
Measure bushing diameters of sliding sheave. 1. Bushing on governor cup side
REQUIRED TOOL
SLIDING SHEAVE SMALL BUSHING
Dial bore gauge
32.000 mm to 32.040 mm
NEW
MEASURING POINT (1.26 in to 1.261 in)
At least 5 mm (1/4 in) from bushing edge SERVICE LIMIT 32.200 mm (1.268 in)
Replace sliding sheave if one of the bushings is

A
out of specification. Visually inspect coatings for
wear.
Fixed Sheave
Check fixed sheave contact surface to the gover-
nor cup for scratches or other damages. If dam-
aged, replace fixed sheave.
R610tran14A 1
1. Bushing on fixed sheave side
Vmr2012-018-010_a
1. Visually check here
vmr2016-036 159
Check for any marks on fixed sheave plate. Re- One-Way Clutch
place if necessary. Clean parts.
Spring Lubricate springs, spring sleeves and between
Measure spring free length and squareness. If one way clutch bearings using recommended
spring is out of specification, replace by a new product.
one. REQUIRED PRODUCT
CLUTCH SPRING FREE LENGTH ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021)
SERVICE LIMIT
Friction Washer
85 MM (3.35 IN)
NOTE: Apply recommended grease on both sides
CLUTCH SPRING SQUARENESS of friction washer.
SERVICE LIMIT REQUIRED PRODUCT
4 MM (.157 IN) ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021)
One-Way Clutch NOTE: Friction washer must be assembled with

Check bearings for excessive play and smooth op- collar towards one way clutch.
eration. Replace bearings if necessary.
NOTICE Be careful not to damage the inside
of one-way clutch during bearing removal.
vmr2007-051-003_a
1. Friction washer
2. Collar
3. One way clutch
Sliding Sheave
vmr2015-035-002_a
Install centrifugal levers with their thrust washers.
1. One-way clutch NOTICE Centrifugal levers must move easily
2. Bearings
after installation.
Measure length of spring sleeves and check if
edges on top of the spring sleeve are excessively Governor Cup
worn. If out of specification, replace both spring Rebuild governor cup with new roller sleeves,
sleeves at the same time. rollers and slider shoes.
SPRING SLEEVE LENGTH NOTICE Final position of roller sleeves must
9.2 mm to 9.4 mm be flush with the sleeve bore in the governor
NEW cup arm (no protrusion).
(.362 in to .37 in)
Assembling the Drive Pulley

For assembly, reverse the disassembly proce-
dure. Pay attention to following details.
160 vmr2016-036
WARNING
Do not apply antiseize or any lubricant on
crankshaft and drive pulley tapers.

wrench for drive pulley removal and instal-
lation.
Clean mounting surfaces as described in DRIVE
PULLEY CLEANING.
Install drive pulley on crankshaft extension.
NOTICE Do not forget to install thrust washer
and conical spring washer as per illustration
that follows.
vmr2006-021-029_a
1. Top edge of roller sleeve NOTE: Install conical spring washer with its con-
2. Mating surface of slider shoes
3. Vice cave side towards drive pulley.
Whenever replacing the roller sleeves, make a

mark in the box on the governor arm using a
punch.
NOTICE Do not tap too hard. Severe damage
to the governor cup may appear.
vmr2006-021-051_a

2. Conical spring washer
3. Thrust washer
vmr2006-021-017
NOTICE Rollers must move easily after in- WARNING

stallation. Never substitute conical spring washer
and/or screw with aftermarket parts. Al-
Carefully press slider shoes in the governor cup ways use genuine BRP parts.
arm so they bottom out evenly in the machined
portion of the governor cup arm. Lock the drive pulley as per removal procedure.
NOTICE Slider shoes must be pressed in Tighten drive pulley screw to specification.
evenly to ensure they are centered in the arm
and slide properly in the guides. NOTICE Never use any type of impact
wrench for drive pulley installation.
Installing the Drive Pulley
TIGHTENING TORQUE
Pay attention to the following details. 120 N•m ± 8 N•m
Drive pulley screw
vmr2016-036 161
5. Remove driven pulley screw and washer. Dis-

card driven pulley screw.
CAUTION Driven pulley is spring loaded.

Hold driven pulley tight and slowly remove the
driven pulley screw to release spring tension.
tmr2013-019-006_a
1. Clutch holder (P/N 529 036 238)

2. Drive pulley
DRIVEN PULLEY
Vmr2012-018-011_a
Removing the Driven Pulley 1. Driven pulley screw

2. Thrust washer
1. Remove drive belt, refer to DRIVE BELT RE-
MOVAL in this subsection. 6. Remove the driven pulley with the spring and
2. Hold the driven pulley and loosen the driven pul- the cam.
ley screw.
NOTE: Do not completely remove the driven pul-
ley screw.
REQUIRED TOOL
CLUTCH HOLDER
(P/N 529 036 238)
vmr2015-035-003_a

2. Sliding sheave of driven pulley
3. Spring
4. Cam
Disassembling the Driven Pulley

Fixed Sheave
1. Remove retaining ring and lift torque gear.
tmr2013-019-007_a

2. Clutch holder (P/N 529 036 238)
3. Remove service tool.

4. Apply axial pressure with your hand on driven
pulley and maintain during screw removal.
162 vmr2016-036
vmr2006-021-035_a
1. Retaining ring
2. Torque gear
R610tran18A
NOTE: The following procedure is not necessary
except if ball bearing or shaft must be removed. 1. Soft hammer
2. Shaft
Refer to INSPECTION before proceeding.
2. Heat ball bearing area up to 100°C (212°F) be- 4. Remove shaft from ball bearing.
fore removing ball bearing. 5. Remove distance sleeve and O-ring from coun-
tershaft.
6. Replace O-ring if brittle, hard or damaged.
tmr2011-015-009_a
1. Ball bearing
2. Shaft vmr2006-021-044_b
1. O-ring
2. Distance sleeve
3. Use a soft hammer to push shaft and bearing
out of fixed sheave. Cleaning the Driven Pulley
When a dust deposit has to be removed from the
cam or the shaft, use a dry cloth.
Clean pulley faces and shaft using fine steel wool
and a dry cloth.
Clean driven pulley using the recommended prod-
uct.
RECOMMENDED PRODUCT
Clean the CVT air guide area from contamination.
vmr2016-036 163
Using a paper towel with PULLEY FLANGE REQUIRED TOOL

CLEANER (P/N 413 711 809), clean countershaft
end and shaft bore. Dial bore gauge
NOTICE To avoid damage, make sure cleaner MEASURING POINT

does not contact the countershaft oil seal. At least 5 mm (1/4 in) from bushing edge
BUSHING INNER DIAMETER

30.060 mm to 30.100 mm
NEW
(1.183 in to 1.185 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, measure bushing inner di-
vmr2006-021-037_a
ameter.
1. Countershaft support
2. Countershaft oil seal NOTE: This bushing cannot be replaced. Replace
fixed sheave if bushing is out of specification. Vi-
Inspecting the Driven Pulley sually inspect coatings.
Sliding Sheave
Check sliding sheave for cracks and sliding con-
sheave if necessary.
Check bushings for cracks, scratches and for
freedom of movement when assembled to slid-
ing sheave.
Measure bushing inner diameter.
NOTE: Bushings cannot be replaced. Replace
sliding sheave if bushings are out of specification.
Visually inspect coatings.
tmr2011-015-010_a
1. Bushing
REQUIRED TOOL
Dial bore gauge
MEASURING POINT
vmr2006-021-038_a
1. Bushings
2. Backside of sliding sheave of driven pulley
164 vmr2016-036
BUSHING INNER DIAMETER

30.060 mm to 30.100 mm
NEW
(1.183 in to 1.185 in)
Check torque gear for visible damage and cracks.

Measure for wear limit using a caliper.
vmr2006-021-041_a
1. Caliper
2. Sliding sheave
3. Contact surface
A. Wear to be measured
WEAR ON CONTACT SURFACE

tmr2011-015-011_a
A. Measurement inside Spring

B. Measurement outside
WEAR ON TEETH (BOTH SIDES) spring is out of specification, replace by a new.
SERVICE LIMIT 7.500 mm (.295 in) SPRING FREE LENGTH
SERVICE LIMIT
Cam
125 MM (4.92 IN)
Check cam for visible damage and measure for
wear using a caliper. CLUTCH SPRING SQUARENESS
SERVICE LIMIT
3.8 MM (.15 IN)
Assembling the Driven Pulley

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
press it in using only the outer race.
vmr2015-121-003_a
1. Caliper
2. Contact surface
A. Width to be measured due to wear on contact surface
WIDTH ON TOP SURFACE

vmr2016-036 165
Installing the Driven Pulley

Place O-ring on countershaft splines and move it
and the distance sleeve into position.
NOTICE Chamfer on inside diameter of the
distance sleeve must face to gearbox side.
vmr2006-021-042_a
1. Ball bearing
NOTICE Do not use a hammer, bearing must

be pressed in only.
vmr2006-021-044_a
1. O-ring
1 2. Distance sleeve
3. Chamfered area of distance sleeve
2 NOTICE Threads of gearbox countershaft

and driven pulley screw must be free of oil
and grease. Lubricants in threads will create
too high preload to tightened driven pulley
R610tran37A
screw.
1. Shaft Clean threads using PULLEY FLANGE CLEANER
2. Fixed sheave
3. Press machine (P/N 413 711 809).
Install cam on countershaft.
Install torque gear then secure it with the retaining
ring. NOTICE Cam splines must engage on coun-
tershaft splines.
REQUIRED PRODUCT
Countershaft splines LOCTITE 767
and countershaft (ANTISEIZE LUBRICANT)
end (P/N 293 800 070)
vmr2006-021-035_a
1. Retaining ring
2. Torque gear
166 vmr2016-036
Vmr2012-018-011_a

2. Thrust washer
Vmr2012-018-014_a
TYPICAL
Install drive belt. Refer to DRIVE BELT in this sub-
1. Countershaft splines section.
2. Cam splines
A. Loctite 767 here REQUIRED TOOL
Insert sliding sheave in fixed sheave.

Place spring behind sliding sheave then align PULLER/LOCKING
TOOL
driven pulley with cam.
(P/N 529 036 098)
Vmr2012-018-015_a
Vmr2012-018-022_a
TYPICAL
1. Cam 1. Puller/locking tool
2. Spring 2. Sliding sheave
3. Sliding sheave
4. Fixed sheave NOTE: If driven pulley sheaves cannot be opened
With your hand, push the driven pulley onto the when the service tool is screwed in, the cam is not
shaft to compress the spring. correctly engaged in the sliding sheave.
Tighten driven pulley screw to specification.
NOTICE A cam not correctly engaged will
cause damage to the driven pulley and cam. REQUIRED TOOL
As you hold the pulley compressed, install a NEW CLUTCH HOLDER

driven pulley screw and thrust washer. (P/N 529 036 238)
NOTICE This assembly uses a stretch screw.
Always install a NEW screw.
NOTE: Tighten the screw with your hand suffi-
ciently for the cam to remain engaged.
vmr2016-036 167
TIGHTENING TORQUE
20 N•m ± 1 N•m
Driven pulley Step A
screw
Step B 180° ± 5°
Check driven pulley end play.

SPECIFICATION
Driven pulley end play 0 mm (0 in)
CVT AIR GUIDE

Removing the CVT Air Guide
1. Remove the DRIVE PULLEY and the DRIVEN
PULLEY.
2. Unscrew the clamps retaining the CVT air
hoses.
3. Remove CVT air guide.
Inspecting the CVT Air Guide

Clean CVT air guide from contamination
Check O-rings. If brittle, hard or damaged, replace
as necessary.
vmr2012-018-020_a
1. CVT air guide

2. O-rings
Installing the CVT Air Guide

For installation reverse the removal procedure.
168 vmr2016-036
Subsection 12 (GEARBOX AND 4X4 COUPLING UNIT)
GEARBOX AND 4X4 COUPLING UNIT

SERVICE TOOLS
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................... 224, 229–230
LOCTITE 5910 ............................................................................... 293 800 081 ......................................... 222
XPS SYNTHETIC GREASE............................................................. 293 550 010 ......................................... 230
vmr2015-023 203
Engine oil
Engine oil
Engine oil
Engine oil
Engine oil
Engine oil
Loctite 767
Engine oil
Engine oil
Engine
Engine oil oil
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
vmr2015-023-001_a
204 vmr2015-023
Loctite 5910
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 5910
3 ± 0,4 N•m
(27 ± 4 lbf•in)
vmr2015-023-002_a
vmr2015-023 205
4X4 COUPLING UNIT
Engine oil
7 N•m
(62 lbf•in)
20 N•m
(15 lbf•ft)
Loctite
243
Loctite
243
NEW
NEW
20 N•m
(15 lbf•ft)
XP-S
synthetic NEW
grease
25 N•m
(18 lbf•ft)
XPS Loctite
synthetic 243
grease

vmr2015-074-101_a
206 vmr2015-023
PROCEDURES
OUTPUT SHAFT
Output Shaft Removal
1. Remove engine from the vehicle. Refer to EN-
GINE REMOVAL AND INSTALLATION subsec-
tion.
2. Measure output shaft axial clearance prior to re-
move it.
vmr2015-023-028_a
1. Output shaft
2. Ball bearings
5. Remove both O-rings and both bearings from

output shaft.
NOTE: Both bearings on output shaft have a tran-
sition fit.
vmr2015-023-003_a
1. Output shaft
2. Dial indicator
OUTPUT SHAFT AXIAL CLEARANCE

0.09 mm to 0.18 mm
NEW
(.004 in to .007 in)
If the output shaft axial clearance is out of specifi-

cation, crankcase must be split and the bevel gear
must be adjusted. See GEARBOX ADJUSTMENT R400trans04A 2 1
in this subsection. 1. O-ring
2. Bearing on front side
NOTICE If the output shaft must be replaced,
always replace the bevel gear shaft at the same
time.
3. Refer to MAGNETO AND STARTER subsection
to remove:
– Output shaft bearing cover
– Magneto cover
– Rotor.
4. Use a soft hammer to remove output shaft with
its bearings from housing.
vmr2015-023 207
Clean crankcase and magneto cover mating sur-

face and especially the bearing areas from metal
particles or other contamination.
Output Shaft Installation

tention to following details.
Install front ball bearing with open side of plastic-
cage facing to the inside of the engine.
R400trans05A 2 1
1. O-ring
2. Bearing on rear side
6. Withdraw adjustment shim.
vmr2015-023-032_a
1. Ball bearing (front side)

2. Open side of plastic cage
3. Output shaft
Adjust axial play as per following procedure:

Install output shaft in crankcase.
NOTICE Do not install thrust washer on out-
put shaft ring gear side yet.
R400trans06A 1 2
Put bearings exactly in place against crankcase.
1. Adjustment shim
2. Output shaft bevel gear REQUIRED TOOL
Soft hammer
Output Shaft Inspection
Check output shaft for bending, cracks and other
visible damages.
NOTICE Always replace output shaft and
bevel gear shaft at the same time.
Check output shaft bevel gear for wear and teeth
damages.
Check if output shaft bearings turn freely and
smoothly. Replace if necessary.
Replace output shaft oil seal if brittle, hard or dam-
aged. Refer to BOTTOM END subsection for re-
placement procedure.
Replace O-rings of output shaft if brittle, hard or vmr2015-023-004_a
damaged. 1. Output shaft ball bearing
2. Soft hammer
Install output shaft bearing cover.

208 vmr2015-023
NOTE: Do not apply sealant on bearing cover yet.

Push output shaft as per following illustration.
vmr2015-023-029_a
1. Output shaft
2. Adjustment shim
3. Ball bearing
4. O-ring
vmr2015-023-005_a
WAY TO PUSH THE BEVEL GEARS TOGETHER Use the measured thickness to choose the re-
1. Bearing cover quired adjustment shim as per the following table.
2. Output shaft bevel gear
MEASURED ADJUSTMENT SHIM
Measure axial gap between bearing and output THICKNESS THICKNESS
shaft bevel gear.
REQUIRED TOOL 0.79 mm to 0.88 mm 0.70 mm (.0276 in)
(.0311 in to .0346 in)
Feeler gauge
0.89 mm to 0.98 mm 0.80 mm (.0315 in)

(.035 in to .0386 in)
0.99 mm to 1.08 mm 0.90 mm (.0354 in)

(.039 in to .0425 in)
1.08 mm to 1.18 mm 1.00 mm (.0394 in)

(.0425 in to .0465 in)
1.19 mm to 1.28 mm 1.10 mm (.0433 in)

(.0469 in to .0504 in)
1.29 mm to 1.38 mm 1.20 mm (.0472 in)

vmr2015-023-006_a
(.0508 in to .0543 in)
1. Output shaft ball bearing
2. Output shaft bevel gear
3. Feeler gauge 1.39 mm to 1.48 mm 1.30 mm (.0512 in)
(.0547 in to .0583 in)
Remove output shaft again and rebuild it with
proper adjustment shim. 1.49 mm to 1.58 mm 1.40 mm (.0551 in)
(.0587 in to .0622 in)
NOTE: Output shaft axial clearance of

0.09 mm to 0.18 mm (.004 in to .007 in) is
included in the above table.
Install output shaft.
Install magneto cover and bearing cover. Refer
to MAGNETO AND STARTER subsection in this
manual for procedure.
vmr2015-023 209
GEARBOX
Gearbox Disassembly
1. Remove engine from vehicle, refer toENGINE
REMOVAL AND INSTALLATION subsection.
NOTE: During gearbox disassembly, inspect the
condition of each part closely.
2. Remove magneto cover and rotor, refer to
MAGNETO AND STARTER subsection.
3. Remove output shaft.
4. Measure the axial clearance of bevel gear.
NOTE: Bevel gear axial clearance should be mea- vmr2015-023-008_a
sured before crankcase separation. 1. Parking lever
2. Shift shaft
REQUIRED TOOL
Feeler gauge
8. Remove shift fork shaft.
BEVEL GEAR AXIAL CLEARANCE
NEW 0.02 mm to 0.11 mm

(.0008 in to .0043 in)
vmr2015-023-009_a
1. Shift fork shaft
9. Remove shift fork.
vmr2015-023-007_a
MEASURE AXIAL CLEARANCE

1. Bevel gear
2. Feeler gauge
5. Separate crankcase, refer to BOTTOM END

subsection.
6. Remove balancer shaft, refer to BOTTOM END
subsection.
7. Remove:
– Parking lever
vmr2015-023-010_a
– Shift shaft. 1. Shift fork (engaged in counter shaft gear)
10. Disengage shift fork from shift drum.
210 vmr2015-023
1 2
vmr2015-023-011_a
1. Shift fork
R400motr208A 13. Remove:

1. Shift fork engagement pin – Thrust washer
2. Shift drum – Axial needle bearing
11. Insert a flat screwdriver in the slot of index – Bevel gear shaft with low range gear as-
lever. Turn screwdriver counterclockwise and sembly.
remove shift drum. .
vmr2015-023-012_a
1. Thrust washer
2. Axial needle bearing
R400trans18A 1 2 3. Bevel gear shaft with low range gear assembly
1. Index lever
2. Shift drum 14. Remove main gear from counter shaft.
12. Remove shift fork.
vmr2015-023 211
17. Remove:
– Sliding gear
– Needle bearing
– Thrust washer
– Reverse gear
– Thrust washer.
vmr2015-023-013_a
1. Main gear
15. Remove distance sleeve including O-ring from

counter shaft on engine PTO side.
vmr2015-023-016_a
1. Sliding gear
2. Needle bearing
3. Thrust washer
4. Reverse gear
5. Thrust washer
18. Remove:
– Intermediate gear shaft
– Distance sleeve
– Thrust washer
– Needle bearing
vmr2015-023-014_a – Intermediate gear.
1. Distance sleeve
2. O-ring
3. Counter shaft
16. Remove counter shaft with high range gear

assembly.
vmr2015-023-017_a
1. Intermediate gear shaft

2. Distance sleeve
3. Thrust washer
4. Needle bearing
vmr2015-023-015_a
Remove index lever only if necessary.
1. Counter shaft with high range gear assembly
NOTE: Check index lever for visible damage and
if it moves freely. Replace if necessary.
212 vmr2015-023
1 A 2
vmr2015-023-031_a
1. Screw
2. Index lever
3. Step ring
4. Index spring
R400motr211A
Gearbox Inspection TYPICAL

1. Main gear
Always verify for the following when inspecting 2. Caliper
gearbox components: A. Engagement groove width
– Gear teeth damage Levers

– Worn or scored bearing surfaces Parking lever for cracks or other damages.
– Bent, worn or scored shift fork
– Worn shift fork engagement pins
– Bent, worn or scored shift fork shaft
– Rounded engagement dogs and slots of gears
– Worn grooves on shift drum
– Worn gear engagement groove
– Worn splines on shafts and gears.
Bearings
Check all ball bearings and needle bearings turn
freely and smoothly. If rough or any excessive
play is detected, replace bearing.
Gears
vmr2015-023-018
Check tooth flanks of gears.
PARKING LEVER
Replace gears only together with the correspond-
ing meshing gears. Roller of index lever must have free movement.
NOTE: Always replace circlips and use special pli-
ers to install them.
Measure the engagement groove width of sliding
gears.
ENGAGEMENT GROOVE WIDTH
NEW 5.00 mm to 5.10 mm

(.197 in to .201 in)
vmr2015-023 213
vmr2015-023-019_a R400trans21A
INDEX LEVER
1. Roller 1. PTO side
Shafts Shift Drum

Check taper grooves and annular grooves of Check tracks of shift drum for scoring or heavy
shafts. Annular grooves must have sharp edges. wear like rounded engagement slots.
Check shift shaft for worn splines and gears. Check index washer on shift drum for scoring or
visible damages.
Check counter shaft for wear.
Replace isolating washer if there are signs of wear
COUNTER SHAFT SERVICE LIMIT or visible damages.
MAG side 17.990 mm (.708 in)
PTO side 24.950 mm (.982 in)
2 1
R400trans20A
1. Mag side
2. PTO side
Check bevel gear shaft.

vmr2015-023-020_a
BEVEL GEAR SHAFT SERVICE LIMIT 1. Shift drum
2. Track for the low/reverse gear shift fork
PTO side 24.990 mm (.984 in) 3. Track for the high gear shift fork
4. Isolating washer
Shift Forks
Check both shift forks for visible damage, wear or
bent shift fork claws.
Measure the shift fork claw thickness.
SHIFT FORK CLAW THICKNESS
NEW 4.800 mm to 4.860 mm

(.189 in to .191 in)
214 vmr2015-023
Gearbox Adjustment
NOTE: Only necessary if the bevel gear backlash
and the axial clearance is out of specification or
if parts are changed (output shaft, bevel gear or
crankcase).
The bevel gear adjustment includes:
– Bevel gear backlash on MAG side crankcase
– Bevel gear axial clearance on PTO side
crankcase.
A The bevel gear backlash is adjusted by finding the
proper thrust washer thickness E as per following
illustration.
The bevel gear axial clearance is adjusted by find-
R400trans19A 1
ing the proper thrust washer thickness J as per
following illustration.
1. Micrometer
A. Shift fork claw thickness
NOTE: Clean mating surface of crankcase before
taking measurements. Refer to BOTTOM END
Thrust Washers subsection.
Check thrust washers for wear. Always replace
thrust washer by a new one with the same thick-
ness, when reassembling the gearbox with exist-
ing output shaft and bevel gear.
vmr2006-022-125_a
1. Thrust washer for adjusting the bevel gear axial clearance on

PTO side
2. Area where wear signs appear
3. Adjustment thickness of the washer
vmr2015-023 215
B H
C G F
D (E) I (J)
Crankcase mating surface

MAG/PTO
Magneto cover
mating surface Output shaft mating surface
R400trans27U
Bevel Gear Backlash Procedure

(MAG Side Crankcase)
Use the following course of calculation to deter-
mine the theoretical thrust washer thickness D:
D=B-C-A
Distance between the thrust surface of bevel
gear and the theoretical center of its taper.
B=
This is defined by manufacturer and written
on the bevel gear shaft.
NOTE: Bevel gear reference number is a value be-
tween - 10 and + 10.
216 vmr2015-023
When all the measurements are taken, calculate

the theoretical thickness D of thrust washer using
the formula (D = B - C - A).
Take the obtained theoretical thrust washer thick-
ness D and choose the proper thrust washer num-
ber E according to the following table.
2 THEORETICAL
THRUST WASHER
THRUST WASHER
NUMBER E
THICKNESS D
1.20 mm to 1.29 mm
120
(.0472 in to .0508 in)
1
1.30 mm to 1.39 mm
130
(.0512 in to .0547 in)
R400tran24B
1.40 mm to 1.49 mm
1. Bevel gear 140
2. Bevel gear reference number location (.0551 in to .0587 in)
Use following course of calculation to find out 1.50 mm to 1.59 mm

150
(.0591 in to .0626 in)
value B.
1.60 mm to 1.69 mm
160
(.063 in to .0665 in)
B=( bevel gear reference number ) + 37.8
1.70 mm to 1.79 mm
100 170
(.0669 in to .0705 in)
Distance between the washer thrust surface 1.80 mm to 1.89 mm
C = in the MAG side and the mating surface of 180
(.0709 in to .0744 in)
crankcase magneto cover.
Bevel Gear Axial Clearance Procedure
NOTE: For a better understanding following illus- (PTO Side Crankcase)
tration is made as a cutaway.
mine the theoretical thrust washer thickness I:
I=F+G-H-A-E
Distance between mating surface (crankcase
F=
PTO) to ball bearing inner race.
vmr2015-023-021_a
MEASUREMENT C
1. Washer thrust surface
2. Mating surface of crankcase to the magneto cover
3. Depth gauge
A = 2 mm (.0787 in) nominal thickness of axial R400trans26A 2 1 3

needle bearing.
1. Ball bearing inner race
2. Mating surface of crankcase PTO
3. Depth gauge
vmr2015-023 217
Distance between mating surface of THEORETICAL

G = crankcase MAG and outer race of needle THRUST WASHER
THRUST WASHER
bearing. NUMBER J
THICKNESS I
1.22 mm to 1.31 mm
120
(.048 in to .0516 in)
1.32 mm to 1.41 mm
130
(.052 in to .0555 in)
1.42 mm to 1.51 mm
140
(.0559 in to .0594 in)
1.52 mm to 1.61 mm
150
(.0598 in to .0634 in)
1.62 mm to 1.71 mm
160
(.0638 in to .0673 in)
1.72 mm to 1.81 mm
170
(.0677 in to .0713 in)
vmr2015-023-022_a
1.82 mm to 1.91 mm
1. Needle bearing inner race 180
2. Mating surface of crankcase MAG (.0717 in to .0752 in)
3. Depth gauge
NOTE: Bevel gear axial clearance of
H = Distance between thrust surfaces of bevel 0.02 mm to 0.11 mm (.0008 in to .0043 in) is
gear shaft. included in the above table.
Gearbox Assembly
Reverse the disassembly procedure. However,
pay attention to the following.
1. Install:
– Intermediate gear shaft , needle bearing, in-
termediate gear, thrust washer and distance
sleeve
– Thrust washer, needle bearing, reverse gear,
thrust washer and sliding gear
R400trans29A – Counter shaft with high range gear assembly.
2. Main gear.
2.00 mm (.0787 in) nominal thickness of needle 3. Bevel gear shaft with low range gear assembly.
A = bearing..
NOTE: If a new bevel gear is used, it is neces-
The thrust washer number nominal value sary to perform the bevel gear adjustments, refer
as found in the BEVEL GEAR BACKLASH to GEARBOX ADJUSTMENT in this subsection. If
E = PROCEDURE. For example, thrust washer the existing bevel gear is used, it is mandatory to
number 170 represents a value of 1.70 mm use new thrust washers with the same thickness
(.0669 in). and also a new axial needle bearing.
When all the measurements are taken, calculate
the theoretical thrust washer thickness I using the
formula (I = F + G - H - A - E).
Take the obtained theoretical thrust washer thick-
ness I and choose the proper thrust washer num-
ber J according to the following table.
218 vmr2015-023
3 1 4 2
R400trans30A vmr2015-023-030_a
1. Mark on shift shaft

1. Intermediate gear 2. First tooth on shift drum
2. Counter shaft
3. Thrust washer after sliding gear on bevel gear
4. Thrust washer between distance sleeve and reverse gear 8. Install parking lever.
4. Install shift forks. 9. Run all gears as a final function check.
5. Put shift forks in place and afterward insert pin 10. Install balancer shaft then close crankcase
with the chamfer on top for a better installation housings. Refer to BOTTOM END subsec-
of crankcase MAG side. tion.
6. Insert a flat screwdriver in the slot of index 11. Install O-ring including distance sleeve on
lever. Turn screwdriver counterclockwise and counter shaft end PTO side.
install shift drum on park position as per the NOTICE Place O-ring including distance
following illustration. sleeve right away. Chamfered bore of distance
sleeve has to face the engine.
vmr2015-023-023_a vmr2015-023-014_b
1. Parking stop location 1. O-ring
2. Reverse stop location 2. Distance sleeve
3. Neutral stop location 3. Main shaft end PTO side
4. High gear stop location
5. Low gear stop location
12. Install output shaft and measure axial clear-
7. Insert shift shaft with mark in line to first tooth ance, refer to OUTPUT SHAFT in this subsec-
on shift drum. tion.
13. Install all other removed parts.
vmr2015-023 219
GEARBOX POSITION INDICATOR

SWITCHES
NOTE: First ensure shifter link rod is properly ad-
justed, Refer to SHIFTER subsection.
The multifunction gauge uses one switch state
(open or closed) for each P, N and R switch to
determine the gearbox position.
Gearbox Position Indicator Switch

Access
The switches are located in the crankcase, behind
the CVT cover.
However, a common connector for the gearbox
position indicator switches is easily accessible on vmr2008-129-055_a
the RH side of the engine. 1. Selected shifter position of vehicle

2. Choose position that matches the vehicle shifter selection
Refer to BODY subsection and remove the follow- 3. Test result (see table below): GREEN is good, RED is bad
ing:
LED AREA IN B.U.D.S.
– Seat
Number shown in
– Console Matching switch
B.U.D.S.
– RH side panel and extension(s). 1 Park
2 Reverse
3 Neutral
A GREEN LED should appear at the proper shifter

position. If so, the switch is working.
A RED LED means the switch or wiring/connector
is faulty. Carry out the resistance test.

Continuity Test
1. Remove parts required for access, refer to
vmr2015-023-024_a
GEARBOX POSITION INDICATOR SWITCH
1. Gearbox position indicator switch connector
ACCESS in this subsection.
2. Disconnect gearbox position indicator switch
Gearbox Position Indicator Switch Test connector.
with B.U.D.S.
1. Connect B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection.
2. Select the Monitoring tab and go to page 2
then use the Sub-transmission area.
3. Set the vehicle shifter lever to the position to
test.
4. In B.U.D.S., select the position matching the
shifter selection.
5. Look at the “LED” area in B.U.D.S.
vmr2015-023-024_a
1. Gearbox position indicator switch connector
220 vmr2015-023
REQUIRED TOOL

(P/N 529 035 868)
3. Using a multimeter, measure resistance of the

position switch while selecting the gearbox to
each position. Compare results with following
table.
SHIFTER
CORRESPONDING SWITCH
POSITION
YELLOW/
BLUE BROWN
GREEN vmr2015-023-025_b
Position 3 Position 1 Position 2 If the indicator switch is good, check the vehicle
L X X harness and/or indicator lights.
H X Gearbox Position Indicator Switch
N X X Removal
R X NOTE: Engine removal is not necessary.
Refer to CONTINUOUSLY VARIABLE TRANSMIS-
P X X
SION (CVT) subsection and remove:
An “X” indicates switch is making ground contact, – CVT cover
thus there should be continuity (R is close to 0 – Driven pulley.
Ohms). Remove:
A blank space indicates switch is not making con- – Retaining screws
tact, there should be no continuity (R = infinite). – Switch protection plate.
vmr2015-023-025_a vmr2015-023-026_a
GEARBOX POSITION INDICATOR SWITCH CONNECTOR 1. Retaining screws

1. Blue wire 2. Switch protection plate
2. Brown wire
3. Yellow/green wire
NOTE: Clean area from dirt and belt dust before
removing gearbox position indicator switch(es).
Take note of corresponding switch position and
wire color.
Remove screw retaining terminals of intermedi-
ate wiring harness to gearbox position indicator
switch.
vmr2015-023 221
vmr2015-023-027_a vmr2015-023-027_b
1. Retaining screws 1. Gearbox position switch position 1 — BLUE wire

2. Intermediate wiring harness 2. Gearbox position switch position 2 — BROWN wire
3. Gearbox position switch position 3 — GREEN/YELLOW wire
Unscrew gearbox position indicator switch.
4. Install protection plate and tighten screws to
Gearbox Position Indicator Switch specification.
Installation PROTECTION PLATE RETAINING SCREWS
1. Reverse the removal procedure. However, pay 10 N•m ± 1 N•m
attention to the following. Tightening torque
2. Take care to avoid damaging threads in switch
bores during installation.
4WD SELECTOR
GEARBOX POSITION INDICATOR SWITCH
4WD Selector Test
LOCTITE 5910 (P/N 293
Service product
800 081) Remove RH side panel. Refer to BODY section.
Unplug connector from coupling unit.
3 N•m ± 0.4 N•m
Tightening torque
NOTICE Do not apply thread locker on switch

plunger as it will lead to switch malfunction.
3. If all terminals were removed, put them back in
the proper location as noted prior to removal.
vmr2015-074-010_a
Using a multimeter, check if the 4WD selector at

handlebar works properly.
Turn ignition key ON.
222 vmr2015-023
Select 2WD position. Refer to BODY subsection to remove;

Install the RED probe to the WHITE wire connec- – RH inner fender panel
tor and the BLACK probe to the WHITE/BLACK – RH side panel
wire connector. Unplug actuator connector.
The obtained value should be 12 Vdc.
vmr2008-141-003_a
Select 4WD position. vmr2015-074-010_a
Install the RED probe to the WHITE/BLUE wire Remove actuator screws.
connector and the BLACK probe to the WHITE
wire connector.
The obtained value should be 12 Vdc.
vmr2015-074-009_a
vmr2008-141-003_b
Pull the actuator out of the housing.

If voltage is not as specified, check wires and con-
nectors. If good, replace the 4WD selector at han- 4WD Actuator Installation
dlebar.
Apply a small amount of engine oil on actuator
4WD Selector Replacement O-ring.
To replace the 4WD selector, refer to THROTTLE
LEVER in STEERING SYSTEM section.
4WD ACTUATOR
4WD Actuator Removal
Lift and support front end of the vehicle.
Remove the RH wheel. Refer to WHEELS AND
TIRES subsection.
vmr2015-023 223
vmr2008-141-011_a
vmr2008-141-008_a
1. Actuator O-ring 1. Actuator fork

2. Sliding sleeve dog
Verify if sliding sleeve is in 2WD position. The slid- Rotate the actuator counterclockwise until it ori-
ing sleeve should be pointed toward the front of ents itself to mounting position.
vehicle.
CAUTION Do not cut or break the actuator
O-ring.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of actuator screws.
Tighten actuator screws to specification.
TIGHTENING TORQUE
20 N•m ± 2 N•m
Actuator screw +
LOCTITE 243 (BLUE)
(P/N 293 800 060)
vmr2008-141-009_a
1. Sliding sleeve Connect actuator.

2. Coupling unit housing
Lift the front of vehicle until front wheels turn
Turn the actuator 37 degrees clockwise from the freely.
mounting position.
Try to turn the front propeller shaft. The shaft
should turn easily.
Place ignition switch to ON position and select the
4WD position.
The front propeller shaft should not turn (the PARK
position must be selected).
If the front propeller shaft turns, the actuator is not
installed correctly. Remove actuator and reinstall
it.
Install all other removed parts.
vmr2008-141-010_a
4WD SWITCH
FROM RH SIDE — ACTUATOR POSITIONS AT 37 DEGREES
4WD Switch Removal
Align the actuator fork with the dog on sliding
sleeve then push the actuator in the housing. Lift and support front end of the vehicle
Remove the RH wheel. Refer to WHEELS AND
TIRES subsection.
Remove RH inner fender panel.
Unplug the 4WD switch connector.
224 vmr2015-023
Unscrew the switch from coupling unit housing. 4WD Switch Installation
Discard the sealing washer. The installation is the reverse of the removal pro-
cedure.
Use a new sealing washer when installing the
switch.
COUPLING UNIT
Coupling Unit Removal
Lift and support front end of the vehicle.
Remove RH inner fender panel. Refer to BODY
V07H0KA 1 subsection.
1. Sealing washer Remove front propeller shaft. Refer to FRONT
PROPELLER SHAFT REMOVAL in this subsec-
4WD Switch Test tion.
Using a multimeter, do the following to check the Unplug coupling unit connector and 4WD switch
switch. connector.
Using an alligator clip, place the BLACK probe on
the external pin.
vmr2006-035-005
Touch the contact pin with the RED probe. The

multimeter should indicate ± 1 . vmr2015-074-007_a
Remove screws (3) retaining the coupling unit

housing to the engine.
vmr2006-035-006
Apply the RED probe on switch body. The mea-

sure should be OL.
vmr2015-074-008_a
vmr2006-035-007
Pull out the coupling unit from the engine.
If switch is out of specifications, replace it.
vmr2015-023 225
Coupling Unit Disassembly

Remove the actuator from the coupling unit by re-
moving the three retaining screws.
vmr2008-141-017_a
1. Sliding sleeve pin
Remove sliding sleeve.
vmr2008-141-014_a
1. Actuator screws
Remove the oil seal.
vmr2008-141-018_a
1. Sliding sleeve
Remove the shifter fork.

vmr2008-141-015_a
1. Oil seal
Remove the Allen set screw.
vmr2008-141-019_a
1. Shifter fork
Pull out the coupling sleeve.
vmr2008-141-016_a
1. Allen set screw
Pull out the sliding sleeve pin.
226 vmr2015-023
vmr2008-141-023_a
vmr2008-141-020_a
1. Coupling unit shaft
1. Coupling sleeve
Remove the inner circlip. Using the BLIND HOLE BEARING PULLER SET
(P/N 529 036 117), remove the ball bearing.
529036117
vmr2008-141-021_a
1. Inner circlilp NOTE: Remove the ball bearing only if it does not
turn freely and smoothly.
Turn the coupling unit housing and remove the
outer circlip. Coupling Unit Inspection
Check disconnect unit housing and actuator for
cracks or other damages. Replace defective
part(s) if necessary.
Check if the actuator O-ring and the coupling unit
housing O-ring are brittle, hard or damaged.
Check splines of coupling sleeve for wear or other
damages. Replace if splines are damaged.
vmr2008-141-022_a
1. Outer circlip
Remove coupling unit shaft.
V07H0TA
vmr2015-023 227
Measure the coupling sleeve groove. If the width Check shifter fork for visible damage, wear or bent
of groove is out of specification replace the cou- claws.
pling sleeve. Measure the shifter fork claw thicknesses.
COUPLING SLEEVE GROOVE WIDTH SHIFTER FORK CLAWS THICKNESS
Service limit 5.00 mm (.197 in) Service limit 2.93 mm (.115 in)
V07H0XA
A. Shifter fork claw thickness
Check inner and outer shaft splines for wear or

other damages. Replace shaft if necessary.
V07H0UA Measure the coupling unit shaft for wear limit.
A. Groove width
COUPLING UNIT SHAFT
Check sliding sleeve dog for bend and measure it. Service limit 29.995 mm (1.181 in)
SLIDING SLEEVE DOG THICKNESS
Service limit 4.80 mm (.189 in)
Measure the sliding sleeve groove.

SLIDING SLEEVE GROOVE WIDTH
Service limit 3.60 mm (.142 in) A
V07H0YA
A. Shaft diameter in the area of bearing

A
Coupling Unit Assembly
The installation is the reverse of removal proce-
dure. However, pay attention to the following:
Apply engine oil on moving parts.
Install the shifter fork and coupling sleeve as per
the following illustrations.
V07H0WA B
A. Sliding sleeve dog thickness
B. Sliding sleeve groove width
228 vmr2015-023
V07H0ZA
V07H12A
Insert pin and install Allen set screw.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on Move the sliding sleeve on right side and check if
threads of Allen set screw. the coupling sleeve is flush with the end of shaft.
Install and tighten the Allen set screw to specifi-
cation.
TIGHTENING TORQUE
7 N•m ± 1 N•m
Actuator screw +
LOCTITE 243 (BLUE)
(P/N 293 800 060)
Check if the shifter plate and the coupling sleeve

are installed properly.
When the sliding sleeve is positioned on left side,
the coupling sleeve is equal with the end of the
shaft splines.
V07H15A
vmr2015-023 229
Install the actuator onto the coupling unit. Refer

to ACTUATOR INSTALLATION in this section.
Coupling Unit Installation

The installation is the reverse of removal proce-
dure. However, pay attention to the following:
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on
coupling unit housing O-ring.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of coupling unit screws and tighten to
specification.
TIGHTENING TORQUE
25 N•m ± 3.5 N•m
Coupling unit screw +
LOCTITE 243 (BLUE)
(P/N 293 800 060)
Install all other removed parts and check if the ac-

tuator is operational. See the procedure in ACTU-
ATOR INSTALLATION in this subsection.
230 vmr2015-023
GEARBOX AND 4X4 COUPLING UNIT
vmr2016-037 169
GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM
Super Lube
grease
Engine
oil 10 ± 1 Nm
Engine (89 ± 9 lbfin)
oil
Loctite 243
25 ± 3 Nm
(18 ± 2 lbfft)
Engine oil
Loctite
Super Lube 243
grease NEW
Engine
oil Engine oil
Engine
oil
NEW
Engine
oil Super Lube
grease

vmr2012-019-001_a
170 vmr2016-037
GEARBOX HOUSING AND 4X4 ACTUATOR UNIT
2.5 ± 0.3 N•m

(22 ± 3 lbf•in)
Petamo grease
Petamo
grease
Petamo
grease

vmr2015-036-001_a
vmr2016-037 171
GENERAL 4 WHEEL DRIVE INDICATION FAILS

1. 4WD indicator switch failure.
OVERVIEW - Test 4WD indicator switch. Replace as required.
- Bad contact. Check for corrosion or loose con-
nector.
- Damaged wires. Repair as required.
4 WHEEL DRIVE DOES NOT ENGAGE OR

DISENGAGE
1. Defective 4WD switch.
- Check 4WD switch operation.
2. Defective actuator.
- Test actuator.
3. Damaged or worn shifting fork or sleeve.
- Remove actuator and inspect shifting fork and
sleeve.
vmr2012-019-003_a
1. Right housing PROCEDURES

2. Center housing
3. Left housing
4.
5.
Output shaft
Bearing cover
GEARBOX POSITION INDICATOR
6.
7.
Countershaft
Shift shaft
SWITCHES
8. Actuator
NOTE: First ensure shifter link rod is properly ad-
justed, refer to SHIFTER subsection.
TROUBLESHOOTING
UNUSUAL GEARBOX NOISE AND/OR Access
VIBRATIONS
1. Low oil level in gearbox. ing:
- Oil leakage from gearbox. Replace damaged gas- – Seat
ket(s) and/or oil seal(s).
– Console
2. Defective bearings. – RH side panel and extension(s)
- Bearing(s) do(es) not turn smoothly. Replace – RH footrest panel.
bearing(s).
3. Damaged or worn gears.
- Inspect gears for damages or missing teeth. Re-
place respective gears.
GEAR INDICATION FAILS

1. Check contact screws on gear housing center.
- Contact(s) is (are) corroded and/or connectors to
wiring harness got loose.
- Damaged wires. Repair as required.
- Shifting indicator switch(es) pin(s) is (are) worn
and/or damaged. Replace shifting indicator
switch(es).
GEAR(S) IS (ARE) HARD TO SHIFT

1. Incorrect shift rod adjustment. vmr2015-036-101
- Adjust shift rod (refer to SHIFT ROD in SHIFTER

subsection).
172 vmr2016-037
Testing the Gearbox Position Indicator A blank space indicates switch is not making con-
Switch Continuity tact, there should be no continuity (R = infinite).
1. Remove parts required for access, refer to If the indicator switch is good, check the vehicle
GEARBOX POSITION INDICATOR SWITCH harness and/or indicator lights.
ACCESS in this subsection.
NOTE: Take note of corresponding switch posi-
Removing the Gearbox Position
tion and wire color. Indicator Switch
2. Disconnect wires from switches. NOTE: Clean area of dirt before removing gear-
box indicator position switch(es). Take note of cor-
NOTE: Remove insulating paint to obtain correct responding switch position and wire color.
readings.
Disconnect indicator switch from engine wiring
3. Using a multimeter, measure the resistance harness.
from the indicator switch to engine ground
while selecting the gearbox to each position.
Compare results with the logic table below.
vmr2012-019-004_a
1. Gearbox position indicator switches

2. BROWN/GREY wire
3. WHITE/RED wire
vmr2012-019-004_b 4. ORANGE/GREY wire
1. Gearbox position indicator switch - position 1
2. Gearbox position indicator switch - position 2 Unscrew switch.
3. Gearbox position indicator switch - position 3
4. BROWN/GREY wire
5. WHITE/RED wire Installing the Gearbox Position
6. ORANGE/GREY wire
Indicator Switch
SHIFTER
CORRESPONDING SWITCH
POSITION tention to the following.
BROWN/ WHITE/ ORANGE/ Take care to avoid damaging threads in switch
GREY RED GREY bores during installation.
Position 1 Position 2 Position 3 Carefully apply some sealant on threads of shift
L X X
indicator switches.
H X NOTICE Do not apply Loctite 5910 on switch

plunger as it will lead to switch malfunction.
N X X
SERVICE PRODUCT
R X
P X X LOCTITE 5910 (P/N 293
Indicator switches
800 081)
An “X” indicates switch is making ground contact,
thus there should be continuity (R is close to 0
Ohms).
vmr2016-037 173
TIGHTENING TORQUE Removing the 4WD Indicator Switch

2.5 N•m ± 0.3 N•m Disconnect 4WD indicator switch connector from
Indicator switches engine wiring harness.
If all switches are removed, make sure to put the

wires back in the correct location as noted prior to
removal.
vmr2012-019-005_a
1. 4WD indicator switch

2. BLACK/BEIGE wire for contact to 4WD
3. Actuator
vmr2012-019-004_a
Testing the 4WD Indicator Switch
1. Indicator switches
2. BROWN/GREY wire Measure switch resistance as follows.
3. WHITE/RED wire
4. ORANGE/GREY wire SWITCH
SWITCH WIRE RESISTANCE
POSITION
4WD INDICATOR SWITCH 2WD BLACK/ Engine Close to 0
4WD Indicator Switch Access 4WD BEIGE ground Infinite (OL)
ing: If the resistance is out of specification, replace the
4WD indicator switch.
– Seat
– Console Installing the 4WD Indicator Switch
– RH side panel and extension(s) Reverse the removal procedure. However, pay at-
– RH footrest panel. tention to the following.
Take care to avoid damaging threads in switch
bore during installation.
Carefully apply some sealant on threads of indica-
tor switch.
NOTICE Do not apply Loctite 5910 on switch
plunger, as it will lead to switch malfunction.
SERVICE PRODUCT
LOCTITE 5910
4WD indicator switch
(P/N 293 800 081)
vmr2015-036-102
4WD INDICATOR SWITCH LOCATIONS
174 vmr2016-037
TIGHTENING TORQUE
2.5 N•m ± 0.3 N•m
4WD indicator switch
4WD ACTUATOR
4WD Actuator Access
To access the actuator, refer to BODY subsection
and remove the following parts:
– Seat
– Console
– RH footrest panel. vmr2012-037-006_a
1. Remove retaining screws from master cylinder support

Testing the 4WD Actuator
REQUIRED TOOL

(P/N 529 035 868)
1. Unplug 4WD actuator connector.

2. Turn ignition key ON.
3. Set emergency engine stop switch to RUN.
4. Measure voltage as follows.
SWITCH
SWITCH WIRE VOLTAGE
POSITION
2WD WHITE/BLUE Battery
WHITE vmr2012-037-007_a
4WD WHITE/BLACK voltage 1. Master cylinder moved apart
If the selector is out of specifications, check 2. Unplug actuator connector.

wires, connectors and replace the selector if nec- 3. Place a drain pan under actuator.
essary. 4. Unscrew actuator bolts.
If the selector is good, check the vehicle harness.
If the vehicle harness is good, replace the actua-
tor.
Removing the 4WD Actuator

NOTE: Before beginning any servicing on the ac-
tuator, make sure the vehicle is in 4WD position.
No need to remove engine from vehicle.
1. Detach brake master cylinder from frame.
vmr2006-022-131_a
5. When all actuator bolts are removed, pull the

actuator out of housing.
vmr2016-037 175
Installing the 4WD Actuator

1. Lubricate actuator O-ring.
SERVICE PRODUCT
SUPER LUBE GREASE
Actuator O-ring
(P/N 293 550 030)
Vmr2015-123-003_a
1. Actuator O-ring
2. Verify if coupling fork is in 4WD position. The vmr2006-022-133_a
coupling fork should be positioned toward the

4. Rotate the actuator counterclockwise until it ori-
front of vehicle.
ents itself to mounting position.
NOTICE Do not cut or break the actuator
O-ring.
5. Install all actuator bolts then torque them to
specification.
TIGHTENING TORQUE
25 N•m ± 3 N•m
Actuator screws
6. Connect actuator.
7. Lift the front of vehicle.
8. Turn front wheels. The front propeller shaft
should not turn (the PARK position must be
vmr2006-022-132_a selected).
3. Align the actuator fork with the pin on coupling If the front propeller shaft turns, the actuator is not
fork then push the actuator in the housing. See installed correctly. Remove actuator and reinstall
the following illustration to position the actuator it.
correctly. 9. Set ignition switch to ON.
11. Select the 2WD position.
12. 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.
176 vmr2016-037
NOTICE Refill missing gearbox oil, refer to

PERIODIC MAINTENANCE PROCEDURES sub-
section.
13. Install all other removed parts.
GEARBOX OIL SEALS

Replacing the Gearbox Oil Seals
Replace oil seals if they are brittle, hard or dam-
aged.
A small flat screwdriver can be used to remove
most of these oil seals.
NOTICE Avoid scoring parts during oil seal
removal.
When replacing an oil seal, take this opportunity vmr2006-022-006_a
1. Countershaft oil seal

to inspect the following: 2. Distance sleeve
– Check bearings behind each oil seal for contam-
ination and/or metal shavings. NOTE: When oil seal is removed also inspect
– Check oil seal running surfaces for scratches. O-ring.
Lubricating the Oil Seal

When installing or reinstalling oil seals, use
PETAMO GREASE GHY 133N (P/N 420 899 271) to:
– Lubricate sealing lips all around.
– Fill up the room between sealing lips halfway
around the perimeter.
vmr2012-019-006_a
1. Distance sleeve
2. O-ring
For countershaft oil seal installation use the fol-

vmr2013-020-001_a lowing service tool.
1. Sealing lips
2. Room between sealing lips REQUIRED TOOL
Countershaft Oil Seal COUNTERSHAFT OIL SEAL

The countershaft oil seal can be removed without PUSHER (P/N 529 036 222)
removing gearbox from vehicle. Remove drive
and driven pulley and CVT air guide.
vmr2016-037 177
vmr2012-019-007_a
1. Countershaft oil seal

2. Oil seal pusher
vmr2012-019-008_a
Shift Shaft Oil Seal 1. Distance sleeve

2. O-ring
The shift shaft oil seal can be removed without
removing the gearbox from the vehicle.
To replace the shift shaft oil seal, refer to BODY
subsection and remove:
– Seat
– Console
– RH side panel
– RH footrest panel
– Shift plate from shift shaft (refer to SHIFTER
subsection.
Using a suitable tube with the proper diameter to
install the shift shaft oil seal.
If gearbox housing is apart, the following tools can
be used for shift shaft oil seal installation.
vmr2006-022-007_a
REQUIRED TOOL 1. Shift shaft oil seal

2. Output shaft oil seal
OIL SEAL INSTALLER
(GEARBOX) (P/N 529 035 758) For output shaft oil seal installation use the follow-
ing service tool.
HANDLE (P/N 420 877 650)
REQUIRED TOOL
NOTICE Oil seal must be installed with seal- DRIVE SHAFT OIL SEAL
ing lip toward gearbox. INSTALLER (P/N 529 036 028)
Output Shaft Oil Seal

Remove propeller shaft. Refer to REAR DRIVE
subsection.
Punch a sharp screwdriver through oil seal for re-
moval.
NOTE: When oil seal is removed also inspect
O-ring.
178 vmr2016-037
3. Remove:
– Distance sleeve
– O-ring.
vmr2006-022-008_a
1. Output shaft oil seal

OUTPUT SHAFT AND COUPLING

MECHANISM vmr2006-022-011_a
1. Distance sleeve
Remove gearbox. Refer to GEARBOX in this sub- 2. O-ring
section.
4. Install the measurement tool at the end of out-
Before removing the right housing and output put shaft.
shaft measure the backlash on output shaft. This
measure will indicate if output shaft adjustment REQUIRED TOOL
is necessary.
BACKLASH MEASUREMENT
Output Shaft Backlash Procedure TOOL (P/N 529 036 030)
1. Engage PARK position on the gear shaft to
block gearbox.
5. From center of tool bolt, measure 47 mm
2. Remove bearing cover with oil seal (1.85 in)and place a mark on the tab.
vmr2006-022-010_a
1. Bearing cover
2. Oil seal
vmr2016-037 179
vmr2006-022-021
vmr2006-022-012_a
1. Backlash measurement tool

2. Mark on tab
A. 47 mm (1.85 in)
6. Position the head of the dial indicator, against

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)
vmr2006-022-022
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. 5. Remove output shaft.
NOTE: Use next thicker shim to increase back- REQUIRED TOOL
lash and next thinner shim to reduce backlash. Soft hammer
Removing the Output Shaft and

Coupling Mechanism
1. Remove actuator.
2. Remove the bearing cover with oil seal.
3. Unscrew all bolts retaining the right housing to
the center housing.
4. To remove right housing, use 2 big screw-
drivers.
180 vmr2016-037
vmr2012-019-009_a vmr2012-019-010_a
1. Output shaft 1. Ball bearing

2. Coupling sleeve 2. Thrust washer
3. Soft hammer 3. Distance ring
6. Remove: 8. Remove:
– Coupling sleeve – Screw
– O-ring – Pin
– Ball bearing – Coupling fork.
– Thrust washer.
vmr2006-022-024_a
vmr2015-036-002_a
1. Coupling sleeve
2. O-ring 1. Screw
3. Ball bearing 2. Pin
4. Thrust washer 3. Coupling fork
7. Remove: Inspecting the Output Shaft and

– Ball bearing Coupling Mechanism
– Thrust washer. Check output shaft and its gear for cracks, bend,
pitting or other visible damages.
Check output shaft splines for wear or other dam-
ages.
NOTICE Always replace output shaft and
bevel gear shaft at the same time. Adjust
these components upon replacement.
Check if the output shaft ball bearings turn freely
and smoothly. Replace if necessary, refer to
GEARBOX ADJUSTMENT in this subsection.
vmr2016-037 181
Replace oil seal if brittle, hard or damaged. COUPLING FORK CLAW THICKNESS
Replace O-rings if brittle, hard or damaged. 4.95 to 5.05 mm
NEW
Check splines of coupling sleeve for wear or other (.195 to .199 in)
damages. SERVICE LIMIT 4.80 mm (.189 in)
Clean housing split surface and especially the

bearing areas from metal particles or other con-
tamination.
Installing the Output Shaft and

Coupling Mechanism
Install thrust washer, bearing, O-ring and coupling
vmr2006-022-030_a
sleeve onto the output shaft.
1. Inspect splines
Install distance ring, thrust washer and ball bear-
Measure the coupling sleeve groove width. ing.
NOTE: O-ring and distance sleeve are not in-
stalled at this time.
Place the output shaft into the center housing.
Use soft hammer to put bearing exactly in place
against center housing.
vmr2006-022-031_a
A. Groove width
COUPLING SLEEVE GROOVE WIDTH

5.25 to 5.35 mm
NEW
(.207 to .211 in)
Check coupling fork claw thickness.
vmr2012-019-011_a
1. Soft hammer
Clean the bearing cover location then attach bear-

ing cover with oil seal to the housing.
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 ham-
mer to take up all gear free play.
vmr2006-022-032_a
Verify output shaft backlash. Refer to OUTPUT
1. Coupling fork SHAFT BACKLASH PROCEDURE in this subsec-
2. Micrometer tion. Adjust as required.
182 vmr2016-037
If backlash is within specifications, remove dial

indicator, backlash measuring tool, bearing cover
and right housing.
NOTE: Install coupling fork, pin and screw in right
housing before applying sealant to the mating sur-
face.
F12R17A
Do not apply in excess as it will spread out inside

housings.
vmr2015-036-003_a
1. Coupling fork
2. Pin method, you may use your finger to uniformly dis-
3. Screw tribute the sealant (using a finger will not affect
the adhesion).
Install all other screws on right housing then the
Housing mating surfaces are best cleaned us- O-ring and the distance sleeve on end of output
ing a combination of LOCTITE CHISEL (GASKET shaft. Chamfered bore of distance sleeve has to
REMOVER) (P/N 413 708 500) and a brass brush.
face the engine.
Brush a first pass in one direction then make the
final brushing perpendicularly (90°) to the first
pass cross (hatch).
NOTICE Do not wipe with rags. Use a new
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.
faces.
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, vmr2006-022-037_a
apply the sealant on housing mating surfaces. 1. O-ring
2. Distance sleeve
NOTE: To install the right housing align the cou-

pling fork with the groove in the coupling sleeve.
Torque the four (4) M8 Torx screws in a crisscross
sequence to following specification.
vmr2016-037 183
TIGHTENING TORQUE Disassembling the Gearbox

Step A Hand tightened NOTE: During gearbox disassembly, inspect the
Right housing condition of each part closely.
M8 screws 25 N•m ± 3 N•m
Step B 1. Remove the output shaft. Refer to OUTPUT
SHAFT AND COUPLING MECHANISM in this
subsection.
2. Push bevel gear with a pin slightly down and
measure the axial clearance of bevel gear with
a feeler gauge.
NOTE: Bevel gear axial clearance must be mea-
sured before center and left housings separation.
vmr2006-022-036_a
Tighten all M6 Torx screws to specification

TIGHTENING TORQUE
Right housing M6 10 N•m ± 1 N•m
Before installing bearing cover, apply LOCTITE

5910 (P/N 293 800 081) on the housing and SUPER vmr2006-022-040_a
1. Bevel gear
LUBE GREASE (P/N 293 550 030) on oil seal.
Install the actuator, refer to ACTUATOR in this
subsection.
Once this is done, complete final assembly.
GEARBOX
Removing the Gearbox
1. Remove engine from vehicle and place it on
footrest support. Refer to ENGINE REMOVAL
AND INSTALLATION subsection for the proce-
dure.
2. Drain gearbox. Refer to GEARBOX OIL DRAIN-
ING PROCEDURE in PERIODIC MAINTE-
NANCE PROCEDURES subsection.
3. Remove drive and driven pulley and CVT air
guide, refer to CONTINUOUSLY VARIABLE
TRANSMISSION (CVT) subsection. vmr2006-022-041
4. Unscrew the three (3) nuts that attach the gear- MEASURE AXIAL CLEARANCE OF BEVEL GEAR
box to the engine.
5. Pull gearbox to separate it from engine.
184 vmr2016-037
BEVEL GEAR AXIAL CLEARANCE

0.02 to 0.15 mm
NEW
(.00079 to .0059 in)
3. Unscrew the left housing screws.

4. Place the left housing on a wood stand, center
housing pointing upwards.
5. Using 2 big flat screwdrivers, lift the center
housing.
vmr2006-022-055_a
1. Shift shaft assembly
8. Remove shift fork shaft.

9. Disengage shift forks from shift drum and re-
move shift fork.
vmr2006-022-045
vmr2006-022-056_a
1. Shift fork shaft

2. Shift fork
3. Shift drum
10. Remove bevel gear shaft with low range gear

assembly and shim.
vmr2006-022-046
6. Remove center housing completely.

7. Remove shift shaft assembly.
vmr2016-037 185
vmr2006-022-058_a
vmr2006-022-060_a
1. Bevel gear 1. Thrust washer
2. Low range gear
3. Shim 2. Needle bearing
3. Reverse gear
11. Remove sliding gear with shift fork. 13. Remove shim on CVT side.
vmr2006-022-059_a vmr2006-022-061_a
1. Sliding gear 1. Shim on CVT side

2. Shift fork
14. Remove countershaft with low range gear and
12. Remove thrust washer, needle bearing and re-
high range gear assembly.
verse gear.
186 vmr2016-037
vmr2006-022-066_a
1. Parking lock lever
17. Remove index lever with washer, step ring

vmr2006-022-062_a
and spring.
1. Countershaft
2. Low range gear
3. High range gear
15. Insert a flat screwdriver in the slot of index

lever. Turn screwdriver clockwise and remove
shift drum.
vmr2006-022-067_a
1. Index lever
2. Washer
3. Step ring
4. Index spring
18. Remove support flange.

vmr2006-022-065_a NOTE: To remove intermediate gear and needle
1. Index lever bearing, use a press bench to push out the inter-
2. Shift drum
mediate gear shaft.
16. Remove parking lock lever.
vmr2016-037 187
vmr2006-022-049_a
vmr2006-022-068_a 1. Bevel gear needle bearing

PRESS SHAFT IN THE DIRECTION AS SHOWN BY THE ARROW 2. Punch
1. Intermediate gear shaft 3. Center housing
2. Left housing
To remove ball bearings of bevel gear and needle
Removing the Bearings bearing of countershaft, use a blind hole bearing
If necessary heat housing up to 100°C (212°F) be- puller.
fore removing ball bearings or needle bearings. For countershaft ball bearing, remove screw and
intermediate gear shaft, then push with a suitable
WARNING puller from outside in.
Clean oil, outside and inside, from housing
before heating.
NOTICE Always support gearbox housings

properly when ball bearings or needle bear-
ings are removed. Housing damages may
occur if this procedure is not performed cor-
rectly.
To remove bevel gear needle bearing use a punch.
vmr2006-022-052_a
1. Screw
3. Ball bearing countershaft
Inspecting the Gearbox

Always verify for the following when inspecting
gearbox components:
– Gear teeth damage
– Worn or scoured bearing surfaces
188 vmr2016-037
– 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
– Worn shift fork engagement groove
– Worn splines on shafts and gears.
Bearings
Check if ball bearings and needle bearings turn
vmr2006-022-076_a
freely and smoothly.
1. Micrometer
Check all bearings, bearing points, tooth flanks, A. Shift fork pin diameter
taper grooves and annular grooves. Annular
grooves must have sharp edges. SHIFT FORK PIN DIAMETER
Shift Forks 6.920 to 6.970 mm

NEW
(.272 to .274 in)
Check both shift forks for visible damage, wear or
bent shift fork claws. SERVICE LIMIT 6.850 mm (.270 in)
Measure the shift fork claw thickness. Shift Drum
Check shift drum tracks for scouring or heavy
wear, like rounded engagement slots.
Replace isolating washer if there are signs of wear
or visible damages.
vmr2006-022-075_a
1. Micrometer
A. Shift fork claw thickness
vmr2006-022-078_a
SHIFT FORK CLAW THICKNESS 1. Track for the low/reverse gear shift fork
(HIGH GEAR SHIFTING) 2. Track for the high gear shift fork
3. Isolating washer on the shift drum
4.80 to 4.90 mm
NEW Levers
(.189 to .193 in)
SERVICE LIMIT 4.70 mm (.185 in) Check parking lever for cracks or other damages.
Index lever with roller must move freely.
SHIFT FORK CLAW THICKNESS
(LOW/REVERSE GEAR SHIFTING) Gears
5.10 to 5.20 mm NOTE: Replace gears only together with the
NEW corresponding meshing gears. Always replace
(.200 to .205 in)
circlips and use special pliers to install them.
Measure the width of shift fork engagement
Measure shift fork pins. groove.
vmr2016-037 189
DIAMETER FREE PINION

29.000 to 29.013 mm
NEW
(1.1417 to 1.1422 in)
Shafts
Check shift shaft for worn splines and gears.
Check intermediate shaft for wear.
vmr2006-022-077_a
1. Main gear
2. Caliper
A. Width for engagement of shift fork
WIDTH OF SHIFT FORK ENGAGEMENT

GROOVE (HIGH GEAR SHIFTING)
5.00 to 5.10 mm
NEW
(.197 to .201 in)
WIDTH OF SHIFT FORK ENGAGEMENT GROOVE vmr2012-019-012_a

(LOW/REVERSE GEAR SHIFTING) 1. Intermediate gear bearing
5.30 to 5.40 mm
NEW INTERMEDIATE GEAR SHAFT
(.209 to .213 in)
SERVICE LIMIT 5.50 mm (.217 in) 24.979 to 25.000 mm
NEW
(.9834 to .9842 in)
Check free pinions for wear. SERVICE LIMIT 24.977 mm (.9833 in)
Check countershaft for wear.
vmr2006-022-123_a
1. MAG side
2. Free pinion bearing
3. CVT side
COUNTERSHAFT
vmr2006-022-080_a
SERVICE LIMIT
TYPICAL
1. Micrometer MAG SIDE 17.990 mm (.708 in)
2. Free pinion
FREE PINION BEARING 24.970 mm (.983 in)
CVT SIDE 24.970 mm (.983 in)
Check bevel gear shaft.
190 vmr2016-037
a brass brush. Brush a first pass in one direction

then make the final brushing perpendicularly (90°)
to the first pass cross (hatch).
NOTICE Do not wipe with rags. Use a new
vmr2006-022-124_a
1. Free pinion bearings
BEVEL GEAR SHAFT

SERVICE LIMIT
FREE PINION BEARING 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 and bevel gear shaft.
vmr2006-022-125_a
1. Shim for adjusting the bevel gear on center housing side

2. Area where wear signs appear
3. Thickness of the shim
Adjusting the Gearbox

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.
Clean mating surface of housing before taking
measurements using a combination of LOCTITE
CHISEL (GASKET REMOVER) (P/N 413 708 500) and
vmr2016-037 191
B H
D(E)
A I(J)
1 G F
vmr2006-022-079_a
1. Mating surface — output shaft

2. Mating surface — left housing
Bevel Gear Backlash Procedure

Use the following course of calculation to determine 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.
192 vmr2016-037
This bevel gear reference number could be be- When the measurements are taken, calculate the
tween - 10 and + 10. theoretical shim thickness D using the formula:
(D = B - C - A).
Take the obtained theoretical shim thickness D
and choose the corresponding shim number E
according 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
(.0512 to .0547 in)
1.40 mm to 1.49 mm
140
(.0551 to .0587 in)
vmr2006-022-085_a
1. Bevel gear 1.50 mm to 1.59 mm

150
2. Bevel gear reference number (.0591 to .0626 in)
Use following formula to find out value B. 1.60 mm to 1.69 mm
160
(.0630 to .0665 in)
Bevel gear reference number 1.70 mm to 1.79 mm

B=( ) + 37.8 170
(.0669 to .0705 in)
100
1.80 mm to 1.89 mm
180
For example: bevel gear reference number = - 3. (.0709 to .0744 in)
B = (- 3/100) + 37.8 = 37.77 NOTE: For example, if the theoretical shim thick-
C = Distance between the shim thrust surface in ness D is 1.53 mm (.0602 in), choose the corre-
the center housing and the mating surface to sponding shim number 150 E. The shim number
right housing. 150 represents a nominal value equal to 1.50 mm
(.0591 in).
NOTE: For a better understanding following illus-
tration is made as a cutaway. Bevel Gear Axial Clearance Procedure
mine the theoretical shim thickness I:
I= F+G-H-A-E
F = Distance between mating surface of left
housing to ball bearing inner race.
vmr2012-019-013_a
1. Deep gauge — measurement C

2. Shim surface in center housing
3. Mating surface to right housing
A = 2 mm (.0787 in) nominal thickness of axial

needle bearing.
vmr2016-037 193
A = 2 mm (.0787 in) nominal thickness of axial

needle bearing.
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
SHIM THICKNESS
-J-
-I-
vmr2006-022-082_a 1.22 mm to 1.31 mm
120
1. Ball bearing inner race (.0480 to .0516 in)
2. Mating surface of left housing
3. Depth gauge 1.32 mm to 1.41 mm
130
(.0519 to .0555 in)
G = Distance between mating surface of center
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
shim number 150 J.
Bevel gear axial clearance of 0.02 to 0.11 mm
(.00079 to .00433 in) is included in the above
vmr2006-022-083_a
table.
1. Mating surface of center gear housing
2. Shim surface
Assembling the Gearbox
H = Distance between thrust surfaces of bevel Reverse the disassembly procedure. However,
gear shaft.
pay attention to the following details.
Installing the Bearings
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.
WARNING
Clean oil, outside and inside, from housing
vmr2006-022-084 before heating.
194 vmr2016-037
Place new bearing in freezer for 10 minutes be-

fore installation.
Use a suitable installer for installing ball bearings
of countershaft and bevel gear.
NOTE: Place gearbox housings on a wood stand
before installing ball bearings.
Install countershaft needle bearing in right hous-
ing.
REQUIRED TOOL
BEARING INSTALLER
(GEARBOX)
(P/N 529 035 762)
HANDLE (P/N 420 877 650) vmr2006-022-051_a
1. Bevel gear needle bearing

2. Center housing
3. Needle bearing installer
4. Installer handle
Install new oil seals with the proper installer (refer

to GEARBOX OIL SEALS in this subsection).
Other Gearbox Components
Fit intermediate gear with needle bearing on inter-
mediate gear shaft.
NOTE: Fit gear with collar facing to housing side
on the intermediate shaft.
vmr2006-022-050_a
1. Countershaft needle bearing

2. Right housing
3. Needle bearing installer
4. Installer handle
Install bevel gear needle bearing.

REQUIRED TOOL
BEARING INSTALLER
(GEARBOX) (P/N 529 035 763)
HANDLE (P/N 420 877 650)
vmr2006-022-089_a
2. Collar facing housing
3. Needle bearing
Press intermediate gear shaft in the left housing.
vmr2016-037 195
vmr2006-022-066_a
1. Parking lock lever

vmr2006-022-052_b

Place shim of CVT side on bearing.
Fit support flange in the left housing and install

index lever.
NOTE: Fit step ring into index lever.
vmr2006-022-090_a
vmr2006-022-092_a
1. Washer
2. Index lever 1. Shim CVT side
3. Step ring
4. Index spring Place reverse gear with needle bearing and thrust
Install parking lock lever, teeth showing to coun- washer.
tershaft. NOTE: Check if the screw to secure countershaft
bearing is installed.
196 vmr2016-037
vmr2006-022-095_a
1. Bevel gear
2. Sliding gear
vmr2006-022-093_a 3. Shift fork
1. Reverse gear
2. Needle bearing Install a new needle bearing and shim.
3. Thrust washer
4. Countershaft bearing screw
Install countershaft with low gear and high gear

assembly.
vmr2006-022-096_a
1. Needle bearing
2. Shim
Insert a flat screwdriver in the slot of the index

lever, turn screwdriver clockwise and install shift
vmr2006-022-094_a
drum on neutral position as per following illustra-
1. Countershaft
2. Low gear tion.
3. High gear
Install a new shim onto bevel gear shaft, 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
in this subsection. If the existing bevel gear is
used, it is mandatory to use a new shim with the
same thickness, a new needle bearing and shim.
vmr2016-037 197
vmr2006-022-097_a vmr2006-022-098_a
1. Index lever 1. Shift shaft assembly

2. Shift drum 2. Isolating washer
3. Neutral position 3. Marks
Install shift fork 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.
vmr2006-022-101_a
1. Parking stop location

2. Reverse stop location
3. Neutral stop location
4. High gear stop location
5. Low gear stop location
Install shift shaft assembly.

NOTE: Marks on shift drum/isolating washer and
shift shaft must align.
vmr2006-022-099_a
1. Shift fork pins

2. Sliding gear
Install shift fork shaft.

NOTE: Run all gears as a final function check be-
fore installing center housing.
Now, close the housings by doing the following:
198 vmr2016-037
Gearbox housing mating surfaces are best TIGHTENING TORQUE

cleaned using a combination of LOCTITE CHISEL
(GASKET REMOVER) (P/N 413 708 500) and a brass Step A Hand tightened
Gear housing
brush. Brush a first pass in one direction then screws 10 N•m ± 1 N•m
Step B
make the final brushing perpendicularly (90°) to (89 lbf•in ± 9 lbf•in)
the first pass cross (hatch).
Install O-ring including distance sleeve on counter-
NOTICE Do not wipe with rags. Use a new shaft CVT side.
NOTICE Place O-ring including distance
IMPORTANT: When beginning the application of sleeve right away. Chamfered bore of distance
the gear housing sealant, the assembly and the sleeve has to face the gearbox.
first torquing should be done within 10 minutes.
It is suggested to have all you need on hand to
save time.
faces.
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, ap-
ply 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
Refer to OUTPUT SHAFT AND COUPLING

MECHANISM to install these components. Mea-
sure the output shaft backlash.
Installing the Gearbox

F12R17A
cedure.
Do not apply in excess as it will spread out inside
gear housing. Before gearbox installation check O-ring in bearing
cover if brittle, hard or damaged. Replace if nec-
essary.
method, you may use your finger to uniformly dis-
tribute the sealant (using a finger will not affect
the adhesion).
Tighten gear housing screws in a crisscross se-
quence.
vmr2016-037 199
vmr2016-037-001_a
1. O-ring
2. Bearing cover
Tighten the three (3) nuts that attaching the gear-

box to the engine.
SERVICE PRODUCT
LOCTITE 243 (BLUE)
Gearbox retaining nuts
(P/N 293 800 060)
TIGHTENING TORQUE
25 N•m ± 3 N•m
Gearbox retaining nuts
After installation refill gearbox oil, refer to PERI-

ODIC MAINTENANCE PROCEDURES.
200 vmr2016-037
Subsection 13 (SHIFTER)
SHIFTER
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 232
CE Models
Loctite 243
(5 ± 0.5 N•m
44 ± 4 lbf•in)
Loctite 243
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
vmr2015-024-101_a
vmr2015-024 231
PROCEDURES
HANDLE
Handle Removal
vmr2015-024-004_a
SHIFT LEVER POSITION
3. Remove parts as indicated in following illustra-

tions.
vmr2015-024-002_a
Step 1: Loosen lock nut

Step 2: Unscrew shift lever handle
Handle Installation
SERVICE PRODUCT WHERE USED
LOCTITE 243 (BLUE)
Shift lever threads
(P/N 293 800 060)
SHIFT LEVER
Shift Lever Access
1. Refer to BODY subsection and remove the fol- vmr2015-024-003_a
lowing components: 1. Shift lever handle

– Seat
– Console
– RH side panel and extension panel.
Shift Lever Removal

1. Remove body parts as required. Refer to SHIFT
LEVER ACCESS in this subsection.
2. Secure vehicle using wheel blocks.
vmr2015-024-006_a
1. Remove spring
232 vmr2015-024
Shift Lever Installation

Adjust shift lever handle as per following illustra-
tion.
vmr2015-024-005_a
vmr2012-021-005_a
SHIFT LEVER HANDLE ALIGNMENT

1. Handle
2. Ridge
A. Handle parallel with ridge
Check if shift lever works properly in all positions.

Ensure throttle cable does not interfere with shift
lever in all positions.
NOTE: Shift lever must be perfectly centered
vmr2015-024-007_a
with the neutral position indicator when transmis-
sion is engaged in neutral.
vmr2015-024-008_a
1. Locking tie to cut vmr2015-024-004_a
SHIFT LEVER ALIGNMENT WITH NEUTRAL POSITION

4. Remove shift lever with shift lever support. INDICATOR
Shift Lever Inspection NOTE: If adjustment is required, refer to SHIFT

Check shift lever for bending or cracks. ROD ADJUSTMENT in this subsection.
Check spring and bushing condition.
Check ball joint condition.
Replace all damaged parts.
vmr2015-024 233
SHIFT ROD
Shift Rod Adjustment
1. Place shift lever in NEUTRAL position.
NOTICE Move vehicle back and forth to en-
sure gearbox is set in neutral position.
4. Loosen shift rod adjuster lock nuts.
NOTE: Be aware that one of the adjuster lock
nuts has LH threads, while the other has RH
threads.
vmr2012-021-006_a
SHIFT LEVER CENTERED WITHIN NEUTRAL NOTCH

A. Shift lever
B. Neutral notch
NOTE: Ensure there is the same thread length

each side of rod adjuster.
vmr2015-024-104_a
1. Adjuster lock nuts
5. Turn rod adjuster to center shift lever in neutral

notch.
vmr2015-024-104_c
EQUAL THREAD LENGTH BOTH SIDES OF ADJUSTER

A. Thread length ball joint end
B. Thread length shift rod end
6. Move shift lever to R position then to H posi-

tion.
8. Check if shift lever is properly centered in neu-
tral notch. Readjust as required.
9. Test the shifter to confirm that the system
vmr2015-024-104_b
works properly in all positions.
1. Shift rod adjuster 10. Hold adjuster steady and tighten lock nuts.
234 vmr2015-024
vmr2015-024-102_a vmr2015-024-106_a
1. Adjuster lock nuts tightened 1. Remove nut and bolt
NOTE: Ensure shift rod ball joint is parallel with 3. Trace an index mark on shift plate and shift
shift plate. It may be necessary to realign shift rod shaft.
ball joint to ensure freedom of movement.
vmr2015-024-107_a
vmr2015-024-103_a
1. Trace a mark on both parts
A. Parallel within +/- 5°
4. Remove shift plate nut and bolt.
WARNING
After adjustment, make sure the PARK posi-
tion is also properly set.
SHIFT PLATE
Shift Plate Removal
NOTE: Do not remove shift plate needlessly.
1. Refer to BODY subsection and remove the fol-
lowing components:
– Seat
– Console vmr2015-024-105_a
– RH side panel 1. Shift plate nut
– RH engine cover 2. Shift plate bolt
2. Remove shift rod from shift plate. 5. Remove shift plate.
Shift Plate Inspection

Check shift plate for:
– Cracks
– Bending
– Spline condition.
vmr2015-024 235
Shift Plate Installation

Ensure gearbox is in NEUTRAL position before
shift plate installation.
Align shift plate using marks previously traced.
If there are no index marks, adjust shift plate as
per following illustration.
1
vmr2015-024-109_a
1. Horizontal plane line (ref. lower frame member)

A. 43.7°
Center the shift plate opening with the groove of

the shift shaft.
vmr2015-024-108_a
1. Shift plate opening

2. Shift shaft groove
Adjust shift rod, refer to SHIFT ROD ADJUST-

MENT in this subsection.
Tighten shift plate nut to specification.
SHIFT PLATE NUT TORQUE
9 N•m ± 1 N•m (80 lbf•in ± 9 lbf•in)
236 vmr2015-024
SHIFTER
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 202
CE Models
Loctite 243
(5 ± 0.5 N•m
44 ± 4 lbf•in)
Loctite 243
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
vmr2015-037-001_a
vmr2016-038 201
PROCEDURES
HANDLE
Handle Removal
vmr2015-024-004_a
SHIFT LEVER POSITION
3. Remove parts as indicated in following illustra-

tions.
vmr2015-024-002_a
Step 1: Loosen lock nut

Step 2: Unscrew shift lever handle
Handle Installation
SERVICE PRODUCT WHERE USED
LOCTITE 243 (BLUE)
Shift lever threads
(P/N 293 800 060)
SHIFT LEVER
Shift Lever Access
1. Refer to BODY subsection and remove the fol- vmr2015-024-003_a
lowing components: 1. Shift lever handle

– Seat
– Console
– RH side panel.
Shift Lever Removal

vmr2015-024-006_a
TYPICAL
1. Remove spring
202 vmr2016-038
Check ball joint condition.

Shift Lever Installation

Adjust shift lever handle as per following illustra-
tion.
vmr2015-024-005_a
TYPICAL
vmr2012-021-005_a
SHIFT LEVER HANDLE ALIGNMENT

1. Handle
2. Ridge
A. Handle parallel with ridge
Check if shift lever works properly in all positions.

Ensure throttle cable does not interfere with shift
vmr2015-024-007_a
lever in all positions.
TYPICAL NOTE: Shift lever must be perfectly centered
with the neutral position indicator when transmis-
sion is engaged in neutral.
vmr2015-024-008_a
TYPICAL
1. Locking tie to cut
vmr2015-024-004_a
4. Remove shift lever with shift lever support. SHIFT LEVER ALIGNMENT WITH NEUTRAL POSITION
INDICATOR
Shift Lever Inspection
NOTE: If adjustment is required, refer to SHIFT
Check shift lever for bending or cracks. ROD ADJUSTMENT in this subsection.
Check spring and bushing condition.
vmr2016-038 203
SHIFT ROD
Shift Rod Adjustment
NOTICE Move vehicle back and forth to en-
sure gearbox is set in neutral position.
4. Remove RH footboard.
5. Loosen shift rod adjustment nuts.
NOTE: Be aware that one of the adjuster lock
nuts has LH threads, while the other has RH
threads. vmr2012-021-006_a
SHIFT LEVER CENTERED WITHIN NEUTRAL NOTCH

A. Shift lever
B. Neutral notch
NOTE: Ensure there is the same thread length

each side of rod adjuster.
vmr2015-037-003_a
1. Adjustment nuts
6. Turn rod adjuster to center shift lever in neutral

notch.
vmr2015-037-003_c
EQUAL THREAD LENGTH BOTH SIDES OF ADJUSTER

A. Thread length ball joint end
B. Thread length shift rod end
7. Move shift lever in R position then in H position.

9. Check if shift lever is properly centered in neu-
tral notch. Readjust as required.
10. Hold adjuster steady and tighten lock nuts.
vmr2015-037-003_b
1. Shift rod adjuster
204 vmr2016-038
– RH side panel
2. Remove shift rod from shift plate.
vmr2015-037-002_a
1. Adjuster lock nuts tightened
11. Test the shifter to confirm that the system

works properly in all positions.
NOTE: Ensure shift rod ball joint is parallel with
vmr2015-037-005_a
shift plate. It may be necessary to realign shift rod
1. Bolt
ball joint to ensure freedom of movement. 2. Spacer
3. Nut
3. Trace an index mark on shift plate and shift

shaft.
vmr2015-037-004_a
1. Shift rod ball joint

2. Shift plate
A. Parallel within +/- 5°
vmr2015-037-006_a
WARNING 1. Trace a mark on both parts
After adjustment, make sure the PARK posi-
tion is also properly set. 4. Remove shift plate nut and bolt.
SHIFT PLATE
Shift Plate Removal
NOTE: Do not remove shift plate needlessly.
lowing components:
– Seat
– Console
vmr2016-038 205
A
OU
T
ATV
3
4
vmr2015-037-010_a
SHIFT PLATE ALIGNMENT

vmr2015-037-007_a
1. "ATV OUT" marking this side
1. Shift plate nut 2. Forward edge of shift plate
3. Horizontal plane (top forward surface crankcase)
4. Center of bolt (secondary alignment reference)
5. Remove shift plate.
A. 110° +/- 2.5°
Shift Plate Inspection Ensure that shift shaft protrudes shift plate as per
Check shift plate for: illustration.
– Cracks
– Bending
– Spline condition.
Shift Plate Installation

Place gearbox in NEUTRAL position before shift
plate installation.
Position shift plate with the marking "ATV OUT"
visible outward.
Align shift plate using marks previously traced.
If there are no index marks, adjust shift plate as
per following illustrations.
vmr2015-037-009_a
1. Shift shaft end

2. Shift plate
A. 2.5 mm ± 1 mm (.1 in ± .040 in)
Adjust shift rod, refer to SHIFT ROD ADJUST-

MENT in this subsection.
Tighten shift plate nut to specification.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Shift plate nut
206 vmr2016-038
Section 04 ELECTRONIC MANAGEMENT SYSTEM
Subsection 05 (DIAGNOSTIC AND FAULT CODES)
DIAGNOSTIC AND FAULT CODES

GENERAL NOTE: In some cases, the CHECK ENGINE mes-
sage can be displayed along with other messages.
MONITORING SYSTEM MULTI-
PILOT FUNCTION
The Engine Management System (EMS) features CAUSE
LAMP GAUGE
a monitoring system that self-diagnoses various MESSAGE
electrical and electronic components. This mode
becomes active when the ignition key is turned LO BATT VOLT Low system voltage
ON. HIGH BATT VOLT High system voltage
NOTE: Some components require the engine to LOW OIL
be running to be monitored (fuel injectors for ex- PRESSURE Low engine oil pressure
ample). STOP ENGINE
The monitoring system continuously validates An important engine
that the components (control modules, sensors management component
LIMP HOME
and actuators) are not faulty or defective. When MODE
is not working properly.
a malfunction is detected, the related electronic Vehicle performance is
module(s): purposely limited
– Sets an active fault code. An engine management
– Adapts the proper protection strategy accord- CHECK ENGINE component is not
functioning properly
ing to the failure.
– Sends out signals to the multifunction gauge to MAINTENANCE Periodic maintenance
REQUIRED required
inform the rider of a particular condition.
ECM NOT Communication error
A fault code is an indication that a glitch or mal-
RECOGNIZED between gauge and ECM
function is detected by the monitoring system of
the vehicle. DPS malfunction (DPS
CHECK DPS
model only)
If a minor fault occurs, the engine and vehicle will
continue to operate without noticeable loss of per- TRANSMISSION Gauge receives an invalid
SIGNAL FAULT gear position data
formance.
Displayed when brake is
If a more important fault occurs, engine RPM may BRAKE applied for more than 15
be limited. The engine/vehicle will continue to op- seconds (while riding)
erate with reduced performance.
If a major component of the EMS fails, engine HI TEMP High engine temperature
RPM will be limited as well as vehicle speed.
These strategies are used to protect
engine/electrical system from damage and Limp Home Mode
to maintain safe operation of the vehicle. In ex- When a major component of the EMS is not oper-
treme cases, the engine may also be completely ating properly, limp home mode will be set.
shut down. Engine RPM will be limited and/or engine behav-
ior and control may be modified depending on the
Pilot Lamps for Problematic cause of the failure.
Conditions
This mode allows the rider to return home, which
When a problem is detected, a pilot lamp will turn would otherwise not be possible without this ad-
on or blink in the multifunction gauge. If the fault vanced system.
that caused the pilot lamp to come on is momen-
tary, the pilot lamp may turn off automatically, or LIMP HOME will be displayed in the multifunction
may need to be reset by powering down the ve- gauge and the CHECK ENGINE light symbol will
hicle and then restarting it. be on in the gauge.
A message may also be displayed to provide ad-
ditional information related to the fault that turned
on the pilot lamp. Refer to the following chart.
vmr2016-043 207
Subsection 01 (ENGINE MANAGEMENT SYSTEM)
ENGINE MANAGEMENT SYSTEM

GENERAL
VSS OPS
GBPS CPS
CTS
INJ 1 ECM
MAPTS IACV
TPS IGN COIL
IN COOLING FAN
ECM IGN SW
START SW
OUT STARTER SOLENOID
ECM
FUEL PUMP
vmr2015-038-001_a
vmr2015-038 419
HIC2
ECM HIC1
TPS
IACV
INJ
MAPTS
BA
CTS
MD
GBPS
CPS
OPS
VSS
vmr2015-038-002_a
ABBREVIATION DEFINITION ABBREVIATION DEFINITION

BA Ignition coil Manifold absolute pressure and
MAPTS
temperature sensor
CPS Crankshaft position sensor
MD 4WD Actuator
CTS Coolant temperature sensor
OPS Oil pressure switch
ECM Electronic control module
SD 4WD Signal
GBPS Gear box position sensor
TPS Throttle position sensor
HIC1‡ Harness interconnect 1
VSS Vehicle speed sensor
‡Refer to applicable WIRING HARNESS AND
IACV Idle air control valve CONNECTORS subsection for the vehicle harness.
INJ1 Injector 1 (front)
420 vmr2015-038
SYSTEM DESCRIPTION Vehicle Speed Limiter

The HIC# connectors connect the vehicle harness The ECM will limit the maximum vehicle speed
to the powertrain harness. both in 2WD and in 4WD. For this purpose, the
ECM uses the VSS and the GBPS .
The MD connector connects to the 4 wheel drive
actuator. Drowned Mode (Flooded Engine)
There are 4 main systems that are controlled by If engine is fuel-flooded and does not start, this
the engine management system (EMS): special mode can be activated to prevent fuel in-
1. Electronic fuel injection (EFI) jection and ignition while cranking. Proceed as fol-
2. Ignition system lows to activate it.
3. Starting system With ignition key in ignition switch at ON position
4. Cooling system. while engine is stopped, press and HOLD throttle
lever at WOT position.
ENGINE CONTROL MODULE Press the start button. The mode is now on.
(ECM) Releasing throttle lever will bring back the normal
mode.
Monitoring System
The ECM monitors the electronic components
of the fuel injection system and also parts of the
electrical system.
For more information, refer to DIAGNOSTIC AND
FAULT CODES.
Limp Home Mode
The ECM may automatically set default parame-
ters to the engine management to ensure the ad-
equate operation of the engine if a component of
vmr2008-132-005
the fuel injection system is not operating prop-
ECM
erly. The engine will operate with reduced per-
The ECM controls the electrical system and the formance to protect the engine. In more severe
engine management functions, by processing the cases, the engine RPM will be limited, also to pro-
information given by various sensors. tect the engine.
The ECM is located on the left hand side of the air These performance-reduced modes allow the
filter housing. rider to go back home which would not be oth-
erwise possible without this advanced system.
Engine RPM Limiter Refer to the MONITORING SYSTEM/FAULT
The ECM will limit the maximum engine speed
CODES.
when vehicle shifter is in: Diagnostic Mode
– Forward position (Hi and LO individually)
The ECM features a self-diagnostic mode when
– Neutral position ignition key is turned on. However, some com-
– Park position ponents need the engine to be running so that
– Reverse position. they can be monitored. Some problems will turn
The ECM uses the CPS and the GBPS for this on a warning lamp or will set the engine in limp
function. home mode. Refer to DIAGNOSTIC AND FAULT
CODES section for more information.
An override switch, on the handlebar, allows the
engine speed to run higher than the RPM limiter
when more power is needed in reverse operation.
Refer to LIGHTS, GAUGE AND ACCESSORIES.
vmr2015-038 421
Subsection 03 (CONTROLLER AREA NETWORK (CAN))
CONTROLLER AREA NETWORK (CAN)

GENERAL
SYSTEM DESCRIPTION
The Controller Area Network (CAN) protocol is an
ISO standard for serial data communication. The
CAN bus links the ECM, multifunction gauge and
DPS module together so that they can communi-
cate to each other and interact as required. The
components (modules) are connected together by
2 wires and are in constant communication at a
rate of about every 20 milliseconds. CAN lines
consist of a pair of wires (WH/BE and WH/BK).
If a component or system malfunction is de-
tected, a module (ECM, multifunction gauge or
DPS) may generate a fault code, which it trans-
mits through the CAN bus as a signal. The fault
signal may be used for various functions such
as triggering the display of an error message
in the multifunction gauge cluster, turning on a
fault indicator light, limiting or inhibiting vehicle or
engine operation, or viewed using the B.U.D.S.
software for troubleshooting.
WH/BE
ECM3 Cl
18
WH/BK
vmr2015-039-001_a
Cl: Multifunction Gauge

DB: Diagnostic Connector
ECM3: Engine Control Module
DPS: Dynamic Power Steering
WH/BE: (wire color code)
WH/BK: (wire color code)
vmr2015-039 427
Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.)
COMMUNICATION TOOLS AND

B.U.D.S.
SERVICE TOOLS
DIAGNOSTIC CABLE .................................................................... 710 000 851 ......................................... 1, 3
MPI-2 INTERFACE CARD .............................................................. 529 036 018 ............................................. 1
MPI-3 INTERFACE CARD .............................................................. 529 036 353 ............................................. 1
GENERAL Multi-Purpose Interface Card

Refer to PROCEDURES for instructions on the
Connection Troubleshooting
communication tools. MPI Status Lights
If communication problems occur, refer to TROU- The MPI card includes 2 status lights that indicate
BLESHOOTING in this subsection. the connection condition: USB and CAN. Both
lights must be GREEN to function properly. Oth-
REQUIRED TOOLS erwise, refer to the following charts.
MANDATORY TOOLS
A personal computer (laptop or desktop)
MPI-2 INTERFACE CARD

(P/N 529 036 018)
OR
MPI-3 INTERFACE CARD (P/N 529 vdd2006-001-151_b
036 353) MPI-2 CARD
DIAGNOSTIC CABLE
(P/N 710 000 851)
OPTIONAL TOOL
USB
Extension cable
available at electronic retail outlets.
Do not exceed 7.5 m (25 ft) CAN
TROUBLESHOOTING
vmr2016-128-001_a
DIAGNOSTIC TIPS MPI-3 CARD
IMPORTANT: Make sure all connections are Prerequisite for USB Communication:
made and vehicle is powered up before starting – PC Computer turned on.
B.U.D.S. to allow proper communication between
– MPI card connected to PC computer.
the vehicle and the BRP Utility and Diagnostic
Software (B.U.D.S.)
vmr2016-128 1
USB LIGHT If one or more “ECU” is not communicating with

the MPI card, refer to DIAGNOSTIC AND FAULT
STATUS WHAT TO DO CODES.
Check USB connection between
Light is MPI card and PC computer.
No Vehicle is Detected
OFF Check USB operation on PC computer If an “X” is shown in the status bar and the pro-
(hardware or USB drivers) tocol indication is blinking between Kw2000 500K
Connections are GOOD. and KW2000, it means that no "ECU" is communi-
Light is cating with the MPI card.
Communication can take place
GREEN
on USB side
Prerequisite for CAN Communication:

– MPI card connected to diagnostic connector on
vehicle.
– Ignition key installed and turned to ON (electri-
cal system powered up without engine started). rmr2010-020-009
– B.U.D.S. started and logged on.

Check the following:
CAN LIGHT – Connections between the PC computer and the
STATUS WHAT TO DO vehicle.
– The multifunction gauge is powered up.
Light is Check connection between MPI card
OFF and diagnostic connector on vehicle If B.U.D.S. does not automatically exit the follow-
ing message box, click the Retry button. This will
Light is Check CAN wires/connectors on
manually establish the communication with the
RED vehicle
vehicle.
Connections are GOOD.
Light is
Communication can take place
GREEN
on CAN side
Communication Problems when Using

B.U.D.S.
rmr2015-124-005
Missing Module
Ensure the appropriate number of modules is PROCEDURES
shown at the bottom of B.U.D.S. screen.
MODEL NUMBER OF MODULES MULTI-PURPOSE INTERFACE
Models
2
CARD (MPI-2 OR MPI-3)
without
(ECM and multifunction gauge) The MPI (Multi-Purpose Interface) in conjunction
DPS
with the diagnostic cable is used with B.U.D.S. to
Models 3 communicate with the ECM (engine control mod-
with DPS (ECM, DPS and multifunction gauge) ule) and other modules.
MPI Card Power

The MPI card uses the power from the PC com-
puter's USB port.
Diagnostic Connector Location

vmr2016-128-002_a
The 6-pin diagnostic connector is located under
TYPICAL
the seat, stored in it's protective cap.
1. Number of modules
2 vmr2016-128
mmr2006-079-200
vmr2012-023-003_a
MPI CARD CABLE CONNECTED TO USB PORT
1. Diagnostic connector
6. Use B.U.D.S. as described further in B.U.D.S.
Connecting the PC to the Vehicle SOFTWARE topic
WARNING B.U.D.S. SOFTWARE
If the computer you are using is connected
to the 110 Vac power outlet, there is a poten- B.U.D.S. is designed for:
tial risk of electrocution when working in con- – Programming ignition key(s) to the vehicle
tact with water. Be careful not to touch water – Monitoring some electrical and electronic com-
while working with the VCK. ponents
– Activating certain components for diagnostic
1. Locate the 6-pin diagnostic connector, refer to purposes
DIAGNOSTIC CONNECTOR LOCATION in this – Updating electronic module software
subsection. – And, to carry out setting changes.
2. Disconnect the 6-pin diagnostic connector from Always use the latest applicable B.U.D.S. version
it's holder (protective cap). available on Knowledge Center.
3. Connect one end of the DIAGNOSTIC CABLE
(P/N 710 000 851) to the vehicle connector. Reading the Electronic Control Units
Using B.U.D.S. Software
IMPORTANT: Ensure all connections have been
made before starting B.U.D.S. to allow proper
operation. Refer to CONNECTING THE PC TO
THE VEHICLE in this subsection.
1. Turn ignition switch to ON. Do not start the en-
gine.
2. Set the emergency engine stop switch to RUN.
710000851 3. Start B.U.D.S. and logon.
DIAGNOSTIC CABLE CONNECTED TO VEHICLE
4. Ensure the status bar shows the appropriate
4. Connect the other end of diagnostic cable to the protocol and the appropriate number of mod-
MPI card. ules to its right according to the vehicle model.
5. Connect the MPI card to the USB port of a PC
(personal computer).
vmr2016-128 3
tmr2015-028-003_a
TYPICAL - SUCCESSFUL CONNECTION

1. Connection protocol
2. Number of modules read
MODEL NUMBER OF MODULES

Models without 2
DPS (ECM and multifunction gauge)
3
Models with
(ECM, DPS and multifunction smr2010-030-002_a
DPS
gauge) TYPICAL
If the number is less than indicated in NUMBER If the update icon is visible, B.U.D.S. indicates that
OF MODULES table, refer to TROUBLESHOOT- a file is available to update at least one of the elec-
ING in this subsection. tronic modules:
5. Read the ECUs by clicking the Read Data but- NOTE: If an update file is available on KNOWL-
ton. EDGE CENTER but the B.U.D.S. software being
used is not up to date, the update icon will not ap-
pear. Refer to the SERVICE BULLETINS to see if
there is an update available.
Use the Module submenu and check all modules
one at a time to see which module(s) can be up-
dated.
vmr2006-012-100_aen
B.U.D.S. is now ready to use.
Updating Electronic Module (ECU)

Software
NOTICE Failure to strictly follow a procedure
to update a module may permanently damage
the module.
Whenever B.U.D.S. is first connected to a vehicle, lmr2010-019-001
check for an update icon in the status bar at the TYPICAL - MODULE SUBMENU LIST
bottom of the Vehicle page.
1. If the Update option is greyed out, no update
file is available for this module.
2. If the Update option is black, an update file is
available for this module.
4 vmr2016-128
NOTE: When selecting the update menu in

B.U.D.S., a dialog box will appear and the update
file description may give some clue to finding
the vehicle-related information on KNOWLEDGE
CENTER .
vbl2012-007-010_a
1. Greyed out: No update to perform

Black: Update file available
Before applying an update, log onto KNOWL-

EDGE CENTER and search the vehicle's VIN to
find the unit's history.
mbg2008-022-100_a
TYPICAL
1. File description
tmr2015-028-001_a Saving Changes to an ECU

Complete all WARRANTY CAMPAIGNS TO VER- If the word Modified appearsat the end of the ve-
IFY. hicle file name at the top of the B.U.D.S. page,
then a change has been made that requires it to
NOTE: PRODUCT HISTORY will show all repairs be saved to the proper electronic module.
performed and claimed under warranty.
rmr2010-020-008_a
TYPICAL
1. Indicate setting or data modified; Write Data to save
Click the Write Data button.
vmr2006-012-100_ben
NOTE: A message box will confirm a successful

operation.
tmr2015-028-002_a
vmr2016-128 5
In such a case, turn ignition switch OFF, then wait

for the message to disappear before disconnect-
ing the MPI.
Disconnect MPI card and store the vehicle diag-
nostic connector in its protective cap.
vmr2012-023-003_a
1. Diagnostic connector in its storage cap
NOTICE Failure to secure the diagnostic con-

nector in its protective cap may result in corro-
sion or other damage to the terminals.
6 vmr2016-128

GENERAL NOTE: In some cases, the CHECK ENGINE mes-
sage can be displayed along with other messages.
MONITORING SYSTEM MULTI-
PILOT FUNCTION
The Engine Management System (EMS) features LAMP GAUGE
CAUSE
a monitoring system that self-diagnoses various MESSAGE
electrical and electronic components. This mode
becomes active when the ignition key is turned LO BATT VOLT Low system voltage
ON. HIGH BATT VOLT High system voltage
NOTE: Some components require the engine to LOW OIL
be running to be monitored (fuel injectors for ex- PRESSURE Low engine oil pressure
ample). STOP ENGINE
The monitoring system continuously validates An important engine
that the components (control modules, sensors management component
LIMP HOME
and actuators) are not faulty or defective. When MODE
is not working properly.
a malfunction is detected, the related electronic Vehicle performance is
module(s): purposely limited
– Sets an active fault code. An engine management
– Adapts the proper protection strategy accord- CHECK ENGINE component is not
functioning properly
ing to the failure.
– Sends out signals to the multifunction gauge to MAINTENANCE Periodic maintenance
inform the rider of a particular condition. REQUIRED required
ECM NOT Communication error
A fault code is an indication that a glitch or mal-
RECOGNIZED between gauge and ECM
function is detected by the monitoring system of
the vehicle. DPS malfunction (DPS
CHECK DPS
model only)
If a minor fault occurs, the engine and vehicle will
continue to operate without noticeable loss of per- TRANSMISSION Gauge receives an invalid
SIGNAL FAULT gear position data
formance.
Displayed when brake is
If a more important fault occurs, engine RPM may BRAKE applied for more than 15
be limited. The engine/vehicle will continue to op- seconds (while riding)
erate with reduced performance.
If a major component of the EMS fails, engine HI TEMP High engine temperature
RPM will be limited as well as vehicle speed.
These strategies are used to protect
engine/electrical system from damage and Limp Home Mode
to maintain safe operation of the vehicle. In ex- When a major component of the EMS is not oper-
treme cases, the engine may also be completely ating properly, limp home mode will be set.
shut down. Engine RPM will be limited and/or engine behav-
ior and control may be modified depending on the
Pilot Lamps for Problematic cause of the failure.
Conditions
This mode allows the rider to return home, which
When a problem is detected, a pilot lamp will turn would otherwise not be possible without this ad-
on or blink in the multifunction gauge. If the fault vanced system.
that caused the pilot lamp to come on is momen-
tary, the pilot lamp may turn off automatically, or LIMP HOME will be displayed in the multifunction
may need to be reset by powering down the ve- gauge and the CHECK ENGINE light symbol will
hicle and then restarting it. be on in the gauge.
A message may also be displayed to provide ad-
ditional information related to the fault that turned
on the pilot lamp. Refer to the following chart.
vmr2015-041 435
FAULT CODES The active fault may or may not compromise

normal operation of the system(s). Service ac-
Fault Code Categories tion should be taken to correct the problem that
A fault code consists of an alphanumeric designa- caused the fault code.
tor followed by a hexadecimal number of 3 digits. Once the fault condition(s) of the active fault is no
The alphanumeric designator defines the category longer present, its state will change to "occurred".
of the fault code while the hexadecimal number
refers to a unique fault. Occurred Fault Codes
FAULT CODE CATEGORIES An occurred fault code indicates a fault that was
active, but no longer is.
EXAMPLE
ALPHANUMERIC MODULE/ The occurred fault does not presently affect sys-
OF FAULT
DESIGNATOR SYSTEM tem or component operation but is retained as a
CODE
history of the faults that were detected.
Power train, TCM
From P0 to P3 P0116 The fault may have been generated due to a
and DPS
system or component that was momentarily op-
Communication erating outside normal parameters. Repeated
From U0 to U3 between module U0073 occurred faults of this type should be considered
and sensors when troubleshooting a problem, and may require
that maintenance action be taken.
RELATED MODULE AND FAULTS
An occurred fault may also be generated when
FAULT CODE disconnecting and reconnecting a component, re-
MODULE
CATEGORY placing a burnt fuse, when the software update of
ECM P and U an electronic module has been carried out, or may
be due to a momentary high or low voltage.
DPS P and U
Cluster P and U Inactive Fault Codes
An inactive fault code represents a fault code that
Fault Code States is neither active, nor occurred. It is simply part of
a list of all possible faults that can be monitored
Fault codes have 3 possible states: by the ECM and multifunction gauge, which may
– Active become active or occurred if the monitoring sys-
– Occurred tem detects an applicable fault. These codes can
– Inactive. be viewed in B.U.D.S.
Click the Fault tab then click on the drop-down list How to Display Fault Codes in the
on the LH lower corner. Multifunction Gauge
Choose the fault code state you want to display. NOTE: A fault code must be in an "Active" state to
be displayed in the multifunction gauge. B.U.D.S.
must be used to read all fault codes states.
1. Use the selector button or mode button and
scroll to Engine Hour (EH) on the gauge.
rmr2011-021-001_a
TYPICAL
1. Drop down list
Active Fault Codes

An active fault code is an indication of a fault that
is currently triggered.
vmr2007-050-002_c
RENEGADE
1. Selector button
436 vmr2015-041
2. Press and HOLD mode button while QUICKLY

toggling HI - LO beam.
NOTE: A minimum of 3 HI - LO toggles must be
completed within 2 seconds.
rmr2011-021-001_a
1. Drop down list
FAULT
INFORMATION
STATE
Display all possible faults regardless
All faults
of state
vdd2008-001-097_a
TYPICAL Active Display only faults matching this state

Step 1: Press and hold faults Empty area if there is no active fault
Step 2: Quickly toggle HI - LO beam
Active and Display only faults that have either state
How to Read Fault Codes Using occurred Empty area if there is neither active
B.U.D.S. faults nor occurred fault
NOTE: All fault code (regardless of their state) can
be read with B.U.D.S.
1. Connect vehicle to the latest applicable
B.U.D.S. Refer to COMMUNICATION TOOLS
AND B.U.D.S. subsection.
2. Click on the Read Data button.
3. Click on the Faults tab.
vbl2012-007-011_a
FAULT PAGE
1. Fault tab
2. Fault indicator light
3. Fault code state drop box
4. Fault description
5. More Details button
6. Clear Fault button
7. Clear Occurred Faults button
8. Selected fault
FAULT PAGE DESCRIPTION

ITEM INFORMATION
rmr2011-070-011_a
1. Fault tab Fault tab Click tab to display the fault page
4. Click on the drop-down list on the LH lower cor- Fault When flashing, it indicates there is
indicator light active fault(s)
ner.
5. Choose the fault state to display. Fault code
Click drop box to select the type of
state drop
faults to display
box
Display specific information and
Fault
statistics related to the fault (see
nomenclature
fault nomenclature table)
vmr2015-041 437
FAULT PAGE DESCRIPTION

ITEM INFORMATION
To display possible causes and
More Details
service actions related to the
button
selected fault
Clear Fault To clear occurred faults one at a
button time
Clear
To clear all occurred faults in related
Occurred
ECU(s)
Faults button
When a fault is selected, additional rmr2011-021-002_a
information pertaining to that SOME COLUMNS REMOVED FOR CLARITY PURPOSE
fault will be displayed when 1. Module that reports a fault
Selected 2. Fault description
clicking the "More details" button.
fault
To select a fault, click on the fault
with the mouse or use the cursor up
Click on the More Details button, on the RH lower
or down to scroll to the desired fault corner, to display the "Possible Causes" and the
"Service Actions" to step further in the diagnosis.
FAULT NOMENCLATURE
COLUMN INFORMATION
Fault code number.
When 2 stars (**) precedes the
Code code, detailed conditions when the
fault occurred, can be displayed by
clicking the "More details" button
Display the fault state (active, occurred,
State
inactive)
Displays the module that reports the
fault code. This is the module that rmr2011-021-050_a
detects or has received a message 1. Click here
of an anomaly and reports it.
Module
List of modules:
- Cluster (multifunction gauge)
- DPS (dynamic power steering)
- ECM (engine control module)
Number of times this fault
Count occurred within the driving cycle.
Value: From 0 to 255
Not to be used.
Cycle time
Value: From 0 to 255 minutes
Not to be used.
Total time
Value: From 0 to 64 255 minutes rmr2011-070-002_a
MORE DETAILS PAGE

Description Provides a short description of the fault 1. Possible causes related to the selected fault
2. Service actions
3. Operating conditions when fault occurred
When reading a fault code in B.U.D.S., pay partic-
ular attention to which module reports a fault. It
is indicated in the Module column.
The Description column gives a short description
of the fault.
438 vmr2015-041
MORE DETAILS PAGE DESCRIPTION NOTE: An active fault code cannot be cleared.
In other words, the problem relevant to the fault
ITEM INFORMATION code must be repaired before the fault can be
Possible List the possible causes that cleared.
causes triggered the fault
Service List the possible actions to perform FAULT CODE DIAGNOSTIC
actions to solve the fault
Missing Module
Conditions List the operating conditions of the
If a module is missing, several fault codes will ap-
when fault engine and/or vehicle when the fault
occurred was triggered pear.
To quickly find which module is missing, perform
How to Clear Fault Codes Using the following:
B.U.D.S. 1. Connect vehicle to the latest applicable
B.U.D.S. software. Refer to COMMUNICA-
TION TOOLS AND B.U.D.S. subsection.
B.U.D.S. software. Refer to COMMUNICA-
TION TOOLS AND B.U.D.S. subsection. 2. Click on the Read Data button.
2. Click on the Read Data button. 3. Click Module in the menu bar.
3. Click on the Faults tab. 4. Look at the list of modules.
The fault(s) (occurred state only) can be cleared by 5. If a module is not visible, then it is not commu-
pressing the Clear Occurred Faultsor Clear Fault nicating through the CAN bus (controller area
buttons in B.U.D.S. network).
rmr2008-039-009
FAULTS PAGE TAB, CLEAR OCCURRED FAULTS
4. Click YES on the following message box.
lmr2010-019-001
TYPICAL - MODULE SUBMENU LIST
6. Refer to the following table to find the appropri-

vbl2012-007-013
ate subsection in this manual to diagnose the
missing module.
The following message will appear. MISSING
SECTION TO REFER TO
MODULE
ECM ELECTRONIC FUEL INJECTION (EFI)
Cluster LIGHTS, GAUGE AND ACCESSORIES
vbl2012-007-012
DPS DYNAMIC POWER STEERING (DPS)
5. Turn ignition OFF and wait until the message Diagnostic Tips
disappears.
To see the last minute of operating conditions,
This will reset the appropriate counter(s) and will click on the History tab in B.U.D.S.
also record that the problem has been fixed in the
related ECU memory.
vmr2015-041 439
NOTE: The page displays data whatever there is HISTORY PAGE DESCRIPTION
fault code(s) or not.
ITEM INFORMATION
Display the minimum and maximum
Minimum/
values encountered. Click "Clear
Maximum
Min/Max" to reset the values
Display the time proportion in what
Run time
mode the engine was running in
RPM Display the RPM range proportion in
profile which the engine was running in
When a minor fault occurs:

– Turn ignition key OFF.
rmr2011-070-003_a – Wait 30 seconds.
1. History tab – Turn ignition key ON.
2. Additional history pages
This should change the fault state from "Active" to
"Occurred".
The vehicle should then operate normally.
If a sensor-related fault persists, you may try
disconnecting/reconnecting the sensor.
Read the following for a general approach to trou-
bleshoot fault codes (active or occurred).
GENERAL GUIDELINES TO SOLVE FAULT CODES
CONDITION ACTION
Use B.U.D.S. to:

Read fault codes.
Display "Active" faults to see components currently not operating normally.
Display "Occurred" faults to troubleshoot intermittent problems.
Monitor system(s), sensor(s), switches and actual conditions.
Troubleshooting vehicle
Activate component(s) for troubleshooting.
Set components (resets etc).
Know the last minute of operating conditions by using the "History" page.
Know the operating conditions, if available, when a fault code occurred by
using the "More details" button in the fault page.
Check sensor connections or mixed up connections.
Before vehicle maintenance:

Read the electronic modules with B.U.D.S.
New fault(s) appear after a vehicle
After vehicle maintenance:
maintenance or repair
Read the electronic modules with B.U.D.S.
Compare the fault code(s) before and after the maintenance
using the printed copy and the current B.U.D.S. reading.
Investigate only the newly fault codes.
Clear all occurred faults in B.U.D.S.
Communication faults displayed as Normal behavior when flashing a module.
"Occurred" after module flashing Clear all occurred faults and check again.
Read the fault description in B.U.D.S.
Click on the "More Details" button.
Sensor "Active" fault Look at the "Conditions" when available.
Read the "Possible Causes".
Apply the "Service Actions".
440 vmr2015-041
GENERAL GUIDELINES TO SOLVE FAULT CODES
CONDITION ACTION
Check related fuse(s) and relay.

Check related power and ground wires.
Low system voltage
Check for common power supply to several sensors/modules
on one module.
(refer to POWER DISTRIBUTION AND GROUNDS).
Power problem on sensor(s)
NOTE: Some sensors are supplied by the battery while others are
supplied by a module.
Low system voltage
Check battery condition and connections.
on several modules
(several communication faults
Check voltage regulator/rectifier.
will also appear)
A battery charger has likely been used to substitute the vehicle battery.
High system voltage on several
Clear all occurred faults and check again.
modules
Check voltage regulator/rectifier.
Check the module that is reported as missing.
When all modules report that a
module is missing
Check related power and ground wires.
When several modules are in fault Search for a common problem such as a faulty sensor.
When several modules and sensors report that a module is missing.
The missing module may report CAN bus off.
Check related CAN wires (continuity, short to
CAN bus OFF
ground, short between CAN low and high).
Check module pins and wiring terminals.
Then, the other modules should stop reporting that module is missing.
May have been generated due to a system or component that was
momentarily operating outside normal parameters.
May be generated when disconnecting and reconnecting a component,
replacing a burnt fuse, or may be due to a momentary high or low voltage.
Before being "Occurred", a fault has always been "Active"
Occurred fault(s) for a certain time, indicating that an unexpected condition
or problem has been present during the driving cycle.
A frequent momentarily fault or an intermittent fault may never
be seen as "Active" in B.U.D.S. while there is still a pending problem.
This type of malfunctions can be discovered by looking at
the "Occurred" faults and then by evaluating the fault count.
As long as a fault is present, it is displayed as "Active".
Low value: Suggests handling problems
Fault count (connections, terminal contact/shape etc.).
(0 - 255) High value: Suggests a frequent and unsolved problem.
The problem should be investigated.
Fault conditions
Look for abnormal, excessive values.
(more details button)
When the basic troubleshooting has been done and the fault
code(s) persists, often the problem is related to the wiring
harness, connections or electromechanical components.
Hard to find problems Short to ground, to battery or between wires.
Wire splices, chafing, terminal problems
(pulled out, bent, out of shape, corroded etc.).
Bad contacts in switch or relay.
vmr2015-041 441
ECUs share information and their systems may interact with each other. Certain faults may cause more
than one ECU to set a fault code or indication (pilot lamp or message) as the failure of some components
may affect the operation of several systems.
FAULT CODE TABLE

ACRONYMS USED IN THE FAULT CODE TABLE
USED IN
FAULT CODE MEANING
TABLE
ECM Engine Control Module
DPS Dynamic Power Steering
CAN Controller Area Network
TPS Throttle Position Sensor
GBPS Gearbox Position Sensor
HOW TO FIND FAULT CODE

DESCRIPTIONS
For the latest fault code table, use the Info Cen-
ter submenu in BOSSWeb and enter the following
search criteria:
– Enclose the search within quotes " "
– Enter: "ATV DTC (All engines) 2015".
442 vmr2015-041
Subsection XX (DIAGNOSTIC AND FAULT CODES)

GENERAL
FAULT CODE TABLE
PCODE MODULE DESCRIPTION CAUSE ACTION
1- Go to Activations - SCM and
start Rear Test routine. If the test
passed, the system is working
properly. Check the harness and
connection to see a potential source
of intermittent dysfunction, if nothing
is found clear the occurred fault and
no more actions have to be done.
Mud, dust or water in the release
tube may explain the fault code. If
Pressure did not drop to the Test status shows a Fail_release,
desired set point after proceed to next action step.
predefined delay 2-Verify the release tube (orange)
for obstruction. If nothing is
Release valve tube found go to next action step.
Release valve
momentary blocked 3- Unplug the valves block connector
C2109 SCM-XMR activation delay
Blown valve fuse and measure that 12V is present
exceeded
Damaged circuit between pin D of the connector
wires or connectors on the SCM side and the battery
Faulty valve block negative post. If not, verify the valve
Faulty SCM fuse and relay (refer to schematics
for more information). Verify the
harness and the connection between
the valve and the SCM. If everything
is fine, go to next action step.
4- Verify the release valve activation
by disconnecting the valve block
electrical connector and applying
12V across pin D and H on valve
connector. If the release valve
is operating, change the SCM,
otherwise change the valve block.
vmr2015 1

1- Go to Activations - SCM and start
Rear Test routine. Verify that the
Shock Absorber Pressure and the
Auxiliary Line Pressure correlates
in BUDS. If the test is done with
no fault, the system is working
is found clear the occurred fault
and no more actions have to be
done. If the Test Status shows a
Fail_Comparison_Sensor_Test, verify
for leak. If no leak found, verify
the wiring and connector of the
external sensor and the SCM. In
the next action step, verify which
of Shock absorber or Auxiliary Line
Pressure sensors is defective.
2-Make sure to have no pressure
in the system by activating the
Too many values of the
relief valve in Activation -SCM.
external sensor out of
Connect the supplied air hose into
range (negative pressure)
the compressor fitting and plug
Auxiliary line it to a known pressure supply in
Sensor disconnect
C2111 SCM-XMR pressure sensor the range of 30 to 120 psi (as car
Damaged circuit
value out of range tire) and compare it to the Shock
wires or connectors
absorber pressure and Auxiliary
Faulty auxiliary line sensor
line pressure, it should be similar.
Faulty SCM
If the Shock absorber pressure
is off, change the SCM module.
Go to next action step to perform
Auxiliary Line Pressure sensor test.
3-Back probe the signal coming from
the sensor between the pin 3 of the
SCM electrical connector and the
negative battery post (this action
must be done with special probe
to not damage the connector seal).
The value must be between 0.9
and 8.3 Volts for a pressure range
of 0 - 100 psi. If not go to next
action step. If the value is in the
range, the Auxiliary Line Pressure
sensor is fine, change the SCM.
5- Unplug the Auxiliary Line Pressure
sensor and make sure to have
12V between pin 3 and 1 on the
connector coming from SCM. If 12V
is present change the sensor, if not
change the SCM.
2 vmr2015

1- Check for leaks. If no leak
found go to next action step.
Rear Test routine. If the test is done
with no fault, the system is working
connector to see a potential source
If the compressor is not starting
check the compressor GND, harness
and connection then continue
to the next action step. If the
compressor is running and the Test
Pressure did not reach Status show a Fail_Pumping_Rear
to desired set point after go to action step 6.
predefined delay 3-Test the compressor with an
external power supply (as a 12V
Leak in the system battery). If the compressor is
Jammed compressor functional go to next action step.
intake tube 4-Unplug the relay and make sure to
System rear
Damaged circuit have 12V between battery negative
suspension
C21E0 SCM-XMR wires or connectors post and relay pin 30. If not, check
pumping delay
Blown compressor fuse the compressor fuse and harness.
exceeded
Corroded or disconnected If 12V is present, test the relay.
compressor GND If the relay is functional plug it
Faulty relay back and go to next action step.
Faulty compressor 5- Disconnect the SCM, take a
Jammed check valve jumper wire and connect pin 8 to the
Faulty SCM battery negative post. If then the
compressor starts, change the SCM.
6- Verify that the compressor intake
tube (transparent) is not blocked or
kinked. Unplug the SCM air tube
(yellow) and start the compressor. If
air blow out of the tube change the
SCM. If not go to next action step.
7- During the Rear Test routine
verify the pressure sensors value.
If the Shock Absorber Pressure and
Auxiliary Line Pressure is not going
up verify the first check valve at
the exit of the compressor. If only
the Shock Absorber Pressure is not
going up verify the second check
valve after green tube.
System rear
1- Verify suspension system for air
C21E1 SCM-XMR suspension high Leak in the system
leaks.
leakage detected
vmr2015 3

1- Disconnect the air line to the
rear shocks. Go to Activations -
SCM and start Rear Test routine.
If the air blows out the system is
working properly. Check the harness
and connection to see a potential
source of intermittent dysfunction, if
nothing is found clear the occurred
fault and no more actions have to
be done. If the air do not blow
Too many occurrence of out continue to next action step.
pressure pumping and 2- Verify the air tube (black) from
release in short delay the valve to the rear suspension. If
nothing found go to next action step.
System rear
Rear valve tube blocked 3- Unplug the valve block electrical
C21E2 SCM-XMR suspension valve
Blown valve fuse connector and verify that 12V is
failure
Faulty valve block present between pin A and battery
Damaged circuit negative post. If not verify valve
wires or connectors fuse, relay and harness (refer to
Faulty SCM schematics for more information). If
12V is read go to next action step.
4- Verify the rear valve activation
electrical connector and applying 12V
across pin A and E while compressor
running (Go to Activations - SCM and
start Rear Test routine). If the rear
valve is opening and filling the shocks
change the SCM. If the rear valve is
not opening, change the block valve.
4 vmr2015

Rear Front routine. If the test is done
If the compressor is not starting
check the compressor GND, harness
and connection then continue
to the next action step. If the
compressor is running and the Test
Pressure did not reach Status show a Fail_Pumping_Rear
to desired set point after go to action step 6.
predefined delay 3-Test the compressor with an
Leak in the system battery). If the compressor is
Jammed compressor functional go to next action step.
intake tube 4-Unplug the relay and make sure to
System front
Damaged circuit have 12V between battery negative
suspension
C21F0 SCM-XMR wires or connectors post and relay pin 30. If not, check
pumping delay
Blown compressor fuse the compressor fuse and harness.
exceeded
Corroded or disconnected If 12V is present, test the relay.
compressor GND If the relay is functional plug it
Faulty relay back and go to next action step.
Faulty compressor 5- Disconnect the SCM, take a
Jammed check valve jumper wire and connect pin 8 to the
Faulty SCM battery negative post. If then the
7- During the Front Test routine
verify the pressure sensors value.
If the Shock Absorber Pressure and
Auxiliary Line Pressure is not going
up verify the first check valve at
the exit of the compressor. If only
the Shock Absorber Pressure is not
going up verify the second check
valve after green tube.
System front
1- Verify suspension system for air
C21F1 SCM-XMR suspension high Leak in the system
leaks.
leakage detected
vmr2015 5

1- Disconnect the air line from the
front shocks. Go to Activations -
SCM and start Front Test routine. If
the air blows out of both shocks the
system is working properly. Check
the harness and connection to see
a potential source of intermittent
dysfunction, if nothing is found clear
the occurred fault and no more
actions have to be done. If the air
does not blow out even from one
shock continue to next action step.
2- Verify the air tubes (blue) from
Too many occurrence of the valves to both front shocks.
pressure pumping and If clear go to next action step.
release in short delay 3- Unplug the valve block electrical
connector and verify that 12V is
System front
Front valve tube blocked present between pin B and battery
C21F2 SCM-XMR suspension valve
Blown valve fuse negative post (right) / between pin
failure
Faulty valve block C and battery negative post (left).
Damaged circuit If not verify valve fuse, relay and
wires or connectors harness (refer to schematics for
Faulty SCM more information). If both 12V
are read go to next action step.
4- Verify the front valves activation
12V across pin B and F (right) or C
and G (wrong in wire diagram) (left)
while compressor running (Go to
Activations - SCM and start Front
Test routine.). If the front valves are
opening and filling the shocks change
the SCM. If either of the front valves
are not opening, change the block
valve.
Check for Crankshaft
Position Sensor fault
Lost of Engine Synchronisation Check for dirty Crankshaft
P0008 ECM
Synchronisation Check Failed Position Sensor.
Check compression on engine
6 vmr2015

Make sure sensor
connector is fully inserted.
Measure voltage between
harness connector pins 1 and 3
. (Expected value: 4.8 to 5.1 volts)
Measure resistance from
Damaged sensor, connector: ECM-F3 to MAPTS-2
Manifold Air damaged circuit wires, (Expected value: < 2 ohms)
P0107 ECM Pressure Sensor damaged connector or Measure resistance from
voltage too Low damaged ECM pins, ECM connector: ECM-A1 to MAPTS-3
voltage supply Low (Expected value: < 2 ohms)
connector: ECM-G2 to MAPTS-1
(Expected value: < 2 ohms)
Measure resistance from connector:
ECM-F2 to MAPTS-4 (Expected
value: < 2 ohms)
Make sure sensor
connector: ECM-F3 to MAPTS-2
Damaged sensor, wires
Manifold Air (Expected value: < 2 ohms)
shorted to battery +,
P0108 ECM Pressure Sensor Measure resistance from
ECM voltage supply too
voltage too High connector: ECM-A1 to MAPTS-3
High.
value: < 2 ohms)
Make sure sensor
Intake Air
damaged circuit wires, (Expected value: < 2 ohms)
Temperature
P0112 ECM damaged connector or Measure resistance from
Sensor 1 circuit
damaged ECM pins, ECM connector: ECM-A1 to MAPTS-3
Low
voltage supply Low (Expected value: < 2 ohms)
value: < 2 ohms)
vmr2015 7

Make sure sensor
connector: ECM-F3 to MAPTS-2
Intake Air Damaged sensor, wires
Temperature shorted to battery +,
P0113 ECM Measure resistance from
Sensor 1 circuit ECM voltage supply too
connector: ECM-A1 to MAPTS-3
High High.
value: < 2 ohms)
Make sure sensor
Intake Air
damaged circuit wires, (Expected value: < 2 ohms)
Temperature
P0114 ECM damaged connector or Measure resistance from
Sensor
damaged ECM pins, ECM connector: ECM-A1 to MAPTS-3
Intermittent
voltage supply (Expected value: < 2 ohms)
value: < 2 ohms)
Disconnect the sensor.
connector: ECM-F4 to CTS-1
Engine Coolant (Expected value: < 2 ohms)
Damaged sensor, wires
Temperature Measure resistance from
P0116 ECM shorted to battery +,
Sensor 1 circuit connector: ECM-C3 to CTS-2
ECM voltage supply.
range/performance (Expected value: < 2 ohms)
Measure CTS resistance value
(Expected value: 2280 to 2736 ohms
at 19 to 21°C (66 to 70°F))
Engine temperature sensor
Temperature Measure resistance from
P0117 ECM or circuit wires shorted to
Sensor 1 circuit connector: ECM-C3 to CTS-2
ground.
Low (Expected value: < 2 ohms)
at 19 to 21°C (66 to 70°F))
8 vmr2015

Temperature Disconnected sensor, or Measure resistance from
P0118 ECM
Sensor 1 circuit sensor resistance too High. connector: ECM-C3 to CTS-2
High (Expected value: < 2 ohms)
at 19 to 21°C (66 to 70°F))
Check for coolant fluid
Engine Coolant
leak and coolant fluid level
Temperature
P011A ECM Correlation Check failed Check radiator condition
Correlation Check
Check for other fault, Check
failed
thermostat
Make sure sensor
connector: ECM-A1 to TPS-1
Throttle Position
Damaged circuit wires, (Expected value: < 2 ohms)
Sensor (TPS)
P0122 ECM damaged sensor or Measure resistance from
Short circuit to
damaged ECM pins. connector: ECM-G3 to TPS-3
GND
ECM-G2 to TPS-2 (Expected value:
< 2 ohms)
Make sure sensor
connector: ECM-A1 to TPS-1
Throttle Position
Damaged circuit wires, (Expected value: < 2 ohms)
Sensor (TPS)
P0123 ECM damaged sensor or Measure resistance from
shorted to battery
damaged ECM pins. connector: ECM-G3 to TPS-3
+
ECM-G2 to TPS-2 (Expected value:
< 2 ohms)
Check for coolant fluid
Engine Coolant leak and coolant fluid level
Coolant fluid temperature
P0217 ECM over temperature Check radiator condition
too high
condition Check for other fault, Check
thermostat
Engine
Overspeed
P0219 ECM Engine speed too high
Condition
detected
vmr2015 9

Check fuse
Measure voltage between harness
connector PF1-12B and ground
(Expected value: 11 to 13 volts)
Blown fuse, damaged connector PF1-11B and ground
Fuel Pump or disconnected (Expected value: 11 to 13 volts)
circuit shorted to fuel pump relay, Measure resistance from harness
P0231 ECM
ground, or open damaged circuit wires, connector: ECM-J1 to PF1-12A
circuit damaged connectors or (Expected value: < 2 ohms)
damaged ECM output pins. Measure resistance from harness
connector: PF1-11A to FP-3
Measure resistance from harness
connector: FP-4 to ground (Expected
value: < 2 ohms)
Check fuse
connector PF1-12B and ground
Blown fuse, damaged connector PF1-11B and ground
or disconnected (Expected value: 11 to 13 volts)
Fuel Pump circuit
fuel pump relay, Measure resistance from harness
P0232 ECM shorted to battery
damaged circuit wires, connector: ECM-J1 to PF1-12A
+
damaged connectors or (Expected value: < 2 ohms)
damaged ECM output pins. Measure resistance from harness
connector: PF1-11A to FP-3
connector: FP-4 to ground (Expected
value: < 2 ohms)
Disconnect injector 1
Measure resistance between
injector pin 1 and 2 (Expected
value = 14 to15 ohms).
Blown fuse, damaged Measure resistance from
Cylinder 1 injector or disconnected injector, harness connector: INJ1-1 to
P0261 ECM open circuit or damaged or disconnected INJ1-2 (Expected value: > OPEN)
shorted to ground circuit wires, damaged Measure voltage between harness
ECM output pins. connector INJ1-2 and ground.
connector: ECM-K4 to INJ1-1
10 vmr2015

Damaged injector, Measure resistance from
Cylinder 1 injector damaged circuit wires, harness connector: INJ1-1 to
P0262 ECM shorted to battery damaged connector or INJ1-2 (Expected value: > OPEN)
+ damaged ECM output Measure voltage between harness
pins. connector INJ1-2 and ground.
connector: ECM-K4 to INJ1-1
Blown fuse, damaged Measure resistance from
Cylinder 2 injector or disconnected injector, harness connector: INJ2-1 to
P0264 ECM open circuit or damaged or disconnected INJ2-2 (Expected value: > OPEN)
shorted to ground circuit wires, damaged Measure voltage between harness
ECM output pins. connector INJ2-2 and ground.
connector: ECM-L4 to INJ2-1
Damaged injector, Measure resistance from
Cylinder 2 injector damaged circuit wires, harness connector: INJ2-1 to
P0265 ECM shorted to battery damaged connector or INJ2-2 (Expected value: > OPEN)
+ damaged ECM output Measure voltage between harness
pins. connector INJ2-2 and ground.
connector: ECM-L4 to INJ2-1
Make sure sensor
Damaged CPS, connector is fully inserted.
damaged circuit wires, Measure resistance from
Crankshaft
damaged connector or connector: ECM-E1 to CPS-1
P0338 ECM Position Sensor
damaged ECM output pins. (Expected value: < 2 ohms)
Spike detected
Wrong mounting position Measure resistance from connector:
of sensor ECM-D1 to CPS-2 (Expected value:
< 2 ohms)
incorect nomber Make sure sensor
of tooth detecded connector is fully inserted.
Damaged CPS, Measure resistance from
Crankshaft
damaged circuit wires, connector: ECM-E1 to CPS-1
P0339 ECM Position Sensor
damaged connector or (Expected value: < 2 ohms)
Intermittent
damaged ECM output pins. Measure resistance from connector:
Wrong mounting position ECM-D1 to CPS-2 (Expected value:
of sensor < 2 ohms)
vmr2015 11

Check fuse
Disconnect relay.
Blown fuse, damaged
terminals 85 and 86 on relay.
or disconnected relay,
(Expected value: 70 to 90 Ohms)
Radiator cooling damaged circuit wires
P0480 ECM Measure resistance between
fan relay or connectors, damaged
harness connector PF-1E and
ECM output pins, damaged
ground. (Expected value > OPEN).
Relay.
connector: ECM-B3 to PF1-1E
Check if vehicle speed is available
No vehicle speed available
in Monitoring page in BUDS.
& Vehicle is in (H or
L Gear) with Engine
harness connector CV-A (red)
Invalid or missing RPM over 4000RPM.
P0500 DPS and CV-C (ground black).
vehicle speed Damaged Vehicle Speed
sensor circuit, Damaged
sensor, Wrong mounting
CI-9 to CV-B (pink) (Expected value:
position of speed sensor.
< 5 ohms) on ATV
Make sure IDLE
connector: ECM-D4 to IDLE-D
Damaged IDLE,
Idle Air Control damaged circuit wires,
connector: ECM-D3 to IDLE-A
P0508 ECM System Circuit damaged connector or
Low damaged ECM output
pins.
connector: ECM-E4 to IDLE-B
ECM-C4 to IDLE-C (Expected value:
< 2 ohms)
Make sure IDLE
connector: ECM-D4 to IDLE-D
Damaged IDLE,
Idle Air Control damaged circuit wires,
connector: ECM-D3 to IDLE-A
P0509 ECM System Circuit damaged connector or
High damaged ECM output
pins.
connector: ECM-E4 to IDLE-B
ECM-C4 to IDLE-C (Expected value:
< 2 ohms)
Use a stored access
A non stored access key
Invalid Access key to turn key switch.
P0513 ECM was detected when key
Key Detected If no stored access keys are
switch was turned to ON.
available program one and try again
12 vmr2015

harness connector OPS and
ground When engine stopped.
Damaged switch, (Expected value < 2 ohms)
Engine oil damaged circuit wires, Measure resistance between
P0523 ECM pressure sensor damaged connector, harness connector OPS and
sticking damaged ECM pins. ground When engine running.
(Expected value = open)
connector: OPS to ECM-E2
harness connector OPS and
ground When engine stopped.
Damaged switch, (Expected value < 2 ohms)
damaged circuit wires, Measure resistance between
Engine oil
P0524 ECM damaged connector, harness connector OPS and
pressure too Low
damaged ECM pins. ground When engine running.
(Expected value = open)
connector: OPS to ECM-E2
TORQUE_ External troubleshooting
P0551 DPS SENSOR_ Damaged DPS is not possible
OPEN Replace the DPS.
SHORT_GND Replace the DPS.
SHORT_5V Replace the DPS.
Check the two DPS fuses
Validate that all the DPS
connectors are secured
Blown fuse, battery
low (damaged
connector DPS2-A&B and ground.
System voltage magneto/regulator),
P0562 DPS (Expected value = 11 to 13 volts)
low damaged circuit wires
Measure battery voltage with
or connection, intense
engine stopped. (Expected
winch usage
value: 11 to 13 volts)
Check ground and positive
connections on battery.
Blown fuse FC, engine stopped. (Expected
battery failure, voltage value: 11 to 13 volts)
regulator failure, Measure battery voltage with
damaged circuit wires engine running. (Expected
System voltage
P0562 ECM or connection, damaged value: 13 to 14.7 volts)
low
magneto generator. Check connections
An external battery charger on voltage regulator.
may have been used. Check ground and positive
Intense winch usage connections on battery.
Check ground on vehicle frame
vmr2015 13

system voltage Rectifier failure, damaged engine Running at 3500RPM.
P0563 DPS
high circuit wires or connection. (Expected value: 13 to 14.7 volts)
Check connections
on voltage regulator.
Damaged regulator. engine running. (Expected
System voltage
P0563 ECM An external battery charger value: 13 to 14.7 volts)
high
may have been used. Check connections
CALIBRATION DPS not calibrated or
P0601 DPS Try updating the DPS
FAULT damage DPS
Bad checksum If an update file is available reflash
P0601 SCM-XMR of Calibration Lost of power on reflash the SCM, if not clear the fault, if it
memory section returns, replace the SCM.
Check start button, Check
Run/Stop button, check if free
weeling diode is in the good way.
Disconnect starter solenoid relay
Damaged relay,
Danaged start switch,
connector: ECM-L3 to SS2
Starter Relay damaged circuit wires,
P0615 ECM (Expected value: < 2 ohms)
circuit open damaged connector,
damaged ECM pins.
connector: MG2-6 to SS1
terminals SS1 and SS2. (Expected
value: 3 to 6 ohms)
Damaged relay,
Starter Relay connector: ECM-L3 to SS2
damaged circuit wires,
P0616 ECM circuit shorted (Expected value: < 2 ohms)
damaged connector,
to ground Measure resistance from harness
damaged ECM pins.
value: 3 to 6 ohms)
14 vmr2015

Damaged relay,
Starter Relay connector: ECM-L3 to SS2
damaged circuit wires,
P0617 ECM circuit shorted (Expected value: < 2 ohms)
damaged connector,
to battery + Measure resistance from harness
damaged ECM pins.
value: 3 to 6 ohms)
External troubleshooting
MOTOR LOW Internal error or damaged
P0636 DPS is not possible
CURRENT FAULT DPS
Replace the DPS.
MOTOR HIGH Internal error or damaged
P0637 DPS is not possible
CURRENT FAULT DPS
Replace the DPS.
Damaged sensor Measure voltage between harness
connected to ECM connector ECM-A1 and ground.
Sensor Reference
P0642 ECM voltage supply, (Expected value: 4.8 to 5.1 volts)
Voltage Low
Damaged ECM voltage Check sensor connected to ECM
supply output. voltage supply output
Damaged sensor Measure voltage between harness
connected to ECM connector ECM-A1 and ground.
Sensor Reference
P0643 ECM voltage supply, (Expected value: 4.8 to 5.1 volts)
Voltage High
Damaged ECM voltage Check sensor connected to ECM
supply output. voltage supply output
DPS motor supply
P0658 DPS PHASE A_LOW is not possible
Damaged DPS
Replace the DPS.
DPS motor supply
P0659 DPS PHASE A_HIGH is not possible
Damaged DPS
Replace the DPS.
High temperature of the
HIGH
P0666 DPS DPS. Extreme usage of the Let the unit cool down.
TEMPERATURE
unit.
vmr2015 15

Check fuse
Disconnect Accessory relay
and Lights relay & turn
key switch (on w/lights)
connector PF1-10E and ground.
diagnosis related to (Expected value: 11 to 13 volts)
Accessories or Light relay, Measure voltage between harness
Blown fuse, damaged connector PF1-6D and ground.
Accessory relay
P0685 ECM or disconnected relay, (Expected value: 11 to 13 volts)
circuit
damaged circuit wires, Measure resistance from harness
damaged connectors or connector: ECM-K2 to PF1-12D
damaged ECM output pins (Expected value: < 2 ohms)
connector: ECM-K2 to PF1-7C
terminals 85 and 86 on the 2 relays.
(Expected value: 70 to 90 ohms)
Check fuse
Accessory relay
Blown fuse, damaged connector PF1-6D and ground.
circuit shorted to
P0686 ECM or disconnected relay, (Expected value: 11 to 13 volts)
ground or open
damaged circuit wires, Measure resistance from harness
circuit
damaged connectors or connector: ECM-K2 to PF1-12D
damaged ECM output pins (Expected value: < 2 ohms)
Check fuse
Accessory relay Damaged relay, connector PF1-6D and ground.
P0687 ECM circuit shorted to damaged circuit wires, (Expected value: 11 to 13 volts)
battery + damaged connector or Measure resistance from harness
damaged ECM output connector: ECM-K2 to PF1-12D
pins. (Expected value: < 2 ohms)
16 vmr2015

Check fuse
Disconnect radiator fan relay
Blown fuse, damaged or connector PF1-3D and ground.
Radiator fan
disconnected fan relay, (Expected value: 11 to 13 volts)
circuit shorted
P0691 ECM damaged circuit wires, Measure resistance from harness
to ground or open
damaged connectors or connector: ECM-B3 to PF1-1E
circuit
damaged ECM output pins. (Expected value: < 2 ohms)
Check fuse
Disconnect radiator fan relay
Damaged fan relay, connector PF1-3D and ground.
Radiator fan damaged circuit wires, (Expected value: 11 to 13 volts)
P0692 ECM circuit shorted damaged connector or Measure resistance from harness
to battery + damaged ECM output connector: ECM-B3 to PF1-1E
pins. (Expected value: < 2 ohms)
Check for disconnected
transmission connector.
Check for misplaced
terminal on gearbox
Measure resistance form each
switch to ground in all position
Wrong Switch
(PR & N) (Expected value if
Subtransmission Combinations
switch activated: < 2 ohms)
Internal switch Damaged Switch,
P0705 ECM Measure resistance from harness
Combinations damaged circuit wires,
connector: ECM-J3 to PRN-1
error damaged connectors or
damaged ECM pins.
connector: ECM-H2 to PRN-2
connector: ECM-H4 to PRN-3
Verify that gear position information
change when you change the
position of gear on vehicle.
Disconnect GBPS
connector GBPS-1 and GBPS-3.
GBPS invalide GBPS position not (Expected value: 4.8 to 5.1 volts)
P0706 ECM
gear position plausible Measure resistance from
connector: ECM-D2 to GBPS-2
connector: ECM-C3 to GBPS-3
Replace GBPS sensor
vmr2015 17

Disconnect GBPS
Gear position connector GBPS-1 and GBPS-3.
sensor shorted to (Expected value: 4.8 to 5.1 volts)
P0707 ECM
ground, or open Measure resistance from
circuit connector: ECM-D2 to GBPS-2
Replace GBPS sensor
Disconnect GBPS
Gear position connector GBPS-1 and GBPS-3.
sensor circuit (Expected value: 4.8 to 5.1 volts)
P0708 ECM
shorted to battery Measure resistance from
+ connector: ECM-D2 to GBPS-2
Replace GBPS sensor
Blown fuse FC,
battery failure, voltage
regulator failure,
System voltage engine running. (Expected
damaged circuit wires
P1562 ECM low (from Key value: 13 to 14.7 volts)
or connection, damaged
switch) Check connections
magneto generator.
An external battery charger
may have been used.
System voltage Damaged regulator. engine running. (Expected
P1563 ECM high (from Key An external battery charger value: 13 to 14.7 volts)
switch) may have been used. Check connections
Wrong throttle body
mechanical position during
TPS adaptation
P1619 ECM reset of closed TPS Replace gauge if necessary.
failure
or no initialization after
ECM replacement.
18 vmr2015

Power output Motor short circuit or Reset fault, If fault re-occur, replace
P1F01 DPS
overload power output failed DPS unit
Power output High voltage at the unit Measure battery voltage with
P1F02 DPS
overload (18V). input. engine running. (Expected
value: 13 to 14.7 volts)
test charging system as per
shop manual
Fault may become Active
Hi temperature detected in extreme use situations.
Electronic Circuit
P1F03 DPS by on board temperature Reset fault and let DPS cool down.
Overheat
sensor. If fault re-occur in normal riding
conditions, replace DPS unit
Motor Motor input vs output External troubleshooting
P1F05 DPS current sensor Current correlation check is not possible
range/performance failed Replace the DPS.
Open the ECM
Activation page in BUDS
Perform an ignition coil
activation and check if ignition
coil is reacting as expected
Damaged ignition coil,
Cyllinder 1 damaged circuit wires,
connector: ECM-M2 to BA-3
P2300 ECM Ignition output damaged connector or
shorted to ground damaged ECM output
pins.
connector BA-2 and ground.
Refer to the service manual
for detailed ignition coil testing
procedure.
Open the ECM
short to V + damaged ECM output
pins.
procedure.
vmr2015 19

Open the ECM
shorted to ground damaged ECM output
pins.
procedure.
Open the ECM
short to V + damaged ECM output
pins.
procedure.
DPS motor supply
P2670 DPS PHASE B_LOW is not possible
Damaged DPS
Replace the DPS.
DPS motor supply
P2671 DPS PHASE B_HIGH is not possible
Damaged DPS
Replace the DPS.
GBPS learning
position failure
Gear position Wrong transmission
Using BUDS performe a GBPS
P280A ECM sensor adaptation mechanical position
initialization.
not plausible during GBPS reset,
No initialization after
ECM replacement.
20 vmr2015

1- Go to Activations - SCM and
start Test routine. Verify that the
Shock Absorber Pressure and the
Auxiliary Line Pressure correlates
in BUDS. If the test is done with
no fault, the system is working
is found clear the occurred fault
and no more actions have to be
done. If the Test Status shows a
Fail_Comparison_Sensor_Test, verify
for leak. If no leak found, verify
the wiring and connector of the
external sensor and the SCM. In
the next action step, verify which
of Shock absorber or Auxiliary Line
Pressure sensors is defective.
2-Make sure to have no pressure
Too many values of the in the system by activating the
external sensor out of relief valve in Activation -SCM.
range (negative pressure) Connect the supplied air hose into
the compressor fitting and plug
Auxiliary line
Sensor disconnect it to a known pressure supply in
P3000 SCM-LTD pressure sensor
Damaged circuit the range of 30 to 120 psi (as car
value out of range
wires or connectors tire) and compare it to the Shock
Faulty auxiliary line sensor absorber pressure and Auxiliary
Faulty SCM line pressure, it should be similar.
If the Shock absorber pressure
is off, change the SCM module.
Go to next action step to perform
Auxiliary Line Pressure sensor test.
4-Back probe the signal coming
from the sensor between the pin
3 of the SCM electrical connector
and the negative battery post (this
action must be done with special
probe to not damage the connector
seal). The value must be between
0.9 and 8.3 Volts for a pressure
range of 0 - 100 psi. If not go to
next action step. If the value is
in the range, change the SCM.
5- Unplug the Auxiliary Line Pressure
sensor and make sure to have
12V between pin 3 and 1 on the
connector coming from SCM. If 12V
is present change the sensor, if not
change the SCM.
vmr2015 21

Test routine. If the test is done
no more actions have to be done. If
the compressor is not starting check
the compressor GND, harness and
connection then continue to the next
action step. If the compressor is
running and the Test Status show
Pressure did not reach
a Fail_Pumping go to action step 6.
to desired set point after
3-Test the compressor with an
predefined delay
battery). If the compressor is
Leak in the system
functional go to next action step.
Jammed compressor
4-Unplug the relay and make sure to
intake tube
System have 12V between battery negative
Damaged circuit
suspension post and relay pin 30. If not, check
P3001 SCM-LTD wires or connectors
pumping delay the compressor fuse and harness.
Blown compressor fuse
exceeded If 12V is present, test the relay.
Corroded or disconnected
If the relay is functional plug it
compressor GND
back and go to next action step.
Faulty relay
5- Disconnect the SCM, take a
Faulty compressor
jumper wire and connect pin 8 to the
Jammed check valve
battery negative post. If then the
Faulty SCM
7- During the Test routine verify the
pressure sensors value. If the Shock
Absorber Pressure and Auxiliary
Line Pressure is not going up verify
the first check valve at the exit of
the compressor. If only the Shock
Absorber Pressure is not going up
verify the second check valve after
green tube.
22 vmr2015

Test routine. If the test passed, the
system is working properly. Check
the harness and connection to see
a potential source of intermittent
dysfunction, if nothing is found clear
the occurred fault and no more
actions have to be done. Mud,
dust or water in the release valve
may explain the fault code. If the
Test status shows a Fail_release,
Pressure did not drop to
proceed to next action step.
desired set point after
2-Verify the release valve
predefined delay
for obstruction. If nothing is
Release valve Release valve
3- Unplug the valve connector and
P3002 SCM-LTD activation delay momentary blocked
verify that 12V is present between
exceeded Blown valve fuse
pin 1 of the connector on the SCM
Damaged circuit
side and the battery negative post.
wires or connectors
If not, verify the valve fuse and
Faulty valve block
relay (refer to schematics for more
Faulty SCM
information). Verify the harness
and the connection between the
valve and the SCM. If everything
is fine, go to next action step.
4- Verify the release valve activation
12V across pin 1 and 2 on valve
connector. If the release valve
is operating, change the SCM,
otherwise change the valve block.
System high 1- Verify suspension system for air
P3003 SCM-LTD Leak in the system
leakage detected leaks
Bad checksum If an update file is available reflash
P3004 SCM-LTD of Calibration Lost of power on reflash the SCM, if not clear the fault, if it
memory section returns, replace the SCM.
1- Verify if all the module
are present in BUDS (under
Communication
Lost of CAN Module Menu), if they are the
P3005 SCM-LTD network
communication vehicle is working properly.
disconnected
2- Check continuity between the
cluster, ECM and SCM CAN network.
Disconnect MPI2 from DB connector.
DB-1 and DB-2 (Expected
value = 50 to 70 ohms).
CAN bus off, no Damaged circuit wires or Measure resistance
U0073 DPS
messages damaged DPS pins. between DB-1 and DPS1-C
(Expected value < 5 ohms).
Measure resistance between DB-2
and DPS1-D (Expected value < 5
ohms).
vmr2015 23

CAN bus off, no Damaged circuit wires or Measure resistance
U0073 ECM
messages damaged CLUSTER pins. between DB-1 and ECM-B1
and ECM-C1 (Expected value < 2
ohms).
Lost value = 50 to 70 ohms).
Damaged CAN Bus
communication Measure resistance
U0100 DPS wires to ECM, damaged
with ECM (lost of between DB-1 and ECM B1
DPS/ECM pins.
CAN ID’s) (Expected value < 5 ohms).
and ECM C1 (Expected value < 5
ohms).
connector CL-17 and ground.
(Expected value = 11 to 13 volts)
Damage CAN Bus
Lost wires to cluster
U0155 DPS communication Damaged circuit wires or
with CLUSTER damaged Cluster module
pins.
and CL-4 (Expected value < 5 ohms).
and CL-19 (Expected value < 5
ohms).
Missing CLUSTER CAN ID Measure resistance
Lost
Module internal error between DB-1 and ECM-B1
U0155 ECM communication
Damaged circuit wires or (Expected value < 2 ohms).
with CLUSTER
damaged module pins. Measure resistance
between DB-2 and ECM-C1
ohms).
24 vmr2015

Check for Cluster fault or ECM fault
Lost Missing CAN ID
communication Module internal error
U0155 ECM DB-1 and ECMB-C1
with CLUSTER Damaged circuit wires or
(lost of CAN ID’s) damaged module pins.
DB-2 and ECMB-C2
ohms).
1- Verify if all the module
are present in BUDS (under
Communication
Lost of CAN Module Menu), if they are the
U0155 SCM-XMR network
communication vehicle is working properly.
disconnected
2- Check continuity between the
cluster, ECM and SCM CAN network.
Check for dirty or oxidized Key
contact. Clean key contact if needed.
Check for broke key contact
Lost Ensure sensor connector
communication The Vehicle Immobilizer is is fully inserted.
U0167 ECM with Vehicle reporting an electrical fault Measure resistance between
Immobilizer on the communication line. ECMB-A1 and CC-C
Control Module (Expected value < 2 ohms).
ECMB-C2 and CC-E (Expected value
< 2 ohms).
Lost Ensure sensor connector
communication The Vehicle Immobilizer is is fully inserted.
U0167 ECM with Vehicle reporting an electrical fault Measure resistance between
Immobilizer on the communication line. ECMB-A1 and CC-C
< 2 ohms).
Install the proper ECM
Invalid Security Incorrect ECM
or CLUSTER on vehicle.
U0300 ECM Exchange or CLUSTER,
Update security coding using
received Incorrect software version.
BUDS
Check in the BUDS Tab
Variant Coding "vehicle configuration" if
Faulty variant coding
U0400 DPS failure Software the DPS option is checked.
Faulty programming
incompatibility Reflash the DPS with the latest
software
vmr2015 25

1- Verify in Setting - Vehicle
Configuration page is correctly set up.
Variant coding Faulty variant coding
U0400 SCM-XMR 2- If Update File is available reflash
failure Faulty programming
the SCM. If not, clear the fault, if it
returns replace the SCM.
1- Verify in Setting - Vehicle
Configuration page is correctly set up.
Variant coding Faulty variant coding
U0400 SCM-LTD 2- If Update File is available reflash
failure Faulty programming
the SCM. If not, clear the fault, if it
returns replace the SCM.
Invalid Data Ensure sensor connector
Received The Vehicle Immobilizer is fully inserted.
U0426 ECM From Vehicle could not read the number Measure resistance between
Immobilizer of the access key. ECMB-A1 and CC-C
< 2 ohms).
Check the two DPS fuses
Ensure DPS connector
Lost of power on DPS
is fully inserted.
that can be caused by
Module improper Check for Damaged tail
U3001 DPS damaged circuit wires
shutdown light, DPS, Cluster circuit wires
or damaged DPS pins.
Check for damaged DPS pins.
26 vmr2015
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION (450))
ELECTRONIC FUEL INJECTION (450)

SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ........................ 218–219, 223,
229, 231, 233–235
FLUKE 115 MULTIMETER ............................................................ 529 035 868 . 218–219, 223, 229, 233–235
OETIKER PLIERS........................................................................... 295 000 070 ......................................... 225
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................... 225, 230, 234
GENERAL Electrical System

WARNING ECM (Electronic Control Module)
Fuel is flammable and explosive under cer- The ECM controls the electrical system and the
tain conditions. Ensure work area is well ven- engine management functions, by processing the
tilated. Do not smoke or allow open flames or information given by various sensors.
sparks in the vicinity. EFI Sensors
The ECM reads the inputs from the sensors
WARNING which it compares to predetermined parameters
Fuel lines remain under pressure at all times. stored in the ECM, makes computations, and ac-
Always proceed with care and use appropri- tivates the outputs accordingly (injectors, ignition
ate safety equipment when working on pres- coils etc.).
surized fuel system. Wear safety glasses.
Signals from sensors are used by the ECM to de-
Wipe off any fuel spillage. Do not allow fuel
termine the injection and ignition parameters (ref-
to spill on hot engine parts and/or on electri-
erenced to fuel maps) as required to maintain the
cal connectors.
optimum air-fuel ratio.
WARNING Air Intake System
Replace any damaged, leaking or deteri- Refer to the AIR INTAKE SYSTEM subsection for
orated fuel lines or connections. Always, additional information.
pressurize the fuel system if any fuel related
component was disconnected or removed. Throttle Body
Proceed with care when removing/installing The throttle body is mounted on the intake mani-
high pressure test equipment. fold.
Air for combustion, drawn in by the engine, flows
SYSTEM DESCRIPTION through the air intake system, then through the
throttle body where it is regulated by a throttle
Refer to the applicable ENGINE MANAGEMENT
plate.
SYSTEM subsection for a general layout of the
various EFI system components.
The electronic fuel injection system (EFI) is com-
prised of various sensors used for detecting ongo-
ing operating conditions of the engine and vehicle,
and includes all the components that perform the
required adjustments to the engine.
vmr2016-044 215
Fuel Injector
The fuel injector is used to inject fuel into the in-
take port of the cylinder head.
Fuel Pump
An electric fuel pump with an integrated pressure
regulator and fuel system filters is used. For more
details on the fuel pump unit, refer to FUEL TANK
vmr2015-042-015_a
ADJUSTMENT
1. Throttle body
2. Idle air control valve (IACV)
3. Intake manifold
IDLE SPEED
Idle speed is not adjustable. The ECM controls
Fitted on the throttle body, a throttle plate regu- the IACV.
lates the amount of air that enters the engine.
A TPS is incorporated on the throttle body. It pro- NOTICE Never attempt to adjust the sealed
vides a signal to the ECM of the actual throttle idle stop screw. It is calibrated at the factory.
plate position. If the screw adjustment is changed, the throt-
tle body must be replaced.
An idle air control valve (IACV) is also incorporated
on the throttle body, It allows the ECM to control The vehicle multifunction gauge can provide an ac-
the idle speed while the throttle plate is closed. curate digital readout of the engine's idle speed.
The engine RPM may also be verified using the ap-
Fuel System plicable B.U.D.S. software version, refer to COM-
Refer to the FUEL TANK AND FUEL PUMP sub- MUNICATION TOOLS AND B.U.D.S. subsection.
section for additional information. In B.U.D.S., click the following:
– Read Data button
– Monitoring tab
– ECM tab.
vmr2015-042-016_a
1. Fuel rail
2. Fuel Injector
3. Intake manifold
Fuel Rail
The fuel rail is mounted on the intake manifold. vmr2012-026-150_a
The fuel rail secures the injector to the manifold VERIFYING ENGINE RPM USING B.U.D.S.
1. Monitoring tab
and provides the injector with fuel from the fuel 2. Engine RPM indication
pump.
NOTE: The multifunction gauge and B.U.D.S. use
The fuel pressure applied to the fuel rail is regu- the same signal to provide the engine RPM indi-
lated by the fuel pressure regulator located in the cation.
fuel pump module.
216 vmr2016-044
CLOSED THROTTLE AND IDLE To reset IACV and TPS, perform the following:
ACTUATOR RESET 1. Connect the vehicle to the latest applicable
B.U.D.S. version, refer to COMMUNICATION
This operation performs a reset of the values in TOOLS AND B.U.D.S. subsection.
the ECM.
2. In B.U.D.S., click the following:
This reset is very important. The setting of the
TPS will determine the basic parameters for all – Read Data button
fuel mapping and several ECM calculations and – Setting tab
the setting of the idle air control valve will deter- – ECM tab
mine the basic parameters for the idle speed con- 3. Click on the Reset button in the Closed Throt-
trol of the engine. tle and Idle Actuator area.
Closed throttle and idle actuator reset must be
done if:
– TPS is loosened, removed or replaced
– Throttle body is replaced
– Idle air control valve is replaced
– ECM is replaced.
NOTICE An improperly set TPS or IACV may
lead to poor engine performance and emission
compliance could possibly be affected. In ad-
dition, improper IACV reset may lead to poor vmr2016-045-010_a
engine starting, improper idle (too low or too If operation is wrong, an error message will be dis-
high) and engine stop on deceleration. played.
Remove throttle body cap and ensure the throttle If TPS is not within the allowed range while re-
cam of throttle body rests against set screw with- setting the Closed Throttle and Idle Actuator, the
out any tension in the cable. ECM will generate a fault code and will not accept
the setting. Repeat the reset procedure.
4. Start engine and make sure it operates nor-
mally through its full engine RPM range. If
fault codes appear, refer to DIAGNOSTIC AND
FAULT CODES subsection for more informa-
tion.
TROUBLESHOOTING
DIAGNOSTIC TIPS
Engine problems are not necessarily related to the
fuel injection system.
It is important to ensure that the engine and
propulsion system, fuel delivery and electrical
vmr2006-014-064_b systems are functioning normally.
1. Contact here
2. Free-play here For diagnostics purposes, use B.U.D.S. software.
See COMMUNICATION TOOLS AND B.U.D.S.
Open throttle approximately one quarter then subsection.
quickly release. Repeat 2 - 3 times to settle throt-
After a problem has been solved, be sure to clear
tle plate. If stopper does not rest against its stop
the fault(s) in the ECM using the B.U.D.S. soft-
lever, perform throttle cable adjustment. Refer to
ware.
THROTTLE CABLE in this subsection.
vmr2016-044 217
WARNING QUICK INDICATION THAT ECM IS FUNCTIONING

(assuming the observed component is
Electrical actuators and electronic modules
in good working order)
may be powered up as soon as the ignition
switch is set to ON and emergency engine Multifunction gauge turns ON.
stop switch is set to RUN. Always disconnect Fuel pump turns on for approx. 5 seconds.
the battery prior to disconnecting any elec-
trical or electronic parts. Rear lights turn on.
Headlamps turn on (ignition key on with lights
Never use a battery charger to temporarily substi- position).
tute the battery as it may cause the ECM to func-
tion erratically, or not at all. ECM Access
Check related-circuit fuse solidity and condition Refer to BODY and remove the LH panel.
with an ohmmeter. A visual inspection could lead
to a false diagnosis.
Electrical Related Problems

It is important to check the following in the elec-
trical system:
– Battery voltage
– Fuses
– Ground connections
– Wiring and connectors.
Ensure that all electronic components are genuine
OEM. Any modification to the wiring harness may
lead to poor system operation or generate fault
codes.
Electrical Connections vmr2012-022-002_a
LH PANEL REMOVED
Pay particular attention to ensure that terminals 1. ECM location
and pins are not out of their connectors, corroded,
or out of shape. ECM Connector
When probing terminals, pay attention not to de- There is one connector connected to the ECM. It
form the terminals as this could cause a loose or links:
intermittent connection that would be difficult to – Engine harness
troubleshoot.
– Vehicle system control harness.
PROCEDURES For connector information, cleaning and probing,
refer to WIRING HARNESS AND CONNECTORS
subsection.
ENGINE CONTROL MODULE
(ECM) ECM Power Supply Test
As a first troubleshooting step, always check for REQUIRED TOOL
applicable fault codes using B.U.D.S. software.
ECM ADAPTER TOOL
Quick Test to Validate ECM Operation (P/N 529 036 166)
Turn ignition key to ON.
Set emergency engine stop switch to RUN. FLUKE 115 MULTIMETER
NOTE: This wakes up the ECM, which then turns (P/N 529 035 868)
on the following. If the following do not turn on,
check ECM fuses (PF1 (F5 and F8)).
1. Disconnect ECM connector.
218 vmr2016-044
2. Install ECM connector on the ECM ADAPTER

TOOL (P/N 529 036 166).
3. Install a jumper wire between K1 and M4 on the
ECM adapter tool.
4. Turn the ignition switch to ON.
6. Set multimeter to Vdc and check for voltage as
follows.
ECM smr2009-030-010_a
BATTERY VOLTAGE
ADAPTER
If any measurement is out of specification, refer to
L1 Negative post Battery voltage POWER DISTRIBUTION and check all grounds.
Ifvoltage is not measured, check the following: CAN Resistor Test
– ECM fuse
Remove the DPS1 connector (4-pin connector)
– Main relay from DPS module (if so equipped). Refer to
– Wiring and connections, refer to the WIRING STEERING SYSTEM subsection.
DIAGRAM.
1. Remove seat to access the diagnostic link con-
7. Check for voltage as follow: nector (DB).
ECM 2. Remove diagnostic link connector from its
BATTERY VOLTAGE
ADAPTER holder.
A4 Negative post Battery voltage
If voltage is not measured, check the following:

– Ignition switch fuse
– Ignition switch
– Run/Stop switch.
Continuity Test of ECM Ground

Circuits
REQUIRED TOOL
ECM ADAPTER TOOL

(P/N 529 036 166)
smr2012-023-003_a
FLUKE 115 MULTIMETER TYPICAL

1. Diagnostic link connector (DB)
(P/N 529 035 868)
3. Set multimeter to setting.
1. Disconnect ECM connector. REQUIRED TOOL
2. Install the ECM ADAPTER TOOL (P/N 529 036 166)
on ECM connector. FLUKE 115 MULTIMETER
(P/N 529 035 868)
3. Set multimeter to and probe adapter termi-
nals as per following table.
ECM BATTERY
RESISTANCE
4. Measure the resistance of the CAN resistors as
ADAPTER POST per following table.
Pins M3 and Close to 0
Ground
M4 (continuity)
vmr2016-044 219
CAN RESISTOR TEST WARNING

DIAGNOSTIC LINK Always reconnect the RED (+) battery cable
RESISTANCE
CONNECTOR first, then reconnect BLACK (–) cable.
Pins 1 and 2 Approximately 60
3. If a new ECM is installed, refer to ECM RE-
TEST RESULT PLACEMENT in this subsection.
READING RESULT ECM Replacement
Approximately ECM and CLUSTER CAN wires 1. Transfer ECM data. Refer to ECM DATA
60 and resistors good TRANSFER for complete procedure.
ECM CAN resistor open, or 2. Perform the CLOSED THROTTLE AND IDLE
CLUSTER CAN resistor ACTUATOR RESET.
Approximately
open, or
120 3. Program the vehicle ignition key(s) in the new
CAN wire to CLUSTER
or ECM open ECM.
Infinite CAN wire to DB connector
4. Calibrate the IACV. Refer to IACV CALIBRA-
(open circuit) open circuit TION in this subsection.
If 120 ohms is read, isolate the CLUSTER from ECM Data Transfer
CAN by disconnecting it and measuring again at To transfer the original ECM recorded information
the diagnostic link connector. to the new ECM, use the B.U.D.S. software and
If 120 ohms is still read, the ECM CAN resistor and proceed as follows.
wires are good. Check for continuity of the CLUS- 1. Connect the original ECM to vehicle.
TER CAN wires, refer to WIRING DIAGRAM. 2. In B.U.D.S., click the Read Data button to load
If an open circuit is read, the ECM CAN resistor the information from the original ECM.
(or wire) is open. Check for continuity of the ECM
CAN wires, refer to WIRING DIAGRAM to deter-
mine if the wires or the resistor is at fault.
If the CAN resistor of a module is at fault, replace
that module.
If a module cannot communicate and the CAN re-
sistor and wires test good, try a new module.
5. Reconnect DPS1 to DPS module,
ECM Removal vmr2006-012-100_aen
NOTE: If a new ECM is to be installed, first read

the procedures in ECM REPLACEMENT in this NOTE: Keep B.U.D.S. running while replacing
subsection. ECMs. The data will remain stored in the PC
computer as long as B.U.DS. is running.
1. Disconnect battery cables.
3. Get the Data from the saved .mpem file.
NOTICE Always disconnect the BLACK (–)
3.1 Click on the Open button.
battery cable first, then disconnect RED (+)
cable.
3. Unscrew all retaining screws and pull out ECM.
ECM Installation
Reverse removal procedure however, pay atten-
tion to the following.
1. Reconnect ECM connector.
2. Reconnect battery cables.
220 vmr2016-044
mmr2009-023-080
3.2 Click once on the Folder Up button in the

open box.
vmr2015-042-012_a
IMPORTANT: Ensure to use the file that specifi-

cally matches the vehicle you are servicing.
NOTE: The file name structure is as follows:
BUDS version_VIN_date read (yyyymmdd)_hour read
(hhmmss).mpem
Example:
A3.5.0.3_3JBLKCK11DJ000319_20130924_093618.mpem
B.U.D.S. version = A3.5.0.3
VIN = 3JBLKCK11DJ000319
Date file was read = 2013-09-24
Hour file was read = 09h 36m 18s
vmr2015-042-010_a
4. Go to the Vehicle tab and record the following
3.3 Double click on the AutoSave folder. information.
– Vehicle (V.I.N.) number
– Engine number (without the leading “M”)
– Model number
– Customer.
vmr2015-042-011_a
NOTE: You may have to go to another Au-

toSave folder from a previous version of vmr2008-022-008
B.U.D.S.
3.4 Choose the latest file saved for this spe- 5. Remove the original ECM.
cific vehicle. 6. Install the new ECM.
7. In B.U.D.S., click the Read Data button to read
the new ECM.
vmr2016-044 221
vmr2006-012-100_aen
8. Select the Vehicle tab and enter the informa-

tion you recorded previously.
– Vehicle serial number
tmr2011-022-017_a
– Engine number (do not enter the “M” at the
ADDING PART IN HISTORY
beginning of the engine number) 1. History tab
– Enter model number. 2. Part Replacement tab
3. Add part in history button
– Customer name. 4. ECM selection
5. Add ECM serial number here
NOTE: The ECM serial number can be found on

the ECM sticker that also identifies the part num-
ber.
11. Click on the OK button.
12. Click on the Write Data button.
smr2009-030-007_a
VEHICLE TAB
9. Click on the following tabs:

– History
– Part Replacement
– Add Part in History.
10. Enter the old ECM serial number in the Add vmr2006-012-100_ben
Part In History window.
FUEL INJECTOR
Refer to the ENGINE MANAGEMENT SYSTEM
subsection for component and connector loca-
tions.
Fuel Injector Leak Test

Carry out the FUEL PUMP PRESSURE TEST as
detailed in the FUEL TANK AND FUEL PUMP sub-
section.
Fuel Injector Input Voltage Test

Disconnect the fuel injector electrical connector.
Turn on ignition switch.
Set emergency engine stop switch to RUN.
222 vmr2016-044
NOTE: Ensure to read voltage before ECM auto- Using a FLUKE 115 MULTIMETER (P/N 529 035 868),
matically turns off. check resistance value between terminals as fol-
Use a multimeter and set it to Vdc. Read voltage. lows.
INJECTOR CONNECTOR FUEL INJECTOR RESISTANCE TEST

MEASUREMENT AT ECM ADAPTER
WIRE
FUSE BOX ECM RESISTANCE @
INJ-2 BAT2 (-) Battery voltage TERMINAL ADAPTER 20°C (68°F)
PF1-B2 L4 11.4 - 12.6
If resistance value obtained is incorrect, perform

an INJECTOR GROUND CIRCUIT RESISTANCE
TEST.
Injector Ground Circuit Resistance Test

Disconnect the fuel injector connector.
Disconnect ECM connector.
Install ECM connector on the ECM ADAPTER TOOL
(P/N 529 036 166).
Using a FLUKE 115 MULTIMETER (P/N 529 035 868),
check resistance value between terminals as fol-
lows.
vmr2006-014-075_a
TYPICAL INJECTOR GROUND

CIRCUIT
If supply voltage is not good, check fuse and if MEASUREMENT
good, perform an INJECTOR POWER CIRCUIT ECM
WIRE
RESISTANCE TEST. ADAPTER
If supply voltage is good, perform a FUEL INJEC- INJ-1 L4 Close to 0

TOR RESISTANCE TEST.
If continuity is not good, repair or replace wiring
Injector Power Circuit Resistance Test going to injector.
Check continuity between main relay and injector If continuity is good, replace the injector.
as follows:
– Remove main relay. Fuel Injector Removal
– Disconnect the fuel injector connector. Remove the fuel rail. Refer to FUEL RAIL in this
– Use a multimeter and set it to . subsection.
– Read resistance.
INJECTOR CIRCUIT
MEASUREMENT
WIRE
INJ-2 PF1-B2 Close to 0

going to injector.
If continuity is good, perform the FUEL INJECTOR
RESISTANCE TEST.
Fuel Injector Resistance Test

Install the ECM connector on the ECM ADAPTER
TOOL (P/N 529 036 166).
Connect the fuel injector connector.
vmr2016-044 223
NOTICE Gently push O-ring in evenly all

around while inserting injector. O-ring must
be completely inserted and not visible, before
completing the insertion of the injector.
vmr2009-022-001_a
TYPICAL - FUEL RAIL ASSEMBLY

1. Fuel rail
2. Fuel injector
3. Injector top O-ring
4. Injector bottom O-ring
5. Manifold O-ring
Pull fuel injector out of the fuel rail.
Fuel Injector Installation

For the installation, reverse the removal proce-
dure. Pay attention to the following details. vmr2006-014-072_a
Apply a thin film of engine oil to O-rings to ease

insertion in rail. Firmly push injector until it bottoms out.
Install fuel injector with your hand. Do not use any Reinstall fuel rail.
tool.
FUEL INJECTOR INSTALLATION
FUEL RAIL
O-RINGS New Lubricate with engine oil Fuel Rail Replacement
Fuel Rail Removal
Position the manifold O-ring on injector as in fol-
lowing illustration. 1. Unscrew rail retaining screws.
2. Gently pull rail off by hand.
vmr2006-014-071_a
TYPICAL - MANIFOLD O-RING POSITION
Carefully insert injector in manifold paying atten-

tion to the manifold O-ring. vmr2006-014-073_a
TYPICAL
To disconnect fuel rail from hose, cut clamp on

fuel hose. Refer to FUEL TANK AND FUEL PUMP
for clamp removal/installation procedures.
224 vmr2016-044
REQUIRED TOOL Throttle Cable Adjustment

Mechanically adjust the throttle cable as follows.
OETIKER PLIERS (P/N 295 Handlebar and throttle cable must be at their
000 070) normal position. Throttle cable routing must have
been performed before adjusting cable.
NOTE: If fuel rail is removed for access to fuel in- Activate throttle lever a few times. Make sure
jector, it is not necessary to cut hose clamp. Only throttle cam of throttle body rests against set
to replace fuel rail. screw without any tension in the cable.
Fuel Rail Installation
For installation, reverse the removal process how-
ever, pay attention to the following.
Install new clamps using pliers as per removal (if
fuel rail was replaced).
Apply a thin film of engine oil to injector O-rings to
ease insertion in rail.
INJECTOR O-RINGS
SERVICE PRODUCT Lubricate with engine oil
Install fuel rail and evenly tighten screws a little at

a time each side.
TIGHTENING TORQUE
vmr2006-014-064_b
LOCTITE 243 (BLUE) 1. Contact here

Service product 2. Free-play here
(P/N 293 800 060)
10 N•m ± 1 N•m
Fuel rail retaining screws CAUTION If there is no free-play at idle
position, it may cause poor idling and starta-
NOTE: Activate fuel pump a few times to built bility problems. Improper cable adjustment
fuel pressure. will cause strain on cable and/or damage cable
bracket or throttle lever at handlebar.
WARNING WARNING
Perform a fuel pressure test and ensure that
Make sure idle speed stopper contacts throt-
there is no leak. Refer to FUEL TANK AND
tle cam when throttle lever is fully released at
FUEL PUMP. handlebar.
THROTTLE CABLE If adjustment is needed, proceed with adjuster at

handlebar. Adjust to have 2 mm (.079 in) free-play
Throttle Cable Removal at the end of throttle lever. When done, slide back
Remove steering cover. cable protector over adjuster.
Remove LH side panel.
Disconnect throttle cable from throttle body. Re-
fer to procedure in this subsection.
Disconnect throttle cable from throttle lever.
Remove throttle cable.
Throttle Cable Installation

Reverse removal procedure.
Proceed with THROTTLE CABLE ADJUSTMENT
in this subsection.
vmr2016-044 225
THROTTLE BODY
Throttle Body Description
vmr2006-014-067_a
TYPICAL
1. Adjuster 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:
vmr2006-014-010_a
– Fully depress throttle lever and hold. 1. Throttle body
– Loosen adjuster lock nut/adjuster until it just re- 2. Throttle cable attachment
3. Throttle plate
leases lever. 4. TPS
5. Idle air bypass channel
– Turn adjuster clockwise until it touches lever 6. Idle air control valve
again.
– From there, tighten adjuster 1/2 turn (to remove Throttle Body Access
strain in cable). Remove the RH side panel. Refer to BODY sub-
– Tighten lock nut. section.
– Release throttle lever.
Throttle Body Inspection
Check that the throttle plate moves freely and
smoothly when depressing throttle lever.
– Check if throttle body idle set screw is loose or
worn.
– Check if TPS is loose.
– Check if idle air control valve is loose.
– Check for corroded or damaged connectors.
NOTICE The throttle body must be replaced
if idle set screw is loose or worn.
Throttle Body Cleaning

vmr2006-014-068_a
1. Check throttle body cleanliness using a flash-
light. Fully open throttle plate and verify:
2. Adjuster – Throttle body bore
Reinstall throttle cable cover. – Throttle plate edge.
Look for:
– Dirt
– Oily surfaces
– Carbon and salt deposits on throttle plate and
the surrounding bore.
2. Clean as necessary.
226 vmr2016-044
3. Use a throttle body cleaner such as GUNK IN-

TAKE MEDIC or an equivalent. Refer to manu-
facturer's instructions.
NOTICE Only use an appropriate throttle
body cleaner that will not damage O-rings and
EFI sensors.
4. To avoid getting dirt into engine, spray cleaner
on a clean rag then rub rag against throttle plate
and bore. A toothbrush may also be used.
5. Gently open throttle plate and hold fully open to
reach all surfaces.
6. To remove residual dirt, spray cleaner on throt-
tle plate and on bore. vmr2012-026-004_a
7. Reinstall removed parts. TYPICAL

Step 1: Loosen
Step 2: Rotate
Throttle Body Removal Step 3: Remove
1. Remove the air intake silencer retaining 7. Rotate throttle lever and pull out cable barrel.
screws.
vmr2006-014-060_b
vmr2012-026-003_a TYPICAL
TYPICAL 1. Throttle lever
1. Remove these screws 2. Cable barrel
2. Lift rear of air intake silencer as much as possi- 8. Remove barrel from cable.
ble and block in this position. 9. Pull out throttle cable.
3. Unplug connectors from TPS and IACV. 10. Pull out throttle body.
4. Loosen both throttle body clamps.
Throttle Body Installation
5. Rotate throttle body to gain access to throttle
cable. Installation of the throttle body is the reverse of
the removal procedure. However, pay attention to
6. Remove throttle cable cover. the following.
Temporarily install throttle body into position.
Properly install cable barrel to throttle cable end.
vmr2016-044 227
vmr2006-014-65_a
vmr2006-014-063_a
Tighten clamps.
Hook cable to throttle lever. – Check throttle cable adjustment. Refer to
– If throttle body was replaced, perform the
Closed Throttle And Idle Actuator Resetand
the IACV CALIBRATION. See procedures in
this subsection.
THROTTLE POSITION SENSOR

(TPS)
Refer to the ENGINE MANAGEMENT SYSTEM
tions.
General
The throttle position sensor (TPS) is a potentiome-
vmr2006-014-064_a
ter that sends a signal to the ECM which is propor-
Rotate throttle body into position and ensure to tional to the throttle plate angle.
index throttle body tab with boot notch.
vmr2015-042-018_a
vmr2008-022-010_b
1. Throttle position sensor (TPS)
228 vmr2016-044
The ECM may generate several fault codes per- it indicates that the TPS needs to be replaced or
taining to the TPS. Refer to DIAGNOSTIC AND the computer used may be too slow to transfer
FAULT CODES subsection for more information. data fast enough for real time display.
TPS Access TPS Resistance Test

Remove the LH side panel. Refer to BODY sub- Ensure correct throttle cable adjustment. Refer to
section. THROTTLE CABLE ADJUSTMENT in this subsec-
Loosen both throttle body clamps. tion.
Ensure TPS is connected to wiring harness.
Disconnect the ECM connector.
Using the following tools, check resistance val-
ues.
REQUIRED TOOL
ECM ADAPTER TOOL (P/N 529 036 166)
FLUKE 115 MULTIMETER (P/N 529 035 868)
THROTTLE WIDE OPEN

ECM ADAPTER IDLE THROTTLE
POSITION POSITION
vmr2015-042-003_a RESISTANCE ( ) @ 20°C
PIN
(68°F)
Rotate throttle body to gain access to TPS.
G3 G2 900-1600 2600-3100
TPS Wear Test G2 A1 1800-2200 1800-2200
IMPORTANT: Prior to testing the TPS, ensure G3 A1 2200-3100 800-1200
that mechanical components of throttle body are
checked.
While engine is not running, activate throttle and
pay attention for smooth operation without phys-
ical stops of the cable.
Using the B.U.D.S. software, use the Throttle
Opening display under Monitoring.
vmr2008-022-005_a
NOTE: The resistance value should change

smoothly and proportionally to throttle move-
ment. Otherwise, replace TPS.
If resistance values are correct, perform the TPS
INPUT VOLTAGE TEST below.
If resistance values are incorrect, check wiring
vmr2006-014-083_aen
harness. If wiring is faulty, repair/replace. If
TYPICAL
wiring is good, replace TPS.
Slowly and regularly depress the throttle. Ob- Reconnect ECM connector.
serve the needle movement. It must change
gradually and regularly as you move the throt- TPS Input Voltage Test
tle. If the needle “sticks”, bounces, suddenly Disconnect connector from TPS.
drops or if any discrepancy between the throttle
movement and the needle movement is noticed, Turn ignition key ON.
vmr2016-044 229
Set emergency engine stop switch to RUN. An idle air control valve with good resistance
Check the voltage readings from harness connec- measurement can still be faulty. It is also pos-
tor as follows. sible that a mechanical failure occurs which is
not detectable without measuring the air flow.
CONNECTION VOLTAGE Replacing the IACV may be necessary as a test.
Pin 1 with battery ground 5.0 V
Pin 2 with battery ground 0 V
BAT
vmr2015-042-004_a
smr2005-056-016_a
IACV Access
Refer to TPS ACCESS in this subsection to gain
If voltage test is not good, check/repair wiring access to IACV.
harness. If wiring tests good, refer to ECM RE-
PLACEMENT. IACV Resistance Test
If voltage test is good, everything is in order (as- Disconnect IACV from the wiring harness.
suming resistance test was performed). Using a multimeter, check the resistance in both
windings.
TPS Replacement
Check the resistance between pins as shown.
Refer to TPS ACCESS in this subsection to gain
access to TPS. IDLE AIR CONTROL VALVE MEASUREMENT
Unplug connector from TPS. RESISTANCE ( )
PIN
Loosen TPS retaining screws. @ 20°C (68°F)
Remove TPS. A D
50 ± 5
Install the new TPS and tighten retaining screws B C
to specification.
If the resistance of any winding is not good, re-
TIGHTENING TORQUE place the idle air control valve.
LOCTITE 243 (BLUE) If resistance test of valve windings is good, check
Service product
(P/N 293 800 060) continuity of circuits C4, D3, D4, E4 at the ECM.
TPS retaining screws 3 N•m (27 lbf•in) If not good, check/repair wiring/connectors.
Perform the Closed Throttle And Idle Actuator IACV Visual Inspection
Reset procedure. Refer to CLOSED THROTTLE NOTE: Make sure the ignition key is turned off
AND IDLE ACTUATOR RESET in this subsection. during the following procedure.
Remove Idle air control valve from throttle body.
IDLE AIR CONTROL VALVE (IACV) Check the piston and bypass channel for dirt/de-
Refer to the ENGINE MANAGEMENT SYSTEM posits which can cause a sticking piston.
tions.
230 vmr2016-044
NOTICE Always keep the ignition key turned NOTE: Take into account that a CPS fault can be
OFF, while the idle air control valve is removed. triggered by bent or missing encoder wheel teeth.
First check fault codes using B.U.D.S., then check
NOTICE Do not try to operate the piston the encoder wheel teeth condition if necessary.
of the idle air control valve when it is dis- Refer to MAGNETO AND STARTER subsections.
mounted. Also do not move the piston by
hand. The drive screw is very sensitive and CPS Access
may be destroyed.
Remove the RH side panel. Refer to BODY sub-
Using a part cleaner, clean idle bypass in throttle section.
body from contamination then blow compressed
air to dry it. CPS Resistance Test
Install ECM connector on ECM ADAPTER TOOL
(P/N 529 036 166).
vmr2006-014-085_a 529036166
1. Clean bore from contamination

Using a multimeter, measure resistance as per ta-
Clean all remaining parts and install the idle air ble.
control valve on the throttle body.
ECM ADAPTER MEASUREMENT
Proceed with the Closed Throttle and Idle Actu-
ator Resetand the IACV CALIBRATION . See pro- RESISTANCE
PIN
cedures in this subsection. @ 20°C (68°F)
D1 E1 700 - 900
IACV Calibration
The IACV calibration is required to avoid a poten- If resistance value is incorrect, check or repair the
tial erratic or frozen RPM needle. connectors and the wiring harness between ECM
connector and the CPS. If resistance value is still
1. Start the vehicle to increase engine tempera- incorrect, replace CPS.
ture.
2. Let engine run at idle until the cooling fan per- CPS Replacement
formed a complete cycle (ON/OFF). Refer to CPS ACCESS in this subsection to reach
3. When the cycle is done, turn ignition key to OFF CPS.
position. Disconnect CPS connector and cut harness lock-
4. The calibration is completed. ing tie (if applicable).
Remove CPS retaining screw and pull up on CPS
CRANKSHAFT POSITION to remove it.
SENSOR (CPS)
Refer to applicable ENGINE MANAGEMENT SYS-
TEM subsection for component and connector lo-
cations.
vmr2016-044 231
vmr2015-042-014_a
1. Retaining screw
2. CPS
Lubricate O-ring of CPS.

vmr2015-042-006_a
O-RING
XPS SYNTHETIC NOTE: This sensor is a multifunction device.
Service product GREASE
(P/N 293 550 010) MAPTS Access
Install new CPS and secure harness with a new section.
locking tie (as applicable).
Tighten CPS retaining screw to specification. MAPTS Pressure Function
TIGHTENING TORQUE
Before the engine is started, when power is ap-
plied to the system, the sensor measures the
10 N•m ± 1 N•m ambient air atmospheric pressure. The ambient
CPS retaining screw
(89 lbf•in ± 9 lbf•in) pressure is, at that moment, stored in the ECM.
Thereafter, once the engine is started, it mea-
MANIFOLD ABSOLUTE sures the air pressure in the intake manifold at
operating RPMs.
PRESSURE AND TEMPERATURE
The sensor must be correctly installed on intake
SENSOR (MAPTS) manifold. Otherwise, the MAPTS could generate
Refer to applicable ENGINE MANAGEMENT SYS- a fault code for an unexpected sensor range at idle
TEM subsection for component and connector lo- when it reads the atmospheric pressure. If this
cations. is the case, remove sensor and check for oil or
dirt on its end and if problem persists, check throt-
tle plate condition/position and the wiring harness.
Perform the following tests.
MAPTS Pressure Function Quick Test
B.U.D.S. software version.
– Monitoring tab
– ECM tab.
vmr2015-042-005_a
232 vmr2016-044
If voltage test is not good, carry out the MAPTS

CIRCUIT CONTINUITY TEST (PRESSURE FUNC-
TION).
MAPTS Circuit Continuity Test (Pressure
Function)
1. Disconnect the ECM connector.
2. Install ECM connector on ECM ADAPTER TOOL
(P/N 529 036 166).
3. Using a multimeter, check continuity of the fol-
lowing circuits.
MAPTS CIRCUIT CONTINUITY TEST
(PRESSURE FUNCTION)
vmr2012-026-150_b
TYPICAL ECM MAPTS RESISTANCE

1. Monitoring tab ADAPTER CONNECTOR VALUE
2. MAPTS pressure reading
A1 Pin 3
3. Look for and take note of the MAPTS pressure
reading while the engine is stopped. F2 Pin 4 Close to 0
4. Perform the same test with a new MAPTS and G2 Pin 1

compare both readings.
If resistance is not within specification, repair or
Values have to be within ± 3.4 kPa (.5 PSI). replace the wiring harness between ECM connec-
MAPTS PRESSURE FUNCTION QUICK TEST tor and the MAPTS.
RESULT SERVICE ACTION MAPTS Temperature Function
Circuit The sensor monitors the temperature in the intake
continuity MAPTS manifold.
Repair or
NO test of input
replace
READING MAPTS voltage MAPTS Quick Test (Temperature Function)
wiring
pressure test 1. Connect vehicle to the applicable B.U.D.S. soft-
function
ware version.
VALUE IS 2. In B.U.D.S., click the following:
OUT OF Replace MAPTS
RANGE – Monitoring tab
– ECM tab.
MAPTS Input Voltage Test 3. Look for the Intake Air temperature reading
Check the voltage output from ECM to the pres- while the engine is stopped.
sure sensor.
1. Turn ignition key ON.
3. Remove electrical connector from MAPTS.
4. Using a FLUKE 115 MULTIMETER (P/N 529 035
868), measure for input voltage as per following
table.
MAPTS CONNECTOR MEASUREMENT
PIN VOLTAGE
1 (-) 3 (+) 5 Vdc
If voltage test is good, replace the MAPTS. vmr2016-045-001_a
TYPICAL
1. Monitoring tab
2. MAPTS temperature reading
vmr2016-044 233
4. Perform the same test with a new MAPTS and MAPTS TEMPERATURE SENSOR TEST RESULTS
RESULT SERVICE ACTION
If the engine MAPTS temperature reading is sig-
nificantly different than the new MAPTS, replace Circuit
it. Continuity MAPTS
Repair or
NO Test of Input
NOTE: Both sensors must feel the same ambient replace
READING MAPTS Voltage
air temperature. wiring
Temperature Test
If there is no reading, carry out a MAPTS RESIS- Function
TANCE TEST (TEMPERATURE FUNCTION). INCORRECT
RESISTANCE Replace MAPTS
MAPTS Resistance Test (Temperature VALUE
Function)
Disconnect the connector from the MAPTS. MAPTS Circuit Continuity Test (Temperature
Using the FLUKE 115 MULTIMETER (P/N 529 035 Function)
868), check the resistance of the sensor itself as MAPTS CIRCUIT CONTINUITY TEST
shown. (TEMPERATURE FUNCTION)
MAPTS MEASUREMENT ECM MAPTS RESISTANCE
ADAPTER CONNECTOR VALUE
RESISTANCE
PIN
@ 20°C (68°F) G2 Pin 1
Close to 0
1 2 2280 - 2740 F3 Pin 2
If resistance is not within specification, replace

the MAPTS.
MAPTS Replacement
Disconnect MAPTS connector and remove the
If resistance tests good, reconnect the MAPTS
MAPTS.
and disconnect the ECM connector.
Install new MAPTS as per following table.
Install ECM-A connector on ECM ADAPTER TOOL
(P/N 529 036 166). TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
6 N•m ± 0.7 N•m
MAPTS retaining screw
CTS (COOLANT TEMPERATURE

SENSOR)
Refer to appropriate ENGINE MANAGEMENT
SYSTEM subsection for component and connec-
529036166 tor locations.
Using a multimeter, recheck resistance value as
per following table.
RESISTANCE
PIN
@ 20°C (68°F)
F3 G2 2280 - 2740
234 vmr2016-044
If resistance value is incorrect, repair or replace

wiring or connectors/terminals.
If resistance test is good, replace the CTS.
CTS Replacement
1. Refer to CTS ACCESS in this subsection to
reach CTS.
2. Disconnect CTS connector and remove CTS.
3. Install the new CTS and torque as specified.
TIGHTENING TORQUE
16 N•m ± 2 N•m
CTS
vmr2015-042-007_a (142 lbf•in ± 18 lbf•in)
CTS Access 4. Reinstall remaining removed parts.

Remove the RH side panel. Refer to BODY sub- 5. Refill and bleed the cooling system. Refer to
section. COOLING SYSTEM subsection.
CTS Resistance Test

2. Using the following tools, check resistance val-
ues.
REQUIRED TOOL
ECM ADAPTER TOOL

(P/N 529 036 166)
3. Install ECM connector on the following tool.

RESISTANCE ( )
PIN
@ 20°C (68°F)
C3 F4 2280 - 2736
If resistance value is incorrect, check wiring con-

tinuity between ECM connector and the CTS. Re-
fer to CTS CIRCUIT CONTINUITY TEST in this sub-
section.
CTS Circuit Continuity Test

1. Disconnect connector from CTS and check the
circuit continuity.
CTS CIRCUIT CONTINUITY TEST
ECM CTS RESISTANCE
Pin F4 Pin 1
Close to 0
Pin C3 Pin 2
vmr2016-044 235
ELECTRONIC FUEL INJECTION (570)

SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 .241, 245, 251, 254, 256, 258
FLUKE 115 MULTIMETER ............................................................ 529 035 868 .........241, 245, 251, 256, 258
OETIKER PLIERS........................................................................... 295 000 070 ......................................... 247
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................... 247, 252, 257
GENERAL Electrical System

WARNING ECM (Electronic Control Module)
Fuel is flammable and explosive under cer- The ECM controls the electrical system and the
tain conditions. Ensure work area is well ven- engine management functions, by processing the
tilated. Do not smoke or allow open flames or information given by various sensors.
sparks in the vicinity. EFI Sensors
The ECM reads the inputs from the sensors
WARNING which it compares to predetermined parameters
Fuel lines remain under pressure at all times. stored in the ECM, makes computations, and ac-
Always proceed with care and use appropri- tivates the outputs accordingly (injectors, ignition
ate safety equipment when working on pres- coils etc.).
Signals from sensors are used by the ECM to de-
Wipe off any fuel spillage. Do not allow fuel
termine the injection and ignition parameters (ref-
to spill on hot engine parts and/or on electri-
erenced to fuel maps) as required to maintain the
cal connectors.
optimum air-fuel ratio.
WARNING Air Intake System
Replace any damaged, leaking or deteri- Refer to the applicable AIR INTAKE SYSTEM sub-
orated fuel lines or connections. Always, section for additional information.
pressurize the fuel system if any fuel related
component was disconnected or removed. Throttle Body
Proceed with care when removing/installing The throttle body is mounted on the intake mani-
high pressure test equipment. fold.
Air for combustion, drawn in by the engine, flows
SYSTEM DESCRIPTION through the air intake system, then through the
throttle body where it is regulated by a throttle
Refer to the appropriate ENGINE MANAGEMENT
plate.
SYSTEM subsection for a general layout of the
various EFI system components.
The electronic fuel injection system (EFI) is com-
prised of various sensors used for detecting ongo-
ing operating conditions of the engine and vehicle,
and includes all the components that perform the
required adjustments to the engine.
vmr2016-045 237
The fuel pressure applied to the fuel rails is regu-

lated by the fuel pressure regulator located in the
fuel pump module.
Fuel Injectors
The fuel injectors are used to inject fuel into the
intake ports of the cylinder head. One injector is
used per cylinder.
Fuel Pump
An electric fuel pump with an integrated pressure
regulator and fuel system filters is used. For more
details on the fuel pump unit, refer to FUEL TANK
vmr2015-073-001_a
TYPICAL
1. Throttle body
ADJUSTMENT
2. Idle air control valve (IACV)
3. Intake manifold
IDLE SPEED
Fitted on the throttle body, a throttle plate regu- Idle speed is not adjustable. The ECM controls
lates the amount of air that enters the engine. the IACV.
A TPS is incorporated on the throttle body. It pro-
NOTICE Never attempt to adjust the sealed
vides a signal to the ECM of the actual throttle
plate position. idle stop screw. It is calibrated at the factory.
If the screw adjustment is changed, the throt-
An idle air control valve (IACV) is also incorporated tle body must be replaced.
on the throttle body, It allows the ECM to control
the idle speed while the throttle plate is closed. The vehicle multifunction gauge can provide an ac-
curate digital readout of the engine's idle speed.
Fuel System The engine RPM may also be verified using the ap-
Refer to the applicable FUEL TANK AND FUEL plicable B.U.D.S. software version, refer to COM-
PUMP subsection for additional information. MUNICATION TOOLS AND B.U.D.S. subsection.
In B.U.D.S., click the following:
– Read Data button
– Monitoring tab
– ECM tab.
vmr2015-073-002_a
1. Fuel rail
2. Fuel Injector
3. Intake manifold
Fuel Rail
Two fuel rails, one for each injector, are mounted
vmr2012-026-150_a
on the intake manifold. The fuel rails, which are
VERIFYING ENGINE RPM USING B.U.D.S.
used to secure the injectors to the manifold, also 1. Monitoring tab
provide to the injectors the fuel pressure that they 2. Engine RPM indication
receive from the fuel pump.
238 vmr2016-045
NOTE: The multifunction gauge and B.U.D.S. use Open throttle approximately one quarter then
the same signal to provide the engine RPM indi- quickly release. Repeat 2 - 3 times to settle throt-
cation. tle plate. If stopper does not rest against its stop
lever, perform throttle cable adjustment. Refer to
CLOSED THROTTLE AND IDLE THROTTLE CABLE in this subsection.
ACTUATOR RESET To reset IACV and TPS, perform the following:
This operation performs a reset of the values in 1. Connect the vehicle to the latest applicable
the ECM. B.U.D.S. version, refer to COMMUNICATION
This reset is very important. The setting of the
TPS will determine the basic parameters for all 2. In B.U.D.S., click the following:
fuel mapping and several ECM calculations and – Read Data button
the setting of the idle air control valve will deter- – Setting tab
mine the basic parameters for the idle speed con- – ECM tab
trol of the engine. 3. Click on the Reset button in the Closed Throt-
Closed throttle and idle actuator reset must be tle and Idle Actuator area.
done if:
– TPS is loosened, removed or replaced
– Throttle body is replaced
– Idle air control valve is replaced
– ECM is replaced.
NOTICE An improperly set TPS or IACV may
lead to poor engine performance and emission
compliance could possibly be affected. In ad-
dition, improper IACV reset may lead to poor
engine starting, improper idle (too low or too vmr2016-045-010_a
high) and engine stop on deceleration.

If operation is wrong, an error message will be dis-
Remove throttle body cap and ensure the throttle played.
cam of throttle body rests against set screw with- If TPS is not within the allowed range while re-
out any tension in the cable. setting the Closed Throttle and Idle Actuator, the
ECM will generate a fault code and will not accept
the setting. Repeat the reset procedure.
4. Start engine and make sure it operates nor-
mally through its full engine RPM range. If
fault codes appear, refer to DIAGNOSTIC AND
FAULT CODES subsection for more informa-
tion.
TROUBLESHOOTING
DIAGNOSTIC TIPS
Engine problems are not necessarily related to the
fuel injection system.
It is important to ensure that the engine and
vmr2006-014-064_b
propulsion system, fuel delivery and electrical
1. Contact here
2. Free-play here systems are functioning normally.
For diagnostics purposes, use B.U.D.S. software.
See COMMUNICATION TOOLS AND B.U.D.S.
subsection.
vmr2016-045 239
After a problem has been solved, be sure to clear NOTE: This wakes up the ECM, which then turns
the fault(s) in the ECM using the B.U.D.S. soft- on the following. If the following do not turn on,
ware. check ECM fuse (PF1 (F5 and F8)).
WARNING QUICK INDICATION THAT ECM IS FUNCTIONING
(assuming the observed component is
Electrical actuators and electronic modules in good working order)
may be powered up as soon as the ignition
switch is set to ON and emergency engine Multifunction gauge turns ON.
stop switch is set to RUN. Always disconnect Fuel pump turns on for approx. 5 seconds.
the battery prior to disconnecting any elec-
trical or electronic parts. Rear lights turn on.
Headlamps turn on (ignition key on with lights
Never use a battery charger to temporarily substi- position).
tute the battery as it may cause the ECM to func-
tion erratically, or not at all. ECM Access
Check related-circuit fuse solidity and condition Refer to BODY and remove the LH panel.
with an ohmmeter. A visual inspection could lead
to a false diagnosis.
Electrical Related Problems

It is important to check the following in the elec-
trical system:
– Battery voltage
– Fuses
– Ground connections
– Wiring and connectors.
Ensure that all electronic components are genuine
OEM. Any modification to the wiring harness may
lead to poor system operation or generate fault
codes.
Electrical Connections vmr2012-022-002_a
LH PANEL REMOVED
Pay particular attention to ensure that terminals 1. ECM location
and pins are not out of their connectors, corroded,
or out of shape. ECM Connector
When probing terminals, pay attention not to de- There is one connector connected to the ECM. It
form the terminals as this could cause a loose or links:
intermittent connection that would be difficult to – Engine harness
troubleshoot. – Vehicle system control harness.
For connector information, cleaning and probing,
PROCEDURES refer to WIRING HARNESS AND CONNECTORS
subsection.
ENGINE CONTROL MODULE
(ECM)
As a first troubleshooting step, always check for
applicable fault codes using B.U.D.S. software.
Quick Test to Validate ECM Operation

Turn ignition key to ON.
240 vmr2016-045
Testing the ECM Power Supply

REQUIRED TOOL
ECM ADAPTER TOOL

(P/N 529 036 166)

(P/N 529 035 868)
smr2009-030-010_a
1. Disconnect ECM connector. If any measurement is out of specification, refer to

2. Install ECM connector on the ECM ADAPTER POWER DISTRIBUTION and check all grounds.
TOOL (P/N 529 036 166).
3. Install a jumper wire between K1 and M4 on the Testing the CAN Resistor
ECM adapter tool. Remove the DPS1 connector (4-pin connector)
4. Turn the ignition switch to ON. from DPS module (if so equipped). Refer to
STEERING SYSTEM subsection.
1. Remove seat to access the diagnostic link con-
6. Set multimeter to Vdc and check for voltage as nector (DB).
follows.
2. Remove diagnostic link connector from its
ECM
BATTERY VOLTAGE
holder.
ADAPTER
L1 Negative post Battery voltage
If voltage is not measured, check the following:

– ECM fuse
– Main relay
– Wiring and connections, refer to the WIRING
DIAGRAM.
Testing the Continuity of ECM Ground

Circuits
REQUIRED TOOL
ECM ADAPTER TOOL

(P/N 529 036 166) smr2012-023-003_a
TYPICAL
FLUKE 115 MULTIMETER 3. Set a multimeter to setting.

(P/N 529 035 868)
REQUIRED TOOL
1. Disconnect ECM connector. FLUKE 115 MULTIMETER

2. Install the ECM ADAPTER TOOL (P/N 529 036 166) (P/N 529 035 868)
on ECM connector.
3. Set multimeter to and probe adapter termi-
nals as per following table. 4. Measure the resistance of the CAN resistors as
ECM BATTERY
RESISTANCE
ADAPTER POST
Pins M3 and Close to 0
Ground
M4 (continuity)
vmr2016-045 241
CAN RESISTOR TEST WARNING

DIAGNOSTIC LINK Always reconnect the RED (+) battery cable
RESISTANCE
CONNECTOR first, then reconnect BLACK (–) cable.
3. If a new ECM is installed, refer to ECM RE-
TEST RESULT PLACEMENT in this subsection.
READING RESULT Replacing the ECM
Approximately ECM and CLUSTER CAN wires 1. Transfer ECM data. Refer to ECM DATA
60 and resistors good TRANSFER for complete procedure.
ECM CAN resistor open, or 2. Perform the CLOSED THROTTLE AND IDLE
CLUSTER CAN resistor ACTUATOR RESET.
Approximately
open, or
120 3. Program the vehicle ignition key(s) in the new
CAN wire to CLUSTER
or ECM open ECM.
Infinite CAN wire to DB connector
4. Calibrate the IACV. Refer to IACV CALIBRA-
(open circuit) open circuit TION in this subsection.
If 120 ohms is read, isolate the CLUSTER from ECM Data Transfer
CAN by disconnecting it and measuring again at To transfer the original ECM recorded information
the diagnostic link connector. to the new ECM, use the B.U.D.S. software and
If 120 ohms is still read, the ECM CAN resistor and proceed as follows.
wires are good. Check for continuity of the CLUS- 1. Connect the original ECM to vehicle.
TER CAN wires, refer to WIRING DIAGRAM. 2. In B.U.D.S., click the Read Data button to load
If an open circuit is read, the ECM CAN resistor the information from the original ECM.
(or wire) is open. Check for continuity of the ECM
CAN wires, refer to WIRING DIAGRAM to deter-
mine if the wires or the resistor is at fault.
If the CAN resistor of a module is at fault, replace
that module.
If a module cannot communicate and the CAN re-
sistor and wires test good, try a new module.
5. Reconnect DPS1 to DPS module,
Removing the ECM vmr2006-012-100_aen
NOTE: If a new ECM is to be installed, first read

the procedures in ECM REPLACEMENT in this NOTE: Keep B.U.D.S. running while replacing
subsection. ECMs. The data will remain stored in the PC
computer as long as B.U.D.S. is running.
1. Disconnect battery cables.
3. Get the Data from the saved .mpem file.
NOTICE Always disconnect the BLACK (–)
3.1 Click on the Open button.
battery cable first, then disconnect RED (+)
cable.
3. Unscrew all retaining screws and pull out ECM.
Installing the ECM

Reverse removal procedure however, pay atten-
tion to the following.
1. Reconnect ECM connector.
2. Reconnect battery cables.
242 vmr2016-045
mmr2009-023-080
3.2 Click once on the Folder Up button in the

open box.
vmr2015-042-012_a
IMPORTANT: Ensure to use the file that specifi-

cally matches the vehicle you are servicing.
NOTE: The file name structure is as follows:
BUDS version_VIN_date read (yyyymmdd)_hour read
(hhmmss).mpem
Example:
A3.5.0.3_3JBLKCK11DJ000319_20130924_093618.mpem
B.U.D.S. version = A3.5.0.3
VIN = 3JBLKCK11DJ000319
Date file was read = 2013-09-24
Hour file was read = 09h 36m 18s
vmr2015-042-010_a
4. Go to the Vehicle tab and record the following
3.3 Double click on the AutoSave folder. information.
– Vehicle (V.I.N.) number
– Engine number (without the leading “M”)
– Model number
– Customer.
vmr2015-042-011_a
NOTE: You may have to go to another Au-

toSave folder from a previous version of vmr2008-022-008
B.U.D.S.
3.4 Choose the latest file saved for this spe- 5. Remove the original ECM.
cific vehicle. 6. Install the new ECM.
7. In B.U.D.S., click the Read Data button to read
the new ECM.
vmr2016-045 243
vmr2006-012-100_aen
8. Select the Vehicle tab and enter the informa-

tion you recorded previously.
– Vehicle serial number
tmr2011-022-017_a
– Engine number (do not enter the “M” at the
ADDING PART IN HISTORY
beginning of the engine number) 1. History tab
– Enter model number. 2. Part Replacement tab
3. Add part in history button
– Customer name. 4. ECM selection
5. Add ECM serial number here
NOTE: The ECM serial number can be found on

the ECM sticker that also identifies the part num-
ber.
11. Click on the OK button.
12. Click on the Write Data button.
smr2009-030-007_a
VEHICLE TAB
9. Click on the following tabs:

– History
– Part Replacement
– Add Part in History.
10. Enter the old ECM serial number in the Add vmr2006-012-100_ben
Part In History window.
FUEL INJECTOR
tor locations.
Fuel Injector Leak Test

Carry out the FUEL PUMP PRESSURE TEST as
detailed in the FUEL TANK AND FUEL PUMP sub-
section.
Testing the Fuel Injector Input Voltage

Disconnect the fuel injector electrical connector.
Turn on ignition switch.
244 vmr2016-045
NOTE: Ensure to read voltage before ECM auto- Testing the Fuel Injector Resistance
matically turns off. Disconnect ECM connector.
Use a multimeter and set it to Vdc. Read voltage. Install the ECM connector on the ECM ADAPTER
INJECTOR TOOL (P/N 529 036 166).
CYLINDER CONNECTOR MEASUREMENT Connect the fuel injector connector.
WIRE Using a FLUKE 115 MULTIMETER (P/N 529 035 868),
FRONT INJ1-2 check resistance value between terminals as fol-
BAT2 lows.
Battery voltage
REAR INJ2-2 (-)
FUEL INJECTOR RESISTANCE TEST
AT ECM ADAPTER
FUSE BOX ECM RESISTANCE
INJECTOR
TERMINAL ADAPTER @ 20°C (68°F)
FRONT K4
PF1-B2 11.4 - 12.6
REAR L4
If resistance value obtained is incorrect, perform

an INJECTOR GROUND CIRCUIT RESISTANCE
TEST.
Testing the Injector Ground Circuit

Resistance
Disconnect the fuel injector connector.
vmr2006-014-075_a
TYPICAL
Install ECM connector on the ECM ADAPTER TOOL
If supply voltage is not good, check fuse and if (P/N 529 036 166).
good, perform an INJECTOR POWER CIRCUIT Using a FLUKE 115 MULTIMETER (P/N 529 035 868),
RESISTANCE TEST. check resistance value between terminals as fol-
If supply voltage is good, perform a FUEL INJEC- lows.
TOR RESISTANCE TEST.
INJECTOR
GROUND CIRCUIT
Testing the Injector Power Circuit CYLINDER MEASUREMENT
Resistance WIRE
ECM
ADAPTER
Check continuity between main relay and injector
as follows: FRONT INJ1-1 K4
Close to 0
– Remove main relay. REAR INJ2-1 L4
– Disconnect the fuel injector connector.
– Use a multimeter and set it to . If continuity is not good, repair or replace wiring
– Read resistance. going to injector.
If continuity is good, replace the injector.
INJECTOR
CYLINDER CIRCUIT MEASUREMENT Removing the Fuel Injector
WIRE Remove the fuel rail. Refer to FUEL RAIL in this
FRONT INJ1-2 subsection.
PF1-B2 Close to 0
REAR INJ2-2

going to injector.
If continuity is good, perform the FUEL INJECTOR
RESISTANCE TEST.
vmr2016-045 245
NOTICE Gently push O-ring in evenly all

around while inserting injector. O-ring must
be completely inserted and not visible, before
completing the insertion of the injector.
vmr2009-022-001_a
TYPICAL - FUEL RAIL ASS’Y

1. Fuel rail
2. Fuel injector
3. Injector top O-ring
4. Injector bottom O-ring
5. Manifold O-ring
Pull fuel injector out of the fuel rail.
Installing the Fuel Injector

dure. Pay attention to the following details. vmr2006-014-072_a
Apply a thin film of engine oil to O-rings to ease

insertion in rail. Firmly push injector until it bottoms out.
Install fuel injector with your hand. Do not use any Reinstall fuel rail.
tool.
FUEL INJECTOR INSTALLATION
FUEL RAIL
O-RINGS New Lubricate with engine oil Replacing the Fuel Rail
Removing the Fuel Rail
Position the manifold O-ring on injector as in fol-
lowing illustration. 1. Disconnect fuel line to reach the rear injector.
Refer to FUEL TANK AND FUEL PUMP subsec-
tion.
2. Unscrew rail retaining screws.
3. Gently pull rail off by hand.
vmr2006-014-071_a
TYPICAL - MANIFOLD O-RING POSITION
Carefully insert injector in manifold paying atten-

tion to the manifold O-ring.
vmr2006-014-073_a
TYPICAL
246 vmr2016-045
To disconnect fuel rail from hose, cut clamp on Proceed with THROTTLE CABLE ADJUSTMENT
fuel hose. Refer to FUEL TANK AND FUEL PUMP in this subsection.
for clamp removal/installation procedures.
Adjusting the Throttle Cable
REQUIRED TOOL
Mechanically adjust the throttle cable as follows.
OETIKER PLIERS (P/N 295 Handlebar and throttle cable must be at their
000 070) normal position. Throttle cable routing must have
been performed before adjusting cable.
Activate throttle lever a few times. Make sure
NOTE: If fuel rail is removed for access to fuel in- throttle cam of throttle body rests against set
jector, it is not necessary to cut hose clamp. Only screw without any tension in the cable.
to replace fuel rail.
Installing the Fuel Rail
For installation, reverse the removal process how-
Install new clamps using pliers as per removal (if
fuel rail was replaced).
Apply a thin film of engine oil to injector O-rings to
ease insertion in rail.
INJECTOR O-RINGS
SERVICE PRODUCT Lubricate with engine oil
Install fuel rail and evenly tighten screws a little at

a time each side.
TIGHTENING TORQUE vmr2006-014-064_b
1. Contact here
LOCTITE 243 (BLUE) 2. Free-play here
Service product
(P/N 293 800 060)
Fuel rail retaining screws

10 N•m ± 1 N•m CAUTION If there is no free-play at idle
(89 lbf•in ± 9 lbf•in) position, it may cause poor idling and starta-
bility problems. Improper cable adjustment
NOTE: Activate fuel pump a few times to built will cause strain on cable and/or damage cable
fuel pressure. bracket or throttle lever at handlebar.
WARNING WARNING
Perform a fuel pressure test and ensure that Make sure idle speed stopper contacts throt-
there is no leak. Refer to FUEL TANK AND tle cam when throttle lever is fully released at
FUEL PUMP. handlebar.
THROTTLE CABLE If adjustment is needed, proceed with adjuster at

handlebar. Adjust to have 2 mm (.079 in) free-play
Removing the Throttle Cable at the end of throttle lever. When done, slide back
Remove steering cover. cable protector over adjuster.
Remove LH side panel.
Disconnect throttle cable from throttle body. Re-
fer to procedure in this subsection.
Disconnect throttle cable from throttle lever.
Remove throttle cable.
Installing the Throttle Cable

Reverse removal procedure.
vmr2016-045 247
THROTTLE BODY
Throttle Body Description
vmr2006-014-067_a
TYPICAL
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:
vmr2006-014-010_a
– Fully depress throttle lever and hold. 1. Throttle body
– Loosen adjuster lock nut/adjuster until it just re- 2. Throttle cable attachment
3. Throttle plate
leases lever. 4. TPS
5. Idle air bypass channel
– Turn adjuster clockwise until it touches lever 6. Idle air control valve
again.
– From there, tighten adjuster 1/2 turn (to remove Throttle Body Access
strain in cable). Remove the RH side panel. Refer to BODY sub-
– Tighten lock nut. section.
– Release throttle lever.
Inspecting the Throttle Body
Check that the throttle plate moves freely and
smoothly when depressing throttle lever.
– Check if throttle body idle set screw is loose or
worn.
– Check if TPS is loose.
– Check if idle air control valve is loose.
– Check for corroded or damaged connectors.
NOTICE The throttle body must be replaced
if idle set screw is loose or worn.
Cleaning the Throttle Body

vmr2006-014-068_a
1. Check throttle body cleanliness using a flash-
light. Fully open throttle plate and verify:
2. Adjuster – Throttle body bore
Reinstall throttle cable cover. – Throttle plate edge.
Look for:
– Dirt
– Oily surfaces
– Carbon and salt deposits on throttle plate and
the surrounding bore.
2. Clean as necessary.
248 vmr2016-045
3. Use a throttle body cleaner such as GUNK IN-

TAKE MEDIC or an equivalent. Refer to manu-
facturer's instructions.
NOTICE Only use an appropriate throttle
body cleaner that will not damage O-rings and
EFI sensors.
4. To avoid getting dirt into engine, spray cleaner
on a clean rag then rub rag against throttle plate
and bore. A toothbrush may also be used.
5. Gently open throttle plate and hold fully open to
reach all surfaces.
6. To remove residual dirt, spray cleaner on throt-
tle plate and on bore. vmr2012-026-004_a
7. Reinstall removed parts. TYPICAL

Step 1: Loosen
Step 2: Rotate
Removing the Throttle Body Step 3: Remove
1. Remove the air intake silencer retaining 7. Rotate throttle lever and pull out cable barrel.
screws.
vmr2006-014-060_b
vmr2012-026-003_a TYPICAL
TYPICAL 1. Throttle lever
1. Remove these screws 2. Cable barrel
2. Lift rear of air intake silencer as much as possi- 8. Remove barrel from cable.
ble and block in this position. 9. Pull out throttle cable.
3. Unplug connectors from TPS and IACV. 10. Pull out throttle body.
4. Loosen both throttle body clamps.
Installing the Throttle Body
5. Rotate throttle body to gain access to throttle
cable. Installation of the throttle body is the reverse of
the removal procedure. However, pay attention to
6. Remove throttle cable cover. the following.
Temporarily install throttle body into position.
Properly install cable barrel to throttle cable end.
vmr2016-045 249
vmr2006-014-65_a
vmr2006-014-063_a
Tighten clamps.
Hook cable to throttle lever. – Check throttle cable adjustment. Refer to
– If throttle body was replaced, perform the
Closed Throttle And Idle Actuator Reset and
the IACV CALIBRATION. See procedures in
this subsection.
THROTTLE POSITION SENSOR

(TPS)
tor locations.
General
The throttle position sensor (TPS) is a potentiome-
vmr2006-014-064_a
ter that sends a signal to the ECM which is propor-
Rotate throttle body into position and ensure to tional to the throttle plate angle.
index throttle body tab with boot notch.
vmr2008-022-010_b
1. Throttle position sensor (TPS)

vmr2006-014-065_a
250 vmr2016-045
The ECM may generate several fault codes per- Slowly and regularly depress the throttle. Ob-
taining to the TPS. Refer to DIAGNOSTIC AND serve the needle movement. It must change
FAULT CODES subsection for more information. gradually and regularly as you move the throt-
tle. If the needle “sticks”, bounces, suddenly
TPS Access drops or if any discrepancy between the throttle
Remove the RH side panel. Refer to BODY sub- movement and the needle movement is noticed,
section. it indicates that the TPS needs to be replaced or
the computer used may be too slow to transfer
Loosen both throttle body clamps. data fast enough for real time display.
Rotate throttle body to gain access to TPS.
Testing the TPS Resistance
Ensure correct throttle cable adjustment. Refer to
THROTTLE CABLE ADJUSTMENT in this subsec-
tion.
Ensure TPS is connected to wiring harness.
Using the following tools, check resistance val-
ues.
REQUIRED TOOL
ECM ADAPTER TOOL (P/N 529 036 166)
THROTTLE WIDE OPEN

vmr2012-026-004_b ECM ADAPTER IDLE THROTTLE
TYPICAL POSITION POSITION
Step 1: Loosen
Step 2: Rotate RESISTANCE ( ) @ 20°C
PIN
(68°F)
Testing the TPS Wear
G3 G2 900-1600 2600-3100
IMPORTANT: Prior to testing the TPS, ensure
that mechanical components of throttle body are G2 A1 1800-2200 1800-2200
checked. G3 A1 2200-3100 800-1200
While engine is not running, activate throttle and
pay attention for smooth operation without phys-
ical stops of the cable.
Using the B.U.D.S. software, use the Throttle
Opening display under Monitoring.
vmr2008-022-005_a
NOTE: The resistance value should change

smoothly and proportionally to throttle move-
ment. Otherwise, replace TPS.
If resistance values are correct, perform the TPS
vmr2006-014-083_aen INPUT VOLTAGE TEST below.
TYPICAL If resistance values are incorrect, check wiring
harness. If wiring is faulty, repair/replace. If
wiring is good, replace TPS.
vmr2016-045 251
Reconnect ECM connector.
Testing the TPS Input Voltage

Disconnect connector from TPS.
Turn ignition key ON.
Check the voltage readings from harness connec-
tor as follows.
CONNECTION VOLTAGE
Pin 1 with battery ground 5.0 V
Pin 2 with battery ground 0 V
vmr2006-012-004_c
TYPICAL – THROTTLE BODY

1. TPS
2. Screws
Install the new TPS and tighten retaining screws

to specification.
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
BAT Service product
(P/N 293 800 060)
smr2005-056-016_a
TPS retaining screws 3 N•m (27 lbf•in)
If voltage test is not good, check/repair wiring Perform the Closed Throttle And Idle Actuator
harness. If wiring tests good, refer to ECM RE- Reset procedure. Refer to CLOSED THROTTLE
PLACEMENT. AND IDLE ACTUATOR RESET in this subsection.
If voltage test is good, everything is in order (as-
suming resistance test was performed). IDLE AIR CONTROL VALVE (IACV)
TPS Replacement SYSTEM subsection for component and connec-
Refer to TPS ACCESS in this subsection to gain tor locations.
access to TPS.
An idle air control valve with good resistance
Unplug connector from TPS. measurement can still be faulty. It is also pos-
Loosen TPS retaining screws. sible that a mechanical failure occurs which is
not detectable without measuring the air flow.
Remove TPS.
Replacing the IACV may be necessary as a test.
252 vmr2016-045
If resistance test of valve windings is good, check

continuity of circuits C4, D3, D4, E4. If not good,
check/repair wiring/connectors.
Inspecting the IACV Visual

NOTE: Make sure the ignition key is turned off
during the following procedure.
Remove Idle air control valve from throttle body.
Check the piston and bypass channel for dirt/de-
posits which can cause a sticking piston.
NOTICE Always keep the ignition key turned
OFF, while the idle air control valve is removed.
NOTICE Do not try to operate the piston
vmr2015-042-004_a
of the idle air control valve when it is dis-
mounted. Also do not move the piston by
IACV Access
hand. The drive screw is very sensitive and
Refer to TPS ACCESS in this subsection to gain may be destroyed.
access to IACV.
Using a part cleaner, clean idle bypass in throttle
Testing the IACV Resistance body from contamination then blow compressed
Disconnect IACV from the wiring harness. air to dry it.
Using a multimeter, check the resistance in both
windings.
Check the resistance between pins as shown.
IDLE AIR CONTROL VALVE MEASUREMENT
RESISTANCE ( )
PIN
@ 20°C (68°F)
A D
50 ± 5
B C
vmr2006-014-085_a
1. Clean bore from contamination
Clean all remaining parts and install the idle air

control valve on the throttle body.
Proceed with the Closed Throttle and Idle Actu-
ator Resetand the IACV CALIBRATION. See pro-
cedures in this subsection.
IACV Calibration
The IACV calibration is required to avoid a poten-
tial erratic or frozen RPM needle.
vmr2015-042-004_a 1. Start the vehicle to increase engine tempera-
ture.
If the resistance of any winding is not good, re-
place the idle air control valve. 2. Let engine run at idle until the cooling fan per-
formed a complete cycle (ON/OFF).
vmr2016-045 253
3. When the cycle is done, turn ignition key to OFF CPS Replacement
position. Refer to CPS ACCESS in this subsection to reach
4. The calibration is completed. CPS.
Disconnect CPS connector and cut harness lock-
CRANKSHAFT POSITION ing tie (if applicable).
SENSOR (CPS) Remove CPS retaining screw and pull up on CPS
Refer to applicable ENGINE MANAGEMENT SYS- to remove it.
TEM subsection for component and connector lo-
cations.
NOTE: Take into account that a CPS fault can be
triggered by bent or missing encoder wheel teeth.
First check fault codes using B.U.D.S., then check
the encoder wheel teeth condition if necessary.
Refer to MAGNETO AND STARTER subsections.
CPS Access
section.
To reach the CPS connector, remove protector
from engine.
Testing the CPS Resistance

Disconnect the ECM connector. vmr2006-014-004_a
Install ECM connector on ECM ADAPTER TOOL TYPICAL

1. CPS
(P/N 529 036 166). 2. Retaining screw
Lubricate O-ring of CPS.

O-RING
XPS SYNTHETIC
Service product GREASE
(P/N 293 550 010)
Install new CPS and secure harness with a new

locking tie (as applicable).
Tighten CPS retaining screw to specification.
529036166
TIGHTENING TORQUE
Using a multimeter, measure resistance as per ta- 10 N•m ± 1 N•m
ble. CPS retaining screw
PIN
RESISTANCE MANIFOLD ABSOLUTE
@ 20°C (68°F) PRESSURE AND TEMPERATURE
D1 E1 700 - 900 SENSOR (MAPTS)
If resistance value is incorrect, check or repair the Refer to applicable ENGINE MANAGEMENT SYS-
connectors and the wiring harness between ECM TEM subsection for component and connector lo-
connector and the CPS. If resistance value is still cations.
incorrect, replace CPS.
254 vmr2016-045
dirt on its end and if problem persists, check throt-

tle plate condition/position and the wiring harness.
Perform the following tests.
MAPTS Pressure Function Quick Test
– Monitoring tab
– ECM tab.
vmr2006-012-004_d
1. Manifold absolute pressure and temperature sensor (MAPTS)
vmr2012-026-150_b
TYPICAL
1. Monitoring tab
2. MAPTS pressure reading
3. Look for and take note of the MAPTS pressure

reading while the engine is stopped.
4. Perform the same test with a new MAPTS and
Values have to be within ± 3.4 kPa (.5 PSI).
vmr2015-042-006_a
MAPTS PRESSURE FUNCTION QUICK TEST
NOTE: This sensor is a multifunction device. RESULT SERVICE ACTION
MAPTS Access Circuit
continuity MAPTS
Remove the RH side panel. Refer to BODY sub- NO test of input
Repair or
section. replace
READING MAPTS voltage
wiring
pressure test
MAPTS Pressure Function function
Before the engine is started, when power is ap- VALUE IS
plied to the system, the sensor measures the OUT OF Replace MAPTS
ambient air atmospheric pressure. The ambient RANGE
pressure is, at that moment, stored in the ECM.
Thereafter, once the engine is started, it mea- Testing the MAPTS Input Voltage
sures the air pressure in the intake manifold at
Check the voltage output from ECM to the pres-
operating RPMs.
sure sensor.
The sensor must be correctly installed on intake
manifold. Otherwise, the MAPTS could generate 1. Turn ignition key ON.
a fault code for an unexpected sensor range at idle 2. Set emergency engine stop switch to RUN.
when it reads the atmospheric pressure. If this 3. Remove electrical connector from MAPTS.
is the case, remove sensor and check for oil or
vmr2016-045 255
4. Using a FLUKE 115 MULTIMETER (P/N 529 035

868), measure for input voltage as per following
table.
MAPTS CONNECTOR MEASUREMENT
PIN VOLTAGE
1 3 5 Vdc
If voltage test is good, replace the MAPTS.

If voltage test is not good, carry out the MAPTS
CIRCUIT CONTINUITY TEST (PRESSURE FUNC-
TION).
vmr2016-045-001_a
Testing the MAPTS Circuit Continuity TYPICAL

(Pressure Function) 1. Monitoring tab
2. MAPTS temperature reading
4. Perform the same test with a new MAPTS and
2. Install ECM connector on ECM ADAPTER TOOL compare both readings.
(P/N 529 036 166).
If the engine MAPTS temperature reading is sig-
3. Using a multimeter, check continuity of the fol- nificantly different than the new MAPTS, replace
lowing circuits. it.
MAPTS CIRCUIT CONTINUITY TEST NOTE: Both sensors must feel the same ambient
(PRESSURE FUNCTION) air temperature.
ECM MAPTS RESISTANCE If there is no reading, carry out a MAPTS RESIS-
ADAPTER CONNECTOR VALUE TANCE TEST (TEMPERATURE FUNCTION).
A1 Pin 3 Testing the MAPTS Resistance (Temperature
F2 Pin 4 Close to 0 Function)
G2 Pin 1 Disconnect the connector from the MAPTS.
Using the FLUKE 115 MULTIMETER (P/N 529 035
If resistance is not within specification, repair or 868), check the resistance of the sensor itself as
replace the wiring harness between ECM connec- shown.
tor and the MAPTS.
MAPTS MEASUREMENT
MAPTS Temperature Function RESISTANCE
PIN
The sensor monitors the temperature in the intake @ 20°C (68°F)
manifold. 1 2 2280 - 2740
Testing the MAPTS Temperature Function
If resistance is not within specification, replace
1. Connect vehicle to the applicable B.U.D.S. soft- the MAPTS.
ware version.
If resistance tests good, reconnect the MAPTS
2. In B.U.D.S., click the following: and disconnect the ECM connector.
– Monitoring tab Install ECM connector on ECM ADAPTER TOOL
– ECM tab. (P/N 529 036 166).
3. Look for the Intake Air temperature reading
while the engine is stopped.
256 vmr2016-045
MAPTS Replacement
529036166
Using a multimeter, recheck resistance value as

RESISTANCE
PIN
@ 20°C (68°F)
F3 G2 2280 - 2740
MAPTS TEMPERATURE SENSOR TEST RESULTS

RESULT SERVICE ACTION vmr2006-012-004_e
1. MAPTS
Circuit 2. Retaining screw
Continuity MAPTS
Repair or
NO Test of Input Disconnect MAPTS connector and remove the
replace
READING MAPTS Voltage MAPTS.
wiring
Temperature Test
Function
Install new MAPTS as per following table.
INCORRECT TIGHTENING TORQUE

RESISTANCE Replace MAPTS LOCTITE 243 (BLUE)
VALUE Service product
(P/N 293 800 060)
Testing the MAPTS Circuit Continuity 6 N•m ± 0.7 N•m

MAPTS retaining screw
(Temperature Function) (53 lbf•in ± 6 lbf•in)
MAPTS CIRCUIT CONTINUITY TEST

(TEMPERATURE FUNCTION) CTS (COOLANT TEMPERATURE
ECM MAPTS RESISTANCE SENSOR)
ADAPTER CONNECTOR VALUE Refer to appropriate ENGINE MANAGEMENT
G2 Pin 1 SYSTEM subsection for component and connec-
Close to 0 tor locations.
F3 Pin 2
vmr2016-045 257
Testing the CTS Resistance

2. Using the following tools, check resistance val-
ues.
REQUIRED TOOL
ECM ADAPTER TOOL

(P/N 529 036 166)
vmr2015-042-007_a 3. Install ECM connector on the following tool.

RESISTANCE ( )
PIN
@ 20°C (68°F)
C3 F4 2280 - 2736
If resistance value is incorrect, check wiring con-

tinuity between ECM connector and the CTS. Re-
fer to CTS CIRCUIT CONTINUITY TEST in this sub-
section.
Testing the CTS Circuit Continuity

1. Disconnect connector from CTS and check the
circuit continuity.
CTS CIRCUIT CONTINUITY TEST
ECM CTS RESISTANCE
vmr2012-026-007_a
LH SIDE OF VEHICLE
1. CTS Pin F4 Pin 1
Close to 0
CTS Access Pin C3 Pin 2
Remove the LH panel. Refer to BODY subsection. If resistance value is incorrect, repair or replace
Remove the CVT duct. wiring or connectors/terminals.
If resistance test is good, replace the CTS.
Replacing the CTS

1. Refer to CTS ACCESS in this subsection to
reach CTS.
2. Remove heat shield over exhaust pipe to ex-
pose CTS. Refer to EXHAUST SYSTEM subsec-
tion.
vmr2012-026-006_a
TYPICAL
1. Pull out
258 vmr2016-045
vmr2012-026-008_a
1. CTS
3. Disconnect CTS connector and remove CTS.

4. Install the new CTS and torque as specified.
TIGHTENING TORQUE
16 N•m ± 2 N•m
CTS
5. Reinstall remaining removed parts.

6. Refill and bleed the cooling system. Refer to
COOLING SYSTEM subsection.
vmr2016-045 259
Subsection 03 (FUEL TANK AND FUEL PUMP (450))
FUEL TANK AND FUEL PUMP (450)

SERVICE TOOLS
FUEL HOSE ADAPTER.................................................................. 529 036 023 ......................................... 493
FUEL PUMP NUT TOOL ............................................................... 529 035 899 ......................................... 501
OETIKER PLIERS........................................................................... 295 000 070 ......................................... 496
PRESSURE GAUGE....................................................................... 529 035 709 ......................................... 493
SMALL HOSE PINCHER ............................................................... 295 000 076 ......................................... 504
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ......................................... 492

FLUKE RIGID BACK PROBE ......................................................... TP88 ......................................... 499
vmr2015-074 489
NEW
To engine
NEW
EUROPE NEW NEW
NEW NEW
NEW NEW
vmr2015-073-100_a
490 vmr2015-074
GENERAL
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.
WARNING
Always disconnect battery prior to working
on the fuel system.
vmr2015-043-001_a
WARNING FUEL TANK VENT SYSTEM

1. Vent hose
Always proceed with care and use appropri- 2. Vent system hose inlet
3. Vent system connected to fuel pump
ate safety equipment when working on pres- 4. Fuel tank
surized fuel system. Wear safety glasses. 5. Engine air intake system
Air can enter the fuel tank at all times through

WARNING the vent system INLET check valve. This prevents
Do not allow fuel to spill on hot engine parts negative pressure within the fuel tank which could
and/or on electrical connectors. cause fuel starvation.
When the repair is completed, ensure that all

hoses are connected and secured. Perform the
FUEL PRESSURE TEST and the FUEL TANK LEAK
TEST as explained in this subsection.
Fuel lines remain under pressure at all times.
Proceed with care when removing/installing high
pressure test equipment.
Use the B.U.D.S. software or disconnect the fuel
pump electrical connector to disable fuel pump
and crank engine to release fuel pressure prior to
disconnecting any fuel hose.
Cover the fuel hose connections with an ab- vmr2015-043-002_a
sorbent shop rag and carefully disconnect them AMBIENT AIR PRESSURE IN
1. Vent inlet check valve
to minimize spilling.
The vent inlet check valve also prevents fuel from
SYSTEM DESCRIPTION flowing out through the inlet of the vent system.
Fuel Tank Vent System If the pressure in the fuel tank builds up and
exceeds 2.5 kPa - 7.6 kPa (.36 PSI - 1.1 PSI), the
The fuel tank is equipped with a vent system that pressure relief valve opens and lets the excess
provides over pressure relief and negative pres- pressure evacuate through the vent system out-
sure relief of the fuel tank. let hose.
vmr2015-074 491
Fuel Pump Pressure Regulator

The fuel pressure regulator is integral to the fuel
pump module. The pressure regulator maintains
proper fuel pressure for the EFI system.
INSPECTION
FUEL TANK LEAK TEST
WARNING
Always carry out a fuel tank leak test when-
vmr2015-043-002_b ever the fuel tank shows signs of wear or
OVER PRESSURE RELIEF damage which may cause a leak, or when the
1. Outlet pressure relief valve fuel pump has been removed or replaced,
Fuel Tank Vent Breather Filter or if you suspect a leak. If the fuel tank is
damaged, the fuel tank should be replaced
The vent system is equipped with an in-line even if no leak is present. Do not attempt to
breather filter that prevents entry of particles repair the fuel tank.
such as dust or small insects. It is located next
to the fuel pump, on the inlet hose, before the air
1. Refill fuel tank and ensure fuel tank cap is in
inlet check valve.
good condition and properly installed.
To access the fuel tank vent breather filter, re-
2. Remove the gauge support for access to the
move the rear body module.
fuel vent inlet hose.
3. Using the VACUUM/PRESSURE PUMP (P/N 529
021 800), pressurize the fuel tank through the
vent hose.
REQUIRED TOOL
VACUUM/PRESSURE PUMP
(P/N 529 021 800)
vmr2015-043-002_c
1. Fuel tank vent breather filter
Fuel Pump Module

The fuel pump module is inserted in the fuel tank.
It provides fuel delivery for the EFI system and en-
compasses the following components:
– Electric fuel pump
– Fuel pump prefilter (replaceable)
– Fuel pressure regulator
– Fuel level sender. vmr2015-043-003_a
1. Fuel tank vent inlet hose

2. Gauge connector
Fuel Filters
The system comprises a replaceable prefilter ele-
ment attached to the bottom of the fuel pump.
492 vmr2015-074
TIME WITHOUT
PRESSURE
PRESSURE DROP
14 kPa (2 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 will
indicate the leak location(s).
vmr2015-043-006_a
NOTE: For access to the fuel tank vent system,
refer to FUEL PUMP ACCESS in this subsection. 9. Install the fuel pressure gauge and fuel hose
adapter between the disconnected injector
FUEL SYSTEM PRESSURE TEST hose and fuel rail (in-line installation).
The pressure test will show the available pressure REQUIRED TOOLS
in the system. It validates the pressure regulator
and the fuel pump, and allows for checking the
fuel system for leaks (high pressure side). PRESSURE GAUGE
(P/N 529 035 709)
NOTE: Refer to the FUEL SYSTEM DIAGNOSTIC
FLOW CHART in this subsection to help diagnose
a fuel system related problem. FUEL HOSE ADAPTER
1. Ensure the fuel level in the tank is sufficient. (P/N 529 036 023)
2. Ensure the battery voltage is over 12 volts.
3. Remove seat.
4. Remove LH side body panel, refer to BODY
subsection.
5. Remove heat shield, refer to EXHAUST subsec-
tion.
6. Remove the fuel pump relay fuse (F5) in the
front fuse box.
vmr2015-043-020_a
PRESSURE GAUGE SETUP

1. Fuel hose adapter location
vmr2015-044-006_a 10. Reinstall the fuel pump relay fuse (F5) in the
forward fuse box.
7. Release fuel pressure by running engine until it
runs out of gas. 11. Turn ignition key ON and observe fuel pres-
sure.
8. Carefully disconnect the fuel hose fitting from
the injector fuel rail by pressing on the release 350 kPa ± 10 kPa
FUEL PRESSURE
tab of the quick disconnect fitting. (51 PSI ± 1 PSI)
NOTE: Valid at 12v ± 0.1v.

12. Start engine and observe fuel pressure.
13. Stop engine.
vmr2015-074 493
14. Remove test equipment and reconnect fuel

hose to injector fuel rail by proceeding in the
same manner as for its installation.
Test Conclusion
The fuel pressure should be within specification in
static or dynamic tests.
Rapid Pressure Drop
If there is a rapid pressure drop after the engine is
stopped, check for leakage at:
– The fuel hose
– The fuel rail.
NOTE: The fuel pump check valve integral to the
fuel pump module may also be at fault.
If no leak is detected, replace fuel pump.
Slow Pressure Drop
If there is a slow pressure drop after the engine
is stopped, check for a fuel injector leak. Refer to
ELECTRONIC FUEL INJECTION (EFI) subsection.
NOTE: The fuel pressure regulator or fuel pump
check valve integral to the fuel pump module may
also be at fault.
494 vmr2015-074
TROUBLESHOOTING
FUEL SYSTEM DIAGNOSTIC FLOW CHART
Fuel pump does not run Activate electric system to enable fuel pump Fuel pump runs
for 2 sec. then stops
Check fuse. Install fuel pressure gauge

Check fuel pump operation. on fuel pressure line
Repair or replace if necessary.
Activate electric system to enable fuel pump Replace fuel

pump module
Fuel pump runs
Repair or Fuel pressure less Fuel pressure within Fuel pressure more
replace than specifications specifications than specifications
Fails
Check fuel line/
rail for leaks
Fails OK Crank or start

Perform fuel pump test engine
OK
Fast Fuel pressure less Fuel pressure more Fuel pressure within
pressure drop than specifications than specifications specifications
No
Yes
Check
OK fuel line/
Verify fuel
pump check rail for leaks Repair or
valve Fails
replace FUEL SYSTEM OK
Fails OK
Fails
OK
Check fuel Perform fuel Replace fuel
injector pump test pump module Retest
OK
lmr2010-023-004_aen
vmr2015-074 495
PROCEDURES 4. Disconnect and remove the battery, refer to

CHARGING SYSTEM subsection.
FUEL HOSE AND OETIKER 5. Remove the rear body module, refer to BODY
CLAMPS subsection.
6. Refer to EXHAUST SYSTEM and remove the
Fuel Hose Replacement following:
When replacing fuel hoses, be sure to use hoses – Muffler assembly
and clamps as available from BRP parts depart- – Muffler/exhaust pipe heat shield.
ment. This will ensure continued proper and safe
operation. 7. Reinstall fuel tank cap to prevent foreign ob-
jects from entering the fuel tank.
WARNING 8. Disconnect the following from the fuel pump
Use of fuel lines other than those recom- module:
mended by BRP may compromise fuel sys- – Fuel pump electric connector
tem integrity. – Fuel system vent hose
– Fuel pump pressure hose.
WARNING
Whenever removing a hose in the fuel sys-
tem, always use new Oetiker clamps at as-
sembly. Then validate fuel system tightness
by performing a fuel pressure test.
Oetiker Clamp Replacement

REQUIRED TOOL
OETIKER PLIERS
(P/N 295 000 070)
FUEL TANK vmr2015-043-005_a
1. Fuel pump connector

Fuel Tank Draining 2. Vent hose
3. High pressure fuel hose
Remove fuel tank cap and siphon gas into an ap-
proved fuel container. 9. Disconnect the positive (+) battery cable from
the starter solenoid.
Fuel Tank Removal
10. Remove the 2 screws that secure the front of
1. Drain fuel tank. Refer to FUEL TANK DRAINING the battery support.
in this subsection.
2. Remove the fuel pump relay fuse (F5) in the
front fuse box.
vmr2015-044-006_a
vmr2012-028-013_a
3. Release fuel pressure by running engine until it 1. Battery support

2. Support retaining screws
runs out of gas.
496 vmr2015-074
NOTE: It is not necessary to remove the wiring

harness or other components from the battery
support.
11. Flip the battery support over towards the RH
side of the vehicle for access to the rear frame
extension.
vmr2015-043-021_a
16. Remove fuel tank retaining screws (4).

NOTE: Note position of washers and bushings on
each screw.
vmr2015-043-022_a
12. Remove the upper mounting bolt from both

rear shock absorbers.
vmr2015-043-013_a
FUEL TANK MOUNTING SCREWS (4)

1. LH rear
2. RH rear
3. Forward top
4. Forward bottom
vmr2015-043-007_a 17. Loosen the front 2 nuts and remove the 4

screws retaining the rear frame extension.
13. Block the front wheels with wooden blocks.
14. Lift back end of vehicle and properly support
under the lower rear portion of the frame, near
the final drive.
CAUTION Before working on vehicle, en-

sure the vehicle is securely supported.
15. Remove vent tube from final drive.
vmr2015-043-008_a
vmr2015-074 497
18. Remove nuts and screws securing trailer hitch

and rear frame support to rear final drive.
vmr2015-043-012_a
Fuel Tank Inspection

vmr2015-043-009_a Inspect fuel tank for any damages or cracks which
may result in fuel leaks.
19. Remove 2 nuts and screws securing rear
frame support to rear frame section. Inspect fuel tank and fuel tank protector on frame
for damages.
Inspect protector for damages.
If cracks, gouges or other damages which may
lead to a fuel leak, or damages to attachment
points that could prevent the tank from being
secure are found, replace fuel tank.
Fuel Tank Installation

Installation is the reverse of the removal proce-
dure. However, pay attention to the following.
Install a bushing on each fuel tank mounting
screw. The bushing inserts within the fuel tank
vmr2015-043-010_a
screw hole cavity.
Be sure to install the washers between the fuel
tank and the fastener as noted at removal.
Install all fuel tank fasteners loosely.
NOTICE The fuel tank fasteners must not be
tightened to specified torque until complete as-
sembly in vehicle.
Install all frame component fasteners loosely,
then apply torque as specified in the FRAME
subsection.
Apply specified torque to fuel tank retaining
screws.
vmr2015-043-011_a
TIGHTENING TORQUE
20. Lift up on rear frame extension and pull fuel Fuel tank retaining 6.5 N•m ± 0.5 N•m
tank out of vehicle. screws (58 lbf•in ± 4 lbf•in)
NOTE: When lifting up on the rear frame exten-
sion, the chock absorbers will fall backwards. Be sure to properly connect and route:
– Fuel tank vent tube
498 vmr2015-074
– Fuel pump pressure hose

– Electrical connectors.
Refuel tank and ensure there are no leaks by
performing a FUEL TANK LEAK TEST and a FUEL
PUMP PRESSURE TEST as described in this sub-
section.
FUEL PUMP
Fuel Pressure Release
Remove fuel pump relay fuse (F5), refer to
POWER DISTRIBUTION subsection.
Start and run engine until it runs out of fuel. vmr2015-043-025_a
Fuel Pump Pressure Test Fuel Pump Input Voltage Test

Refer to INSPECTION in this subsection. 1. Disconnect the fuel pump connector.
Fuel Pump Quick Test 2. Turn ignition key ON.
1. Turn ignition key to ON. 3. Read voltage as follows.
2. Listen for fuel pump operation. REQUIRED TOOLS
NOTE: Fuel pump should come ON for a few sec-
onds, then stop. FLUKE 115 MULTIMETER
If fuel pump does not come ON, carry out the fol- (P/N 529 035 868)
lowing:
– Check fuel pump relay fuse (F5). FLUKE RIGID BACK PROBE
– Check in B.U.D.S. for applicable fault codes. (P/N TP88)
Refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection. FUEL PUMP INPUT VOLTAGE TEST
– Carry out a fuel pump input voltage test. TEST PROBES
VOLTAGE
READING
Fuel pump Fuel pump
connector connector Battery voltage
Pin 3 Pin 4
If battery voltage is read, carry out a fuel pump

resistance test.
If battery voltage is not read, test fuel pump
power input as follows.
vmr2015-044-006_a
FUEL PUMP POWER WIRE TEST
Fuel Pump Connector Access VOLTAGE
TEST PROBES
READING
Remove rear body module. Refer to BODY sub-
section. Fuel pump
connector Battery ground Battery voltage
Pin 3
If battery voltage is now read, check fuel pump

ground circuit between fuel pump connector FP-4
and battery ground.
If battery voltage is still not read, check fuel pump:
– Fuse (F5)
– Fuel pump relay (R4)
vmr2015-074 499
– Fuel pump relay input voltage (control and If test failed at pump connector, replace fuel
power circuits) pump.
– Fuel pump relay control circuit continuity to If test succeeded at pump connector, check
ECM-J1 wiring and connectors from:
– Fuel pump power circuit – Fuse box to fuel pump
– Wiring and connectors. – Fuel pump to battery ground.
Fuel Pump Resistance Test Repair or replace as necessary.
1. Ensure fuel pump connector is properly con- Fuel Pump Access
nected.
Remove rear body module, refer to BODY subsec-
2. Remove fuel pump relay (R4). tion.
Fuel Pump Removal

1. Remove the fuel pump relay fuse (F5) to disable
fuel pump:
vmr2015-044-006_a
3. Using a multimeter, measure fuel pump resis-

tance as follows.
FUEL PUMP RESISTANCE TEST vmr2015-044-006_a
(AT FUSE BOX)
2. Release fuel pressure by running engine until it
RESISTANCE
TEST PROBES runs out of gas.
@ 20°C (68°F)
3. Disconnect the following from the fuel pump:
Fuse box Battery
Approximately 2 – Fuel pump electric connector
contact A11 ground
– Fuel system vent hose
– Fuel pump pressure hose.
vmr2012-028-006_a
TYPICAL - FUSE BOX COORDINATES
If resistance test failed, disconnect fuel pump

connector and measure resistance at fuel pump vmr2015-043-005_a
connector. 1. Fuel pump connector
2. Vent hose
FUEL PUMP RESISTANCE TEST 3. High pressure fuel hose
(AT FUEL PUMP CONNECTOR)
4. Remove fuel pump retaining nut.
500 vmr2015-074
WARNING
Fuel vapors are flammable and explosive un-
der certain conditions. Use only non-spark-
ing tools.
CAUTION Replace fuel pump gasket

whenever fuel pump retaining nut is loosened.
REQUIRED TOOL
FUEL PUMP NUT TOOL

(P/N 529 035 899)
vmr2015-043-016_a
WARNING
Ensure gasket ring makes good contact all
around fuel pump and fuel pump mounting
neck on fuel tank.
3. Ensure proper fuel pump orientation as in fol-

lowing illustration.
vmr2015-043-014_a
5. Carefully pull out and rotate fuel pump as re-

quired.
NOTICE Pay attention not to damage fuel
sender and fuel pump prefilter.
6. Discard gasket ring.
7. Wipe off any fuel spillage.
vmr2015-043-017_a
Fuel Pump Installation 1. Fuel tank pump index

2. Fuel pump index
cedure. However, pay attention to the following:
Rotate fuel pump during insertion as per removal
procedure.
CAUTION Pay attention not to damage

fuel sender and fuel pump prefilter.
1. Install a NEW gasket ring.
2. Place gasket so that it is properly located be-
tween fuel pump and fuel pump mounting neck
on fuel tank.
vmr2015-074 501
WARNING
ing tools. Ensure pump locking ring is fully
engaged.
7. Install fuel pressure hose on fuel pump using a

NEW Oetiker clamp.
8. Install fuel vent tube on fuel pump.
9. Install electrical connector on fuel pump.
10. Install fuel pump relay fuse.
11. Refuel tank and ensure there are no leaks by
performing a FUEL TANK LEAK TEST and a
vmr2015-043-018_a
FUEL PUMP PRESSURE TEST as described in
ALIGNEMENT OF FUEL PUMP IN TANK
this subsection.
4. Insert fuel pump retaining nut over the fuel 12. Check fuel level sender operation.
pressure hose and electrical wiring connector.
5. While firmly holding pump against tank, engage FUEL PUMP PREFILTER
fuel pump retaining nut on fuel tank flange. (STRAINER)
NOTE: If necessary, move the pump in order to
ensure the flange is sitting completely flat on the Fuel Pump Prefilter Replacement
tank. 1. Remove FUEL PUMP, see FUEL PUMP RE-
6. Tighten fuel pump retaining nut to specification. MOVAL in this subsection.
2. Unlock 3 tabs on strainer plastic ring.
TIGHTENING TORQUE
29 N•m ± 1 N•m
Fuel pump retaining nut
NOTE: To apply the proper torque to the fuel

pump retaining nut, install the fuel pump nut tool
on a torque wrench with it's handle perpendicu-
larly (90°) to the torque wrench.
vmr2015-043-027_a
3. Remove rubber pad.
vmr2015-043-024_a
TORQUE WRENCH PERPENDICULAR TO TOOL HANDLE
Ensure pump is properly aligned with index marks

after nut it tightened to specification.
502 vmr2015-074
6. Lubricate assembly area of new strainer and

fuel pump with O-ring lubricant or clean oil
vmr2015-043-028_a
vmr2015-043-031_a
4. Remove push nut securing strainer to fuel
pump. Be careful not to break the assembly 7. Insert the new strainer on fuel pump making
locator pin. sure to press it in tightly against the fuel pump
surface.
8. Using a small nut socket, press in a NEW push
nut to secure strainer.
FUEL LEVEL SENDER

The fuel level sender is a float actuated variable
resistance type that is part of the fuel pump.
vmr2015-043-029_a
5. Pull strainer off fuel pump.
vmr2015-043-023_a
FUEL LEVEL SENDER
Fuel Level Sender Resistance Test

(Fuel Pump Module Installed)
1. Disconnect multifunction gauge, refer to the
LIGHTS/GAUGE/ACCESSORIES subsection.
2. Using a multimeter, measure the resistance of
the fuel level sender as follows.
vmr2015-043-030_a
vmr2015-074 503
FUEL LEVEL SENDER RESISTANCE TEST FUEL LEVEL SENDER INPUT VOLTAGE TEST
RESISTANCE FUEL PUMP
GAUGE BATTERY VOLTAGE
FUEL LEVEL CONNECTOR
CONNECTOR
@ 20°C (68°F)
Negative
Pin 2 5V
Full 5 ±1 terminal
Pins 4 and 21
Empty 100 ±5
TEST RESULT SERVICE ACTION
Test wiring continuity
between fuel level
5V is not read
sender and multifunction
gauge
Replace multifunction
Wiring continuity is good
gauge
Wiring continuity is not
Repair or replace wiring
obtained
Fuel Level Sender Replacement

Replace fuel pump. Refer to FUEL PUMP in this
subsection.
FUEL TANK VENT VALVES

Fuel Tank Vent Valve Test
Inlet Check Valve Test
vmr2006-020-052_c
1. Remove rear body module, refer to BODY sub-
section.
If readings are out of specification, refer to FUEL
LEVEL SENDER RESISTANCE TEST (AT FUEL 2. Remove multifunction gauge for access to
PUMP CONNECTOR). the vent system inlet hose, refer to the
If readings are as specified, refer to FUEL LEVEL
SENDER INPUT VOLTAGE TEST. 3. Install a small hose pincher between the vent
pressure relief valve and the fuel pump vent in-
Fuel Level Sender Resistance Test let.
(at Fuel Pump Connector) REQUIRED TOOL
FUEL LEVEL SENDER RESISTANCE TEST
FUEL PUMP RESISTANCE SMALL HOSE PINCHER
FUEL LEVEL (P/N 295 000 076)
CONNECTOR @ 20°C (68°F)
Full 5 ±1
Pins 1 and 2
Empty 100 ±5
If resistance test at fuel pump connector is failed,

replace fuel pump module.
Fuel Level Sender Input Voltage Test

1. Set ignition switch to ON.
2. Disconnect fuel pump connector, refer to FUEL
PUMP CONNECTOR ACCESS in this subsec-
tion.
3. Using a multimeter, measure input voltage as
follows.
504 vmr2015-074
Pressure Relief Valve Test

1. Install the small hose pincher between the inlet
check valve and the fuel pump vent inlet fitting.
vmr2015-043-019_a
1. Pressure relief valve

2. Fuel pump vent inlet
4. Connect the vacuum/pressure pump to the fuel

tank vent hose inlet. vmr2015-043-019_b
1. Inlet check valve

2. Fuel pump vent inlet fitting
2. Set vacuum/pressure pump to PRESSURE and

activate pump. The gauge should increase in
reading.
3. Set vacuum/pressure pump to VACUUM and
activate pump. The gauge on the pump should
not change in reading.
If the test failed, carry out the following:
– Ensure pressure relief valve is properly in-
stalled, refer to PRESSURE RELIEF VALVE
INSTALLATION in this subsection.
vmr2015-043-003_a
– Replace pressure relief valve if it fails the test.
1. Fuel tank vent hose inlet
2. Gauge connector
5. Remove fuel tank cap.

reading.
– Ensure breather filter is properly installed, refer
to PERIODIC MAINTENANCE PROCEDURES.
– Ensure inlet check valve is properly installed, re-
fer to FUEL TANK VENT VALVE INSTALLATION
in this subsection. vmr2015-043-019_c
– Test inlet check valve separately. If good, re- 1. Pressure relief valve flow direction arrow
place the breather filter, refer to PERIODIC
MAINTENANCE PROCEDURES.
vmr2015-074 505
Fuel Tank Vent Valve Installation

Inlet Check Valve Installation
Ensure white portion of inlet check valve is to-
wards the vent breather filter.
vmr2015-043-019_d
1. Vent breather filter

2. White portion of inlet check valve
Pressure Relief Valve Installation

Ensure pressure relief valve flow arrow is pointing
away from fuel pump vent fitting.
vmr2015-043-019_c
1. Pressure relief valve flow direction arrow
506 vmr2015-074
FUEL TANK AND FUEL PUMP (570)

SERVICE TOOLS
FUEL HOSE ADAPTER.................................................................. 529 036 023 ......................................... 265
FUEL PUMP NUT TOOL ............................................................... 529 035 899 ......................................... 272
OETIKER PLIERS........................................................................... 295 000 070 ......................................... 267
PRESSURE GAUGE....................................................................... 529 035 709 ......................................... 265
SMALL HOSE PINCHER ............................................................... 295 000 076 ......................................... 275
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ......................................... 264

FLUKE RIGID BACK PROBE ......................................................... TP88 ......................................... 270
vmr2016-047 261
NEW
NEW
To engine
NEW
NEW
EUROPE NEW NEW
NEW NEW
NEW NEW
vmr2015-043-100_a
262 vmr2016-047
GENERAL Air can enter the fuel tank at all times through
the vent system INLET check valve. This prevents
WARNING negative pressure within the fuel tank which could
Fuel is flammable and explosive under cer- cause fuel starvation.
tain conditions. Ensure work area is well ven-
tilated. Do not smoke or allow open flames or
sparks in the vicinity.
WARNING
Always disconnect battery prior disconnect-
ing a fuel system pressure hose.
WARNING
Always proceed with care and use appropri-
ate safety equipment when working on pres-
vmr2015-043-002_a
AMBIENT AIR PRESSURE IN

WARNING 1. Vent inlet check valve
Do not allow fuel to spill on hot engine parts
The vent inlet check valve also prevents fuel from
and/or on electrical connectors.
flowing out through the inlet of the vent system.
When the repair is completed, ensure that all If the pressure in the fuel tank builds up and
hoses are connected and secured. Perform the exceeds 2.5 kPa - 7.6 kPa (.36 PSI - 1.1 PSI), the
FUEL PRESSURE TEST and the FUEL TANK LEAK pressure relief valve opens and lets the excess
TEST as explained in this subsection. pressure evacuate through the vent system out-
let hose.
Fuel lines remain under pressure at all times.
Proceed with care when removing/installing high
pressure test equipment.
SYSTEM DESCRIPTION
Fuel Tank Vent System
The fuel tank is equipped with a vent system that
provides over pressure relief and negative pres-
sure relief of the fuel tank.
vmr2015-043-002_b
OVER PRESSURE RELIEF

1. Outlet pressure relief valve
Fuel Tank Vent Breather Filter

The vent system is equipped with an in-line
breather filter that prevents entry of particles
such as dust or small insects. It is located next
to the fuel pump, on the inlet hose, before the air
inlet check valve.
vmr2015-043-001_a
To access the fuel tank vent breather filter, re-
FUEL TANK VENT SYSTEM move the rear body module.
1. Vent hose
2. Vent system hose inlet
3. Vent system connected to fuel pump
4. Fuel tank
5. Engine air intake system
vmr2016-047 263
3. Using the VACUUM/PRESSURE PUMP (P/N 529

021 800), pressurize the fuel tank through the
vent hose.
REQUIRED TOOL
VACUUM/PRESSURE PUMP
(P/N 529 021 800)
vmr2015-043-002_c
1. Fuel tank vent breather filter
Fuel Pump Module

The fuel pump module is inserted in the fuel tank.
It provides fuel delivery for the EFI system and en-
compasses the following components:
– Electric fuel pump
– Fuel pump pre-filter (replaceable)
– Fuel pressure regulator
– Fuel level sender. vmr2015-043-003_a
1. Fuel tank vent inlet hose

Fuel Filters 2. Gauge connector
The system comprises a replaceable prefilter ele- TIME WITHOUT
ment attached to the bottom of the fuel pump. PRESSURE
PRESSURE DROP
Fuel Pump Pressure Regulator 14 kPa (2 PSI) 3 minutes
The fuel pressure regulator is integral to the fuel If pressure drops, locate fuel leak(s) and repair or
pump module. The pressure regulator maintains replace leaking component(s).
proper fuel pressure for the EFI system.
To locate a leak, check for a fuel smell or leaking
fuel.
INSPECTION
To ease locating leak(s), spray soapy water on all
FUEL TANK LEAK TEST hose connections and components; bubbles will
indicate the leak location(s).
WARNING NOTE: For access to the fuel tank vent system,
Always carry out a fuel tank leak test when- refer to FUEL PUMP ACCESS in this subsection.
ever the fuel tank shows signs of wear or
damage which may cause a leak, or when the FUEL SYSTEM PRESSURE TEST
fuel pump has been removed or replaced,
or if you suspect a leak. If the fuel tank is The pressure test will show the available pressure
damaged, the fuel tank should be replaced in the system. It validates the pressure regulator
even if no leak is present. Do not attempt to and the fuel pump, and allows for checking the
repair the fuel tank. fuel system for leaks (high pressure side).
NOTE: Refer to the FUEL SYSTEM DIAGNOSTIC
1. Refill fuel tank and ensure fuel tank cap is in FLOW CHART in this subsection to help diagnose
good condition and properly installed. a fuel system related problem.
2. Remove the gauge support for access to the 1. Ensure the fuel level in the tank is sufficient.
fuel vent inlet hose. 2. Ensure the battery voltage is over 12 volts.
3. Remove seat.
264 vmr2016-047
4. Remove LH side body panel, refer to BODY

subsection.
5. Remove heat shield, refer to EXHAUST subsec-
tion.
6. Disconnect the fuel pressure hose from the fuel
injector fuel rail. Refer to DISCONNECTING A
FUEL PRESSURE HOSE in FUEL HOSE AND
OETIKER CLAMPS.
7. Remove the 2 most forward locking ties secur-
ing the fuel hose to the upper cable support.
NOTE: This is required to provide more hose
length for proper connection to test equipment.
vmr2012-028-010_a
PRESSURE GAUGE SETUP

1. Pressure gauge to fuel hose adapter
2. Fuel hose adapter to fuel rail
3. Fuel hose adapter to fuel pump pressure hose
9. Reinstall the fuel pump relay (R4) in the forward

fuse box.
10. Turn ignition key ON and observe fuel pres-
sure.
FUEL PRESSURE 350 kPa ± 10 kPa
(Valid at 12v ± 0.1v) (51 PSI ± 1 PSI)
11. Start engine and observe fuel pressure.

vmr2015-043-004_a
12. Stop engine.
1. Forward injector rail fitting 13. Remove test equipment and reconnect fuel
2. Locking ties
hose to injector fuel rail by proceeding in the
8. Install the fuel pressure gauge and fuel hose same manner as for its installation.
adapter between the disconnected injector
hose and fuel rail (in-line installation). Test Conclusion
The fuel pressure should be within specification in
REQUIRED TOOLS
static or dynamic tests.
Rapid Pressure Drop
PRESSURE GAUGE
(P/N 529 035 709) If there is a rapid pressure drop after the engine is
stopped, check for leakage at:
– A fuel hose
FUEL HOSE ADAPTER – A fuel rail.
(P/N 529 036 023) NOTE: The fuel pump check valve integral to the
fuel pump module may also be at fault.
Slow Pressure Drop
If there is a slow pressure drop after the engine
is stopped, check for a fuel injector leak. Refer to
ELECTRONIC FUEL INJECTION (EFI) subsection.
NOTE: The fuel pressure regulator or fuel pump
check valve integral to the fuel pump module may
also be at fault.
vmr2016-047 265
TROUBLESHOOTING
FUEL SYSTEM DIAGNOSTIC FLOW CHART
Fuel pump does not run Activate electric system to enable fuel pump Fuel pump runs
for 2 sec. then stops
Check fuse, relay and connections. Install fuel pressure gauge

Check fuel pump operation. on fuel pressure line
Repair or replace if necessary.
Activate electric system to enable fuel pump Replace fuel

pump module
Fuel pump runs
Repair or Fuel pressure less Fuel pressure within Fuel pressure more
replace than specifications specifications than specifications
Fails
Check fuel line/
rail for leaks
Fails OK Crank or
Perform fuel pump test start
OK
Fast Fuel pressure less Fuel pressure more Fuel pressure within
pressure drop than specifications than specifications specifications
No
Yes
Check
OK fuel line/
Verify fuel
pump check rail for leaks Repair or
valve Fails
replace FUEL SYSTEM OK
Fails OK
Fails
OK
Check fuel Perform fuel Replace fuel
injector pump test pump module Retest
OK
vmr2016-047-001_aen
266 vmr2016-047
PROCEDURES FUEL TANK

Fuel Tank Draining
FUEL HOSE AND OETIKER
Remove fuel tank cap and siphon fuel into an ap-
CLAMPS proved fuel container.
Disconnecting a Fuel Pressure Hose
Fuel Tank Removal
1. Remove the fuel pump relay (R4) in the front
fuse box. 1. Drain fuel tank. Refer to FUEL TANK DRAINING
in this subsection.
2. Disconnect the fuel pressure hose from the fuel
injector fuel rail. Refer to DISCONNECTING A
FUEL PRESSURE HOSE in FUEL HOSE AND
OETIKER CLAMPS.
3. Disconnect and remove the battery, refer to
CHARGING SYSTEM subsection.
4. Remove the rear body module, refer to BODY
subsection.
vmr2015-044-006_a
5. Reinstall fuel tank cap to prevent foreign ob-
2. Release fuel pressure by running engine until it jects from entering the fuel tank.
runs out of fuel. 6. Refer to EXHAUST SYSTEM and remove the
3. Carefully disconnect the fuel hose fitting from following:
the injector fuel rail by pressing on the release – Muffler assembly
tab of the quick disconnect fitting. – Muffler/exhaust pipe heat shield.
Fuel Hose Replacement 7. Disconnect the following from the fuel pump
module:
When replacing fuel hoses, be sure to use hoses
– Fuel pump electric connector
and clamps as available from BRP parts depart-
ment. This will ensure continued proper and safe – Fuel system vent hose
operation. – Fuel pump pressure hose.
WARNING
Use of fuel lines other than those recom-
mended by BRP may compromise fuel sys-
tem integrity.
WARNING
Whenever removing a hose in the fuel sys-
tem, always use new Oetiker clamps at as-
sembly. Then validate fuel system tightness
by performing a fuel pressure test.
Oetiker Clamp Replacement

REQUIRED TOOL vmr2015-043-005_a

2. Vent hose
OETIKER PLIERS 3. High pressure fuel hose
(P/N 295 000 070)
8. Disconnect the RED (+) battery cable from the
starter solenoid.
9. Remove the 2 screws that secure the front of
the battery support.
vmr2016-047 267
13. Lift back end of vehicle and properly support

under the lower rear portion of the frame, near
the final drive.
WARNING
Before working on vehicle, ensure the vehicle
is securely supported.
14. Remove vent tube from final drive.
vmr2012-028-013_a
1. Battery support
2. Support retaining screws
NOTE: It is not necessary to remove the wiring

harness or other components from the battery
support.
10. Flip the battery support over towards the RH
side of the vehicle for access to the rear frame
extension.
vmr2015-043-021_a
15. Remove fuel tank retaining screws (4).

NOTE: Note position of washers and bushings on
each screw.
vmr2015-043-022_a
11. Remove the upper mounting bolt from both

rear shock absorbers.
vmr2015-043-013_a
FUEL TANK MOUNTING SCREWS (4)

1. LH rear
2. RH rear
3. Forward top
4. Forward bottom
16. Loosen the front 2 nuts and remove the 4

screws retaining the rear frame extension.
vmr2015-043-007_a
12. Block the front wheels with wheel chocks.
268 vmr2016-047
vmr2015-043-011_a
vmr2015-043-008_a
19. Lift up on rear frame extension and pull fuel
17. Remove nuts and screws securing trailer hitch tank out of vehicle.
and rear frame support to rear final drive. NOTE: When lifting up on the rear frame exten-
sion, the shock absorbers will fall backwards.
vmr2015-043-009_a
vmr2015-043-012_a
18. Remove 2 nuts and screws securing rear
frame support to rear frame section. Fuel Tank Inspection
Inspect fuel tank for any damages or cracks which
may result in fuel leaks.
Inspect fuel tank and fuel tank protector on frame
for damages.
Inspect protector for damages.
If cracks, gouges or other damages which may
lead to a fuel leak, or damages to attachment
points that could prevent the tank from being
secure are found, replace fuel tank.
Fuel Tank Installation

vmr2015-043-010_a Installation is the reverse of the removal proce-
dure. However, pay attention to the following.
Install a bushing on each fuel tank mounting
screw. The bushing inserts within the fuel tank
screw hole cavity.
vmr2016-047 269
Be sure to install the washers between the fuel

tank and the fastener as noted at removal.
Install all fuel tank fasteners loosely.
NOTICE The fuel tank fasteners must not be
tightened to specified torque until complete as-
sembly in vehicle.
Install all frame component fasteners loosely,
vmr2015-044-006_a
then apply torque as specified in the FRAME
subsection.
Fuel Pump Connector Access
Apply specified torque to fuel tank retaining
screws. Remove rear body module. Refer to BODY sub-
section.
TIGHTENING TORQUE
Fuel tank retaining 6.5 N•m ± 0.5 N•m
Be sure to properly connect and route:

– Fuel tank vent tube
– Fuel pump pressure hose
– Electrical connectors.
Refuel tank and ensure there are no leaks by
performing a FUEL TANK LEAK TEST and a FUEL
PUMP PRESSURE TEST as described in this sub-
section.
FUEL PUMP vmr2015-043-025_a
Fuel Pump Pressure Test Fuel Pump Input Voltage Test

Refer to INSPECTION in this subsection.
1. Disconnect the fuel pump connector.
Fuel Pump Quick Test 2. Turn ignition key ON.
1. Turn ignition key to ON. 3. Read voltage as follows.
2. Listen for fuel pump operation. NOTE: The fuel pump voltage will be read only
NOTE: Fuel pump should come ON for a few sec- when the fuel pump is activated.
onds, then stop. REQUIRED TOOLS
If fuel pump does not come ON, carry out the fol-
lowing: FLUKE 115 MULTIMETER
– Check fuel pump relay fuse (F5) and fuel pump (P/N 529 035 868)
relay (R4).
– Check in B.U.D.S. for applicable fault codes. FLUKE RIGID BACK PROBE
Refer to COMMUNICATION TOOLS AND (P/N TP88)
B.U.D.S. subsection.
– Carry out a fuel pump input voltage test. FUEL PUMP INPUT VOLTAGE TEST
VOLTAGE
TEST PROBES
READING
Fuel pump Fuel pump
connector connector Battery voltage
Pin 3 Pin 4
If battery voltage is read, carry out a fuel pump

resistance test.
270 vmr2016-047
If battery voltage is not read, test fuel pump

power input as follows.
FUEL PUMP POWER WIRE TEST
VOLTAGE
TEST PROBES
READING
Fuel pump
connector Battery ground Battery voltage
Pin 3
If battery voltage is now read, check fuel pump

ground circuit between fuel pump connector FP-4 vmr2012-028-006_a
and battery ground. TYPICAL - FUSE BOX COORDINATES

If battery voltage is still not read, check fuel pump:
If resistance test failed, disconnect fuel pump
– Fuse (F5) connector and measure resistance at fuel pump
– Fuel pump relay (R4) connector.
– Fuel pump relay input voltage (control and
FUEL PUMP RESISTANCE TEST
power circuits) (AT FUEL PUMP CONNECTOR)
– Fuel pump relay control circuit continuity to
ECM-J1 Pins 3 and 4 Approximately 2
– Fuel pump power circuit If test failed at pump connector, replace fuel
– Wiring and connectors. pump.
Fuel Pump Resistance Test If test succeeded at pump connector, check
wiring and connectors from:
1. Ensure fuel pump connector is properly con-
– Fuse box to fuel pump
nected.
– Fuel pump to battery ground.
2. Remove fuel pump relay (R4).
Repair or replace as necessary.
Fuel Pump Access

Remove rear body module, refer to BODY subsec-
tion.
Fuel System Pressure Release

Refer to DISCONNECTING A FUEL PRESSURE
HOSE in this subsection.
vmr2015-044-006_a
Fuel Pump Removal
3. Using a multimeter, measure fuel pump resis- 1. Release the pressure of the fuel system.
tance as follows. 2. Disconnect the following from the fuel pump:
FUEL PUMP RESISTANCE TEST – Fuel pump electric connector
(AT FUSE BOX) – Fuel system vent hose
RESISTANCE – Fuel pump pressure hose.
TEST PROBES
@ 20°C (68°F)
Fuse box Battery
Approximately 2
contact B12 ground
vmr2016-047 271
Fuel Pump Installation

Rotate fuel pump during insertion as per removal
procedure.
NOTICE Pay attention not to damage fuel
1. Install a NEW gasket ring.
2. Place gasket so that it is properly located be-
tween fuel pump and fuel pump mounting neck
on fuel tank.
vmr2015-043-005_a

2. Vent hose
3. High pressure fuel hose
3. Remove fuel pump retaining nut.
WARNING
ing tools.
NOTICE Replace fuel pump gasket whenever

fuel pump retaining nut is loosened.
vmr2015-043-016_a
REQUIRED TOOL
NOTICE Ensure gasket ring makes good
FUEL PUMP NUT TOOL contact all around fuel pump and fuel pump
(P/N 529 035 899)
mounting neck on fuel tank.
3. Ensure proper fuel pump orientation as in fol-
lowing illustration.
vmr2015-043-014_a
4. Carefully pull out and rotate fuel pump as re-

quired. vmr2015-043-017_a
1. Fuel tank pump index

NOTICE Pay attention not to damage fuel 2. Fuel pump index

5. Discard gasket ring.
6. Wipe off any fuel spillage.
272 vmr2016-047
TIGHTENING TORQUE
29 N•m ± 1 N•m
Fuel pump retaining nut
7. Install fuel pressure hose on fuel pump using a

NEW Oetiker clamp.
8. Install fuel vent tube on fuel pump.
9. Install electrical connector on fuel pump.
10. Install fuel pump relay (R4).
11. Refuel tank and ensure there are no leaks by
performing a FUEL TANK LEAK TEST and a
FUEL PUMP PRESSURE TEST as described in
this subsection.
vmr2015-043-018_a
12. Check fuel level sender operation.
ALIGNMENT OF FUEL PUMP IN TANK
4. Insert fuel pump retaining nut over the fuel FUEL PUMP PRE-FILTER
pressure hose and electrical wiring connector. (STRAINER)
5. While firmly holding pump against tank, engage
fuel pump retaining nut on fuel tank flange. Fuel Pump Pre-filter Replacement
NOTE: If necessary, move the pump in order to 1. Remove FUEL PUMP, see FUEL PUMP RE-
ensure the flange is sitting completely flat on the MOVAL in this subsection.
tank. 2. Unlock 3 tabs on strainer plastic ring.
6. Tighten fuel pump retaining nut to specification.
6.1 Ensure pump locking ring is fully engaged.
6.2 To apply the proper torque to the fuel
pump retaining nut, install the fuel pump
nut tool on a torque wrench with it's han-
dle perpendicularly (90°) to the torque
wrench.
6.3 Ensure pump is properly aligned with in-
dex marks after nut it tightened to speci-
fication.
vmr2015-043-027_a
3. Remove rubber pad.
vmr2015-043-024_a
TORQUE WRENCH PERPENDICULAR TO TOOL HANDLE
vmr2016-047 273
6. Lubricate assembly area of new strainer and

fuel pump with O-ring lubricant or clean oil
vmr2015-043-028_a
vmr2015-043-031_a
4. Remove push nut securing strainer to fuel
pump. Be careful not to break the assembly 7. Insert the new strainer on fuel pump making
locator pin. sure to press it in tightly against the fuel pump
surface.
8. Using a small nut socket, press in a NEW push
nut to secure strainer.
FUEL LEVEL SENDER

The fuel level sender is a float actuated variable
resistance type that is part of the fuel pump.
vmr2015-043-029_a
5. Pull strainer off fuel pump.
vmr2015-043-023_a
FUEL LEVEL SENDER
Fuel Level Sender Resistance Test

(Fuel Pump Module Installed)
1. Disconnect multifunction gauge, refer to the
2. Using a multimeter, measure the resistance of
the fuel level sender as follows.
vmr2015-043-030_a
274 vmr2016-047
FUEL LEVEL SENDER RESISTANCE TEST FUEL LEVEL SENDER INPUT VOLTAGE TEST
RESISTANCE FUEL PUMP
GAUGE BATTERY VOLTAGE
FUEL LEVEL CONNECTOR
CONNECTOR
@ 20°C (68°F)
Negative
Pin 2 5V
Full 5 ±1 terminal
Pins 4 and 21
Empty 100 ±5
TEST RESULT SERVICE ACTION
Test wiring continuity
between fuel level
5V is not read
sender and multifunction
gauge
Replace multifunction
Wiring continuity is good
gauge
Wiring continuity is not
Repair or replace wiring
obtained
Fuel Level Sender Replacement

Replace fuel pump. Refer to FUEL PUMP in this
subsection.
FUEL TANK VENT VALVES

Fuel Tank Vent Valve Test
Inlet Check Valve Test
vmr2006-020-052_c
1. Remove rear body module, refer to BODY sub-
section.
If readings are out of specification, refer to FUEL
LEVEL SENDER RESISTANCE TEST (AT FUEL 2. Remove multifunction gauge for access to
PUMP CONNECTOR). the vent system inlet hose, refer to the
If readings are as specified, refer to FUEL LEVEL
SENDER INPUT VOLTAGE TEST. 3. Install a small hose pincher between the vent
pressure relief valve and the fuel pump vent in-
Fuel Level Sender Resistance Test let.
(at Fuel Pump Connector) REQUIRED TOOL
FUEL LEVEL SENDER RESISTANCE TEST
FUEL PUMP RESISTANCE SMALL HOSE PINCHER
FUEL LEVEL (P/N 295 000 076)
CONNECTOR @ 20°C (68°F)
Full 5 ±1
Pins 1 and 2
Empty 100 ±5
If resistance test at fuel pump connector is failed,

replace fuel pump module.
Fuel Level Sender Input Voltage Test

1. Set ignition switch to ON.
2. Disconnect fuel pump connector, refer to FUEL
PUMP CONNECTOR ACCESS in this subsec-
tion.
3. Using a multimeter, measure input voltage as
follows.
vmr2016-047 275
Pressure Relief Valve Test

1. Install the small hose pincher between the inlet
check valve and the fuel pump vent inlet fitting.
vmr2015-043-019_a
1. Pressure relief valve

2. Fuel pump vent inlet
4. Connect the vacuum/pressure pump to the fuel

tank vent hose inlet. vmr2015-043-019_b
1. Inlet check valve

2. Fuel pump vent inlet fitting

reading.
– Ensure pressure relief valve is properly in-
stalled, refer to PRESSURE RELIEF VALVE
INSTALLATION in this subsection.
vmr2015-043-003_a
– Replace pressure relief valve if it fails the test.
1. Fuel tank vent hose inlet
2. Gauge connector
5. Remove fuel tank cap.

reading.
– Ensure breather filter is properly installed, refer
to PERIODIC MAINTENANCE PROCEDURES.
– Ensure inlet check valve is properly installed, re-
fer to FUEL TANK VENT VALVE INSTALLATION
in this subsection. vmr2015-043-019_c
– Test inlet check valve separately. If good, re- 1. Pressure relief valve flow direction arrow
place the breather filter, refer to PERIODIC
MAINTENANCE PROCEDURES.
276 vmr2016-047
Fuel Tank Vent Valve Installation

Inlet Check Valve Installation
Ensure white portion of inlet check valve is to-
wards the vent breather filter.
vmr2015-043-019_d
1. Vent breather filter

2. White portion of inlet check valve
Pressure Relief Valve Installation

Ensure pressure relief valve flow arrow is pointing
away from fuel pump vent fitting.
vmr2015-043-019_c
1. Pressure relief valve flow direction arrow
vmr2016-047 277
Section 06 ELECTRICAL SYSTEM
Subsection 01 (POWER DISTRIBUTION AND GROUNDS)
POWER DISTRIBUTION AND GROUNDS

SERVICE TOOLS
vmr2015-044 525
GENERAL
POWER DISTRIBUTION DIAGRAM
FUSE BOX 1 (PF1)

4WD SW (BD)
R3
F12 20A LIGHT SW (MG2)
ECM (ECM3)
12 V DC OUTLET (DC)
FUSE BOX 2 (PF2)
F8 10A ECM
30A
30A
REGULATOR/
RECTIFIER
(RD) IGNITION (CC)
F9 20A
F3
F1
DPS FLASHER MODULE

(ce models only)
(DPS1, DPS2, DPS3) R2 ECM3
FUSE BOX 3 (PF3) F4 10A GAUGE (CL)

IGNITION COIL (BA)
F2 40A
F5 10A
ECM3 FUEL INJECTOR (INJ)
VEHICLE
STARTER COMMUNICATION SPEED SENSOR (VSS)
SOLENOID CONNECTOR (DB)
(SS)
R1
FAN (FT)
BAT
ECM3
R4
FUEL PUMP (FP)
BRAKE LIGHT (PR)

R8
ECM3
BRAKE SW (FRR)
vmr2015-044-001_a
Refer to WIRING HARNESS AND CONNECTORS for wiring harness layout and component locations.
526 vmr2015-044
FUSE BOX 1
vmr2015-044-006_a
vmr2015-044-005_a
FUSE IDENTIFICATION RATING

4 Speedo / Relay 10 A
5 Injector(s) / Ignition / Fuel Pump 10 A
Fuse 8 Key Switch / Starter Solenoid 10 A
9 Cooling Fan 20 A
12 DC Out. / Lights / Acc. 20 A
RELAY
RELAY STATE (ON) RELAY STATE (OFF)
IDENTIFICATION
R1 Cooling fan See COOLING SYSTEM
Approximately 30 seconds
When ignition key is turned ON
after ignition key is turned OFF
R2 Main AND
OR
Run/Stop switch is set to RUN
Approximately 30 minutes if ignition key is left ON
When ignition key is turned OFF
OR
Approximately 30 minutes if ignition key is left ON
R3 Accessories Same as main relay
OR
When engine speed is less than
1000 RPM for at least 50 minutes
R4 Fuel pump See FUEL TANK AND FUEL PUMP
R8 Brake lights See BRAKES
RELAY CONTINUITY TEST

1. Remove relay.
REQUIRED TOOL
3. Probe relay as follows.

TERMINAL RESISTANCE
Open circuit
30 87
(OL)
smr2007-027-050_a
vmr2015-044 527
4. Connect battery as shown and probe relay FUSE BOX 3 (PF3)

again as follows.
TERMINAL RESISTANCE
0.5 max.
30 87
(continuity)
vmr2015-044-004_a
FUSE IDENTIFICATION
Fuse 2 DPS 40 A
smr2007-027-060_a
GROUNDS
If relay failed any test, replace it. All grounds are grouped at the same location on
RH side of frame.
FUSE BOX 2 (PF2)
vmr2015-044-003_a
FUSE IDENTIFICATION vmr2015-065-001_a
RH SIDE
1 Main 30 A 1. Battery ground
2. Harness ground (BN1)
Fuse - Spare 30 A 3. BN2
4. Engine ground
3 Fan / Accessories 30 A
528 vmr2015-044
POWER DISTRIBUTION AND GROUNDS

SERVICE TOOLS
GENERAL
POWER DISTRIBUTION DIAGRAM
FUSE BOX 1 (PF1)

4WD SW (BD)
R3
F12 20A LIGHT SW (MG2)
ECM (ECM3)
12 V DC OUTLET (DC)
FUSE BOX 2 (PF2)
F8 10A ECM
30A
30A
REGULATOR/
RECTIFIER
(RD) IGNITION (CC)
F9 20A
F3
F1
DPS FLASHER MODULE

(DPS1, DPS2, DPS3) R2 (ce models only) ECM3
FUSE BOX 3 (PF3) F4 10A GAUGE (CL)

IGNITION COIL (BA)
F2 40A
F5 10A
ECM3 FUEL INJECTOR (INJ)
VEHICLE
STARTER COMMUNICATION SPEED SENSOR (VSS)
SOLENOID CONNECTOR (DB)
(SS)
R1
FAN (FT)
BAT
ECM3
R4
FUEL PUMP (FP)
BRAKE LIGHT (PR)

R8
ECM3
BRAKE SW (FRR)
vmr2016-048-001_aen
Refer to WIRING HARNESS AND CONNECTORS for wiring harness layout and component locations.
vmr2016-048 279
FUSE BOX 1 FUSE IDENTIFICATION RATING

4 Speedo / Relay 10 A
Injector(s) / Ignition /
5 10 A
Fuel Pump
Fuse Key Switch / Starter
8 10 A
Solenoid
9 Cooling Fan 20 A
12 DC Out. / Lights / Acc. 20 A
vmr2015-044-005_a
RELAY CONTINUITY TEST
1. Remove relay.
REQUIRED TOOL
3. Probe relay as follows.

TERMINAL RESISTANCE
Open circuit
vmr2015-044-006_a 30 87
(OL)
RELAY IDENTIFICATION
RELAY STATE (ON) RELAY STATE (OFF)
R1 (Cooling Fan)
See COOLING SYSTEM
R2 (Main)
When ignition
key is turned ON Approximately
AND 30 seconds after ignition
Run/Stop switch is key is turned OFF
set to RUN
R3 (Accessories) smr2007-027-050_a
When ignition key

4. Connect battery as shown and probe relay
is turned OFF
OR again as follows.
Same as main relay
When engine speed TERMINAL RESISTANCE
is less than 1000 RPM
for at least 50 minutes 0.5 max.
30 87
(continuity)
R4 (Fuel Pump)
See FUEL TANK AND FUEL PUMP
R8 (Brake Lights)
See BRAKES
280 vmr2016-048
GROUNDS
All grounds are grouped at the same location on
RH side of frame.
smr2007-027-060_a
If relay failed any test, replace it.
FUSE BOX 2 (PF2)

vmr2015-065-001_a
RH SIDE
1. Battery ground
2. Harness ground (BN1)
3. BN2
4. Engine ground
vmr2015-044-003_a
FUSE IDENTIFICATION
1 Main 30 A
Fuse - Spare 30 A
3 Fan / Accessories 30 A
FUSE BOX 3 (PF3)
vmr2015-044-004_a
FUSE IDENTIFICATION
Fuse 2 DPS 40 A
vmr2016-048 281
Subsection 02 (WIRING HARNESS AND CONNECTORS)
WIRING HARNESS AND CONNECTORS

SERVICE TOOLS
CRIMPING TOOL (HEAVY GAUGE WIRE) .................................... 529 035 730 ......................................... 541
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 539
ECM TERMINAL REMOVER 2.25................................................. 529 036 175 ......................................... 539
ECM TERMINAL REMOVER 3.36................................................. 529 036 174 ......................................... 539

GM TERMINAL EXTRACTOR........................................................ 12094430 ......................................... 540
SNAP-ON TERMINAL REMOVER TOOL ...................................... TT600-4 ......................................... 536
vmr2015-045 529
GENERAL ABBREVIATION DESCRIPTION

The illustrations in this subsection are typical. M Starter positive terminal
Several variants of the connector types, such as MC1 Turn light relay
different number of pin cavities, are used on the
vehicle. MC2 Turn light relay
MD 4WD actuator
CONNECTOR ABBREVIATION MG1 LH multifunction switch
DESCRIPTION
MG2 LH multifunction switch
ABBREVIATION DESCRIPTION
MG3 LH multifunction switch
BD RH multifunction switch
PF1 Front Fuse box
BN1 Ground terminal
Rear fuse holder (main and
PF2
BN2 Ground terminal accessories)
BN4 Ground terminal PF3 Rear fuse holder (DPS)
BP1 Positive terminal PG LH headlight
Positive terminal (DPS model PD RH headlight
BP2
only)
BP3 Positive terminal LL License plate light
RFF RH front turn light RPL RH marker light
LFF LH front turn light LPL LH marker light
RRF RH rear turn light PR Park/Brake light
LRF LH rear turn light RD Voltage regulator/rectifier
CC Ignition switch SS1 Starter solenoid
CL Cluster SS2 Starter solenoid
CAD Rear RH turn light ‡ Refer to applicable EMS subsection for powertrain
harness.
CAG Rear LH turn light
DB Diagnostic connector
DC1 Accessory outlet
DPS1 Dynamic power steering
FP Fuel pump
FRR Rear brake light switch
FT Cooling fan
HICa Harness interconnect
KX1 Horn
KX2 Horn
530 vmr2015-045
WIRING HARNESS ARRANGEMENT
BN
MG1 DC3
BN1 CI
BN4
BN2 DC2 PF1
CC
BD
DC1
HIC1 MG2
HIC2 FT
DB DPS3
DPS2
DPS1
RD1
M
PF3 PF2
FP
FRR
BP2 BP1
PR
SS
BP3
SS2
SS1
M
vmr2015-045-012_a
vmr2015-045 531
CE models
MC2 MC1 CAG
MG3 CAD
KX2
KX1
MG1
HICa
MG2
PL
CAG2
CAG1
vmr2015-045-001_b
532 vmr2015-045
DIODE AND JOINT TERMINAL LOCATIONS
JT BU
JT GN
JT RD/BK
JT BK3
JT OR/GN
JT BE
JT VI/BU
JT VI/GY
JT RD/BE
JT RD/OR
JT WH/BK JT RD/JY
JT WH/BE JT RD/GY
D2
JT RD/BK
vmr2015-045-010_a
vmr2015-045 533
CE models
JT BE
JT BK
JT RD/BK
JT BN
R1
JT GY
vmr2015-045-011_a
534 vmr2015-045
PROCEDURES
DEUTSCH CONNECTORS
Deutsch Connector Application
A variety of Deutsch connectors are used on var-
ious systems:
– Diagnostic connector
– Vehicle speed sensor (VSS) connector.
The following procedures may be used on each as
they are similar in construction.
Deutsch Connector Disassembly and

Reassembly
3 1
V01G0OA 1
TYPICAL — FEMALE CONNECTOR
1. Female lock
3
2
4
F00H1CA
TYPICAL —DEUTSCH CONNECTOR

1. Male connector
2. Female connector
3. Secondary lock
4. Sealing cap
NOTICE Do not apply dielectric grease on ter-

minal inside connector.
Terminal Removal
To remove terminals from connector, proceed as
follows:
V01G0PA 1
1. Using long nose pliers, pull out the secondary
TYPICAL — MALE CONNECTOR
plastic lock from between the terminals. 1. Male lock
NOTE: Before pin extraction, push wire forward

to relieve pressure on retaining tab.
2. Insert a 4.8 mm (.189 in) wide screwdriver
blade inside the front of the terminal cavity.
3. Pry the retaining tab away from the terminal
while gently pulling the wire and terminal out
of the back of the connector.
vmr2015-045 535
1 PACKARD CONNECTORS
Packard Connector Application
Packard connectors are used to connect:
– Electrical harnesses
– Gauges.
3-Pin Packard Connector
1
V01G0QA 1
TYPICAL — FEMALE CONNECTOR
1. Retaining tabs
Terminal Insertion C B A
1. For insertion of a terminal, ensure the sec-
ondary plastic lock is removed.
2. Insert terminal through the back of the connec- F04H45A
tor in the appropriate position, and push it in as VIEW OF A 3-PIN PACKARD CONNECTOR
far as it will go. You should feel or hear the ter- 1. Identification letters
minal lock engage.
NOTE: This type of connector also comes in other
3. Pull back on the terminal wire to be sure the pin configurations.
retaining tabs are holding the terminal.
To remove a terminal from a 3-pin Packard connec-
4. After all required terminals have been inserted, tor, use the SNAP-ON TERMINAL REMOVER TOOL
the lock must be installed. (P/N TT600-4).
F01B1JA
WARNING
1 1 Ensure all terminals are properly crimped on
wires and connectors are properly fastened.
PACKARD CONNECTOR
(MULTIFUNCTION GAUGE)
Firmly push down tab and hold to unlock connec-
F04H6LA tor while pulling it out.
TYPICAL — CONNECTOR PIN-OUT
1. Terminal position identification numbers
536 vmr2015-045
A33Z01A 2 1
TYPICAL
1. Retainer
2. Tab (one on each side)
vmr2006-032-001_a
Open housing by lifting 4 tabs.
A33Z02A 1
TYPICAL
1. Tabs (2 on each side)
Lift the top plastic lock of the female terminal to

be removed and hold in position. Lift the female
vmr2006-032-001_b terminal to unlock from the housing and push out
CONNECTOR PINOUT of housing.
Push on both tabs to remove retainer.
vmr2015-045 537
vmr2008-022-014_a
A32E3XA
TYPICAL Pull out connector.

1. Lift and hold plastic lock
2. Lift to unlock and push out
MOLEX CONNECTOR
Molex Connector Application
Molex connectors are used on the following sys-
tem:
– ECM
Molex Connector Removal

Push and hold the locking tab.
vmr2008-022-015_A
Molex Connector Installation

Fully open connector lock.
vmr2008-022-013_a
Rotate connector lock until it stops.
vmr2008-022-015_b
Install connector to ECM.

538 vmr2015-045
Rotate connector lock until it snaps locked.
vmr2008-139-016_a
1. ECM connector (harness side)

2. ECM adapter
NOTICE Never probe directly on ECM har-

ness connector. This could change the shape
or enlarge the terminals and create intermit-
vmr2008-022-013 _b tent or permanent contact problems.
1. Locked here
Molex Connector Inspection
Molex Connector Probing Before replacing an ECM, always check electrical
The most recommended and safest method to connections.
probe ECM connector terminals is to use the ECM 1. Ensure connector locking mechanism is func-
ADAPTER TOOL (P/N 529 036 166). This tool will tioning properly.
prevent deforming or enlarging terminals which
would lead to bad ECM terminal contact creating 2. Ensure all wire terminals (pins) are properly
intermittent or permanent problems. locked in the connector.
3. Ensure they are very tight, make good contact
with the pins in the ECM.
4. Ensure the pins in the harness connector
and the ECM connector are clean, shiny and
corrosion-free.
5. Check wiring harness for signs of scoring.
NOTE: A “defective ECM module” could possi-
bly be repaired simply by disconnecting and recon-
necting it.
NOTICE Do not apply any lubricant product
529036166
to the pins of the ECM connector.
Disconnect the ECM connector and reconnect on
the tool connector. Probe required terminals di- Molex Connector Terminal Removal
rectly in the tool holes. (Harness Connector)
To remove a signal terminal from the ECM har-
ness connector, use the ECM TERMINAL RE-
MOVER 2.25 (P/N 529 036 175).
To remove a power terminal, use the ECM TERMI-
NAL REMOVER 3.36 (P/N 529 036 174).
vmr2015-045 539
529036175
1. Remove rear protector from connector.

2. Pull out the connector lock.
smr2009-045-027_a
NOTICE Before installing wire terminals in

the connector, ensure all terminals are prop-
erly crimped on wires. After installation of
wire terminals in the connectors, ensure they
are properly locked by gently pulling on them
as if to extract them.
FURUKAWA CONNECTOR
Furukawa Connector Application
Voltage regulator/rectifier.
smr2009-045-025_a Terminal Removal

3. Insert tool to unlock terminal. 1. Remove the secondary lock (plastic insert).
smr2010-050-021_a
smr2009-045-026_a Step 1: Remove the secondary lock
1. Unlock here
2. Carefully insert the GM TERMINAL EXTRACTOR
4. Gently pull on the wire to extract the terminal (P/N 12094430) between the lock and the pin to
out the back of the connector. release the pin.
smr2010-052-003
GM TERMINAL EXTRACTOR (P/N 12094430)
540 vmr2015-045
A
A32E2QA
A. 10 mm (3/8 in)
smr2010-050-022_a
Step 2: Insert GM terminal extractor tool (P/N 12094430)

NOTE: Make sure not to cut wire strands while
3. Gently pull on the wire to extract the pin out the stripping the wire.
back of the connector. Install the appropriate terminal on the wire ac-
cording to the requirement. Refer to appropriate
PARTS CATALOG.
A32E2RA
INSTALLATION OF TERMINAL
Follow the instructions provided with the CRIMP-

ING TOOL (HEAVY GAUGE WIRE) (P/N 529 035 730)
smr2010-050-023_a
to select the proper position of the tool.
Step 3: Pull wire to extract pin
NOTICE Before installing terminals in the

connectors, ensure all terminals are properly
crimped on the wires. After installation of the
wire terminals in the connectors, ensure they
are properly locked by gently pushing on them 529035730
as if to extract them. NOTE: Different wires require different crimping

pliers settings.
BATTERY AND STARTER CABLE
TERMINALS
Cable Crimping
Carefully strip the wire approximately to 10 mm
(3/8 in) in length, using a wire stripping tool or
sharp blade/knife.
vmr2015-045 541
NOTICE Never weld the wire to the terminal.

Welding can change the property of the wire
and it can become brittle and break.
1 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
terminal.
NOTICE Make sure that the protective heat
shrink rubber tube has been properly installed
and no part of wire is exposed.
2
A32E2SA
POSITIONING THE CRIMPING PLIERS

Step 1: Press
Step 2: Rotate
After positioning the crimping pliers, crimp the ter-

minal already installed on wire.
A32E2TA
CRIMPING OF WIRE
A32E2UA
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.
542 vmr2015-045
Subsection 03 (IGNITION SYSTEM (450))
IGNITION SYSTEM (450)

SERVICE TOOLS
ECM ADAPTER TOOL (ONE CONNECTOR)................................. 529 036 085 ......................................... 548
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 544–548
GENERAL No Multifunction Gauge and Taillight

If the multifunction gauge and taillight do not func-
IGNITION SYSTEM OPERATION tion, the ECM may not be powered. Check the fol-
lowing:
The battery supplies 12 Vdc from fuse F5, to the
primary side of the ignition coil. The ECM com- 1. Fuses. Refer to WIRING DIAGRAM.
pletes the circuit by switching it to ground at the 2. Battery (refer to CHARGING SYSTEM).
right moment.
If the items in the previous list tested good, the
As the engine rotates, a signal from the crankshaft problem may also be related to one of the follow-
position sensor (CPS) relative to the position of ing:
the piston in the cylinder, is produced and sent to – Main relay
the ECM. The ECM uses this signal as well as en-
– Ignition switch
gine RPM to establish the exact moment at which
the ignition spark is required. It then provides the – Engine STOP switch
ground to the primary winding of the ignition coil. – ECM.
With the ground provided by the ECM, current For the main relay circuit and ECM testing, refer
flows through the primary coil winding which in- to the ELECTRONIC FUEL INJECTION (EFI) sub-
duces a higher current potential in the secondary section.
winding. This high current potential jumps across Multifunction Gauge and Taillight Turn ON
the spark plug gap and ignites the fuel/air mixture
within the cylinder. If the multifunction gauge and taillight turn ON,
the ignition switch and engine shut off switch are
Ignition Timing functioning normally.
Ignition timing is not adjustable. Test the following items in the indicated order:
1. Spark plug
TROUBLESHOOTING 2. Battery (refer to CHARGING SYSTEM subsec-
tion)
IGNITION SYSTEM TESTING 3. Ignition coil
NOTE: It is good practice to check for fault codes 4. CPS (refer to ELECTRONIC FUEL INJECTION
using B.U.D.S. software as a first troubleshooting (EFI) subsection)
step. Refer to DIAGNOSTIC AND FAULT CODES 5. ECM (refer to ELECTRONIC FUEL INJECTION
subsection. (EFI) subsection).
The ECM controls the ignition system and can de-
tect an open or short circuit in the ignition coil pri- Intermittent Ignition Problems
mary winding. However, it does not monitor the In dealing with intermittent problems there is no
secondary winding. easy diagnosis. Problems that occur only during
normal engine operation may be related to vibra-
Ignition Testing Sequence tions, or the engine operating temperature, and
Set engine stop switch to RUN. have to be tested under similar conditions.
Turn the ignition switch to the ON position. Some intermittent problems may be attributable
to loose, dirty or corroded connections, or water
infiltration, and may be resolved by cleaning the
contacts and applying a dielectric grease for pro-
vmr2015-046 543
tection. Always check for these problems before which then waits for the START switch signal to
replacing expensive components and apply the engage the starter, and control ignition timing for
protective grease as specified in the procedures. proper engine operation.
If the engine is running and the ignition switch
Multiple Problems is turned to the OFF position, ignition will cease
There is always the possibility of more than one immediately, the engine will shut down, but
component being at fault. If, after a component the ECM will maintain power on the vehicle for
has been replaced, the problem still persists, care- 30 seconds.
fully repeat the testing procedure to find the other
faulty part. Ignition Switch Input Voltage Test
Remove console, refer to the BODY subsection.
PROCEDURES Disconnect the ignition switch connector.
SAFETY PRECAUTIONS
WARNING
To prevent powerful electric shock while
cranking engine, do not touch any of the ig-
nition components (ignition coil, spark plug
wire, etc.) nor tester leads. Also make sure
that tester leads do not touch any metallic
object.
IGNITION SWITCH
vmr2015-046-003_a
Ignition Switch Operation

Set the FLUKE 115 MULTIMETER (P/N 529 035 868)
The ignition switch is a three position switch, OFF, to Vdc.
ON with headlights, ON without headlights.
Measure the ignition switch input voltage as fol-
lows.
IGNITION SWITCH INPUT VOLTAGE TEST
Ignition switch connector (CC) Voltage
Pin “C” (BE wire) Battery ground Battery voltage
vmr2015-046-001_a
1. OFF
2. ON with headlights
3. ON without headlights
The primary function of the ignition switch is to

provide a signal to the ECM of the intent to start
vmr2008-137-001_b
(wake up signal) and run the engine.
IGNITION SWITCH INPUT VOLTAGE TEST
The ignition switch receives 12 Vdc directly from
the ECM fuse (F8). When the ignition switch is If you do not obtain battery voltage, test:
set to ON (with or without headlights), it sends a 1. Fuses
power signal to the ECM through the engine stop 2. Wiring harness.
switch (RUN position). This wakes up the ECM
If ignition switch input voltage is good, test the:
1. Ignition switch continuity
544 vmr2015-046
2. Engine stop switch

3. Wiring and connectors.
Ignition Switch Continuity Test

to .
Measure the resistance through the ignition
switch between the following pins.
NOTE: Connector pins “B” and “E” are not used.
IGNITION SWITCH CONTINUITY TEST
Ignition
Ignition switch
switch RESISTANCE
pins
POSITION
Pins “A” to “F” V07G1BA 1
OFF Infinite (OL) TYPICAL
Pins “C” to “D” 1. Disconnect ignition switch connector
ON Pins “A” to “F”

0.2 ± 0.2 max. While holding switch with one hand, unscrew the
(w/lights) Pins “C” to “D” ignition switch retaining nut with the other.
ON Pins “A” to “F” Infinite (OL)
(w/o lights) Pins “C” to “D” 0.2 ± 0.2 max.
vmr2015-046-001_b
1. Remove retaining nut

vmr2008-137-001_c
IGNITION SWITCH CONTINUITY TEST

Ignition Switch Installation
For installation of the ignition switch, reverse the
Replace switch if defective. removal procedure.
Ignition Switch Removal TIGHTENING TORQUE
Remove the console, refer to the BODY subsec- Ignition switch retaining
4 N•m (35 lbf•in)
tion. nut
Disconnect the ignition switch connector.
ENGINE STOP SWITCH
Engine Stop Switch Operation
The engine stop switch functions as an engine
shutoff switch for a normal shutdown or for an
emergency situation. It can be quickly activated
without letting go of the handlebars.
vmr2015-046 545

to .
Measure the resistance through the stop switch
(steering harness side) as per following table.
ENGINE STOP SWITCH CONTINUITY TEST
POSITION Connector RESISTANCE
MG2 pin 3 MG1 pin 3
1 max.
Switch to (BK) (BK/WH)
STOP MG1 pin 1 MG1 pin 2
Infinite (OL)
(BR) (YL)
vmr2015-046-005_a
1. Engine stop switch button MG2 pin 3 MG1 pin 3

2. RUN position Infinite (OL)
Switch to (BK) (BK/WH)
3. STOP position
RUN MG1 pin 1 MG1 pin 2
When the engine stop switch is set to RUN, it 1 max.
(BR) (YL)
completes a circuit between the ignition switch
and the ECM. This circuit provides the 12 Vdc
power used to initialize the ECM.
If the engine is running and the engine stop switch
is set to OFF, the ignition will cease immediately,
the engine will shut down, but the ECM will main-
tain power on the vehicle for 30 seconds.
When the switch is set to STOP, it opens the
12 Vdc circuit to pin “A4” of the ECM and applies
a ground to pin “K3”.
If the engine stop switch is left in the STOP po-
sition when the ignition switch is turned to ON,
the ECM will not be initialized, the multifunction
gauge and tail light will not turn ON. vmr2008-137-003_a
MG1 AND MG2 PIN OUT

Engine Stop Switch Continuity Test
Remove the front steering cover, refer to the Replace multifunction switch assembly if engine
BODY subsection. stop switch continuity test results are not as per
specification.
Disconnect the multifunction switch connectors,
MG1 and MG2.
IGNITION COIL
The ignition coil is mounted under the top RH side
of the frame, along the steering column, in front
of the engine.
vmr2008-139-002_b
MULTIFUNCTION SWITCH CONNECTORS

1. Disconnect MG1
2. Disconnect MG2
546 vmr2015-046
vmr2008-138-006_b
IGNITION COIL LOCATION
When troubleshooting an ignition coil problem, vmr2008-137-005_a
first carry out a spark occurrence test, refer to 1. Remove plastic pin lock
SPARK PLUG in this subsection.
If there is no spark, carry out the Ignition Coil Input to Vdc.
Voltage test and Ignition Coil Ground Circuit Con-
Measure battery voltage between the battery ter-
tinuity Test.
minal on the starter solenoid and battery ground.
Ignition Coil Input Voltage Test Set engine stop switch to RUN.
Ensure ignition coil is properly powered as fol- Turn ignition switch to ON.
lows. Measure coil input voltage as follows.
Remove RH inner fender. Refer to the BODY sub- IGNITION COIL INPUT VOLTAGE TEST
section.
IGNITION COIL
Disconnect the ignition coil input connector. VOLTAGE
CONNECTOR
Pin 2 with chassis ground Battery voltage
vmr2008-137-004_a
1. Ignition coil
2. Coil input connector
Using a small screwdriver, remove the plastic con- vmr2008-137-006_a

nector pin lock for easy access to pins. IGNITION COIL INPUT VOLTAGE TEST
1. Pin 1 (VIOLET/BLUE)
2. Pin 2 (BROWN/ORANGE)
If you did not read battery voltage, check:

– Fuses and relay. Refer to WIRING DIAGRAM.
– Continuity of the ignition coil input circuit.
If battery voltage was read, proceed with the Igni-
tion Coil Ground Circuit Continuity Test.
vmr2015-046 547
If the measure is out of specification, verify the

coil ground wire and connection.
Ignition Coil Ground Circuit Continuity

Test
Disconnect ignition coil input connector.
vmr2008-137-006_b
COIL GROUND CIRCUIT CONTINUITY TEST

1. Pin 1 (BROWN/ORANGE)
Ignition Coil Resistance Tests

NOTE: An ignition coil with good resistance mea-
surements can still be faulty. Voltage leak can oc-
cur at high voltage levels which is not detectable
with an ohmmeter. Replacing the ignition coil may
be necessary as a test.
vmr2008-139-008_a
1. Press to release connector lock Primary Winding Resistance Test

2. Push to rotate connector lock upwards
Disconnect the ignition coil input connector.
Install the ECM connector onto the ECM ADAPTER
TOOL (ONE CONNECTOR) (P/N 529 036 085).
to and test the coil resistance as follows.
IGNITION COIL PRIMARY WINDING
RESISTANCE TEST
resistance @ 25°C
ignition coil input connector
(77°F)
Pin 1 Pin 2 0.47 ± 0.05
vmr2008-139-016_a
1. ECM connector
2. Adapter tool
Measure for continuity through the coil ground

wire to the ECM as follows.
IGNITION COIL GROUND CIRCUIT vmr2015-046-006_a
CONTINUITY TEST COIL PRIMARY WINDING RESISTANCE TEST
TEST PROBES RESISTANCE If the primary coil resistance is not within specifi-
Coil input cation, replace the ignition coil.
ECM pin M1 Close to 0
connector pin 1
Secondary Winding Resistance Test
A resistance test of the ignition coil secondary
winding is not possible due to internal circuitry.
548 vmr2015-046
Spark Plug Cable Resistance Test If the starter rotates the engine and there is no
Disconnect the spark plug cable from the spark spark indicated by the tester, follow the ignition
plug and the ignition coil. system troubleshooting sequence as indicated.
Measure resistance through the cable. If the inductive spark tester indicates ignition to
the spark plug, install a new spark plug.
RESISTANCE @
SPARK PLUG CABLE
20°C (68°F)
If a known good spark plug does not solve the
problem, continue testing the other system com-
Spark plug ponents. The ignition spark may not be correct
Coil side 5K ±1K
side due to other system components being out of tol-
erance.
NOTE: Keep in mind that even if there is a spark
during this static test, the voltage requirement to
produce a spark in the combustion chamber is
higher when the engine is running. The ignition
coil may not be functioning properly. Replacing
the ignition coil may be necessary as a test.
Troubleshooting a Fouled Spark Plug

Fouling of the spark plug is indicated by irregular
running or misfiring of the engine, decreased
engine speed due to misfiring, reduced perfor-
vmr2008-137-011_a
mance, and increased fuel consumption. This
SPARK PLUG CABLE RESISTANCE TEST may be due to a loss of compression.
Other possible causes are: a clogged air filter, in-
If resistance value obtained is not close to value correct or bad fuel, defective ignition system, in-
specified, or cable shows signs of deterioration, correct spark plug gap, lubricating oil entering the
replace spark plug cable. combustion chamber, or use of a spark plug with a
temperature rating too cold for the engine require-
SPARK PLUG ment.
For spark plug replacement procedure refer to PE- The plug face of a fouled spark plug has either a
RIODIC MAINTENANCE PROCEDURES subsec- wet or dry black carbon deposit. Such coatings
tion. form a conductive connection between the center
electrode and the ground electrode.
Testing for Spark Occurrence
Spark Plug Analysis
WARNING
Never check for ignition spark from an open
coil and/or spark plug as spark may cause po-
tential fuel vapors to ignite.
Use an approved inductive type spark tester to

test for ignition. Follow spark tester manufacturer
procedures.
Remove the LH side panel for access to the spark A00E0AA 1 2 3
plug and spark plug cable. TYPICAL
1. Overheated (light grey, white)
Turn ignition switch to ON. 2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, grey, melted coating)
Set engine stop switch to RUN.
Press and hold the start button. The plug face reveals the condition of the engine,
If nothing happens when the start button is operating condition, method of driving and fuel
pressed, refer to the STARTING SYSTEM subsec- mixture. For this reason it is advisable to inspect
tion.
vmr2015-046 549
the spark plug at prescribed intervals, examining

the plug face (i.e. the part of the plug projecting
into the combustion chamber).
550 vmr2015-046
IGNITION SYSTEM (570)

SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ................................. 284, 286
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 285–286
GENERAL 2. Defective CPS

- Check operation of CPS and replace if necessary.
SYSTEM DESCRIPTION Refer to ELECTRONIC FUEL INJECTION (EFI)
subsection.
The battery supplies the primary side of ignition
3. Defective trigger wheel
coils through the main relay (R2) while the ECM
completes the circuit for each cylinder by switch- - Inspect trigger wheel. Refer to MAGNETO AND
STARTER subsection.
ing it to ground at the right moment. The ECM
can detect an open and short circuit in the primary 4. Defective ignition circuit
winding but it does not check the secondary wind- - Check fuse 5 of fuse box 1, ignition coil and wiring
ing. condition.
The Engine Management System (EMS) controls 5. Defective fuel pump
the ignition system. For more information, refer - Check fuel pump, refer to FUEL TANK AND FUEL
to ENGINE MANAGEMENT subsection. PUMP subsection.
Ignition Timing 6. Defective fuel injectors or circuit

- Check fuel injectors, refer to ENGINE MANAGE-
Ignition timing is not adjustable. MENT SYSTEM subsection.
TROUBLESHOOTING ENGINE HARD TO START

It is good practice to check for fault codes using 1. Spark plug faulty, fouled or worn out
the B.U.D.S. software as a first troubleshooting - Check spark plug condition. Replace if necessary.
step. Refer to DIAGNOSTIC AND FAULT CODES
subsection. 2. Low fuel pressure
- Test fuel pressure, refer to FUEL TANK AND
Always refer to the WIRING DIAGRAM when FUEL PUMP subsection.
troubleshooting an electrical circuit.
Refer to POWER DISTRIBUTION AND GROUNDS ENGINE MISFIRES, RUNS IRREGULARLY
for fuse and relay information. 1. Fouled, defective, worn spark plugs
Refer to WIRING HARNESS AND CONNECTORS - Check/verify heat range/gap/replace.
for vehicle wiring harness layout and component
locations. 2. Damaged trigger wheel/loose CPS
- Inspect trigger wheel. Refer to MAGNETO AND
Refer to ENGINE MANAGEMENT SYSTEM (EMS) STARTER subsection.
for powertrain wiring harness layout and compo-
nent locations. 3. Defective ignition circuit
- Check ignition coil, fuse 5, and wiring condition.
DIAGNOSTIC GUIDELINES 4. Poor engine grounds
The following is provided to help in diagnosing the - Check/clean/repair.
probable cause of a problem. It is a guideline and
should not be assumed to list all possible causes. ENGINE CONTINUALLY BACKFIRES
1. Fouled, defective spark plugs
ENGINE WILL NOT START (ENGINE
- Clean/replace spark plugs.
TURNS OVER)
1. Fouled or defective spark plug
- Replace.
vmr2016-051 283
2. Damaged trigger wheel/defective or loose CPS EMERGENCY ENGINE STOP

- Inspect trigger wheel and CPS, refer to MAG- SWITCH
NETO AND STARTER and ELECTRONIC FUEL
INJECTION (EFI) subsections. Testing the Emergency Engine Stop
Switch at ECM
PROCEDURES 1. Disconnect ECM connector and install it on the
ECM adapter tool.
IGNITION SWITCH
Ignition Switch Quick Test
Turn ignition switch to ON position.
If multifunction gauge turns on (assuming it
works), the ignition switch is good.
If multifunction gauge does not turn on, check the
following in this order:
– Battery
– Fuse 1 of fuse box 2
– Fuse 4, 5 and 8 of fuse box 1
– ECM is properly powered (refer to ELEC-
TRONIC FUEL INJECTION (EFI) subsection)
vmr2012-031-005_b
– Ignition switch
TYPICAL
– Emergency engine stop switch. 1. ECM
2. ECM connector cover
Ignition Switch Access REQUIRED TOOL
Refer to BODY subsection and remove the LH
side panel. ECM ADAPTER TOOL
(P/N 529 036 166)
2. Remove ignition key switch fuse (F8), refer to

POWER DISTRIBUTION AND GROUNDS sub-
section.
3. Turn ignition key to ON position.
4. Test for continuity as per following table.
EMERGENCY ENGINE STOP SWITCH
TEST AT ECM
FUSE BOX ECM
FUNCTION RESULT
CONTACT ADAPTER
Close to
RUN 5E A4
vmr2012-031-001_a 0
TYPICAL position
1. Ignition key — G2 to K3 Open
2. Ignition switch connector
3. ECM 5E A4 circuit
STOP
position — Close to
G2 to K3
0
If switch fails the test, refer to TESTING THE

EMERGENCY ENGINE STOP SWITCH AT MUL-
TIFUNCTION SWITCH CONNECTORS.
284 vmr2016-051
Testing the Emergency Engine Stop

Switch at Multifunction Switch
Connectors
Refer to WIRING HARNESS AND CONNECTORS
subsection for connector locations.
The emergency engine stop switch is wired into
the LH multifunction switch connectors (MG1 and
MG2).
1. Remove gauge support, refer to LIGHTS,
GAUGE AND ACCESSORIES subsection.
2. Disconnect MG1 and MG2 connectors.
3. Test switch continuity as per following table.
vmr2012-031-002_a
EMERGENCY ENGINE STOP SWITCH PIN-OUT TYPICAL
1. Ignition coil location
FUNCTION PROBE RESULT
MG1-2 to Installing the Ignition Coil
Open circuit
MG2-3 Install a new elastic nut and tighten to the speci-
RUN position
MG1-1 to fied torque.
MG1-3
Close to 0 TIGHTENING TORQUE
MG1-2 to
8 N•m ± 1 N•m
MG2-3 Ignition coil retaining bolt
STOP position (71 lbf•in ± 9 lbf•in)
MG1-1 to
Open circuit
MG1-3 Testing the Ignition Coil Input Voltage
If switch tests good, test continuity of wiring. Re- 1. Disconnect the 3-pin connector from the igni-
fer to WIRING DIAGRAM. tion coil. Refer to IGNITION COIL ACCESS.
IGNITION COIL
tmr2011-026-002_a
1. Ignition coil connector

3. Turn ignition switch to ON.
4. Read voltage as per following table.
vmr2006-018-100
REQUIRED TOOL
Ignition Coil Access FLUKE 115 MULTIMETER

Refer to BODY subsection and remove RH inner (P/N 529 035 868)
fender panel(s) for access to the ignition coil.
vmr2016-051 285
IGNITION COIL INPUT VOLTAGE TEST Testing the Ignition Coil Resistance
CONNECTORS VOLTAGE An ignition coil with good resistance measure-
ment can still be faulty. Voltage leakage can occur
Pin 2 with battery ground Battery voltage at high voltage levels which is not detectable with
an ohmmeter. Replacing the ignition coil may be
If battery voltage is NOT read, check continuity of necessary as a test.
ignition coil supply circuit. Refer to WIRING DIA-
GRAM. Primary Windings
1. Disconnect HIC2 connector.
Testing the Ignition Coil Ground Circuit
Continuity
1. Disconnect the ECM connector and connect
it to the ECM adapter tool. Refer to ELEC-
TRONIC FUEL INJECTION (EFI) subsection.
vmr2012-031-005_a
TYPICAL
1. ECM
2. ECM connector cover
3. HIC2 connector
2. Disconnect ECM connector and connect it to

vmr2012-031-005_b
the ECM adapter tool.
TYPICAL
1. ECM
2. ECM connector cover REQUIRED TOOL
REQUIRED TOOLS ECM ADAPTER TOOL

(P/N 529 036 166)
ECM ADAPTER TOOL
(P/N 529 036 166)
3. Using a multimeter set to , check resistance
in primary windings as follows.
FLUKE 115 MULTIMETER IGNITION COIL RESISTANCE TEST
(P/N 529 035 868)
ENGINE RESISTANCE
PRIMARY ECM
CONNECTOR @ 20°C
CIRCUIT CONNECTOR
(HIC2) (68°F)
2. Check wiring continuity as per following table.
Cylinder 1
IGNITION COIL GROUND CIRCUIT M1
(front)
CONTINUITY TEST Pin C .3 - .6
Cylinder 2
PIN M2
PIN (rear)
(IGNITION
COMPONENT (ECM
COIL If any resistance is not good, measure resistance
CONNECTOR)
CONNECTOR) directly on coil. If second test is ok, check wiring.
Cylinder 1 (front) 1 M1
Secondary Windings
Cylinder 2 (rear) 3 M2 Due to the integrated diode, it is not possible
to take any resistance measurement of the sec-
ondary winding.
286 vmr2016-051
SPARK PLUG
For spark plug replacement procedure, refer to
PERIODIC MAINTENANCE PROCEDURES sub-
section.
Troubleshooting Fouled Spark Plug

Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed
due to misfiring, reduced performance, and in-
creased fuel consumption. This is due to a loss
of compression. Other possible causes are: pro-
longed idling or low-speed riding, a clogged air
filter, incorrect fuel, defective ignition system,
incorrect 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
coatings form a conductive connection between
the center electrode and ground.
Spark Plug Analysis
A00E0AA 1 2 3
TYPICAL
1. Overheated (light grey, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, grey, melted coating)
The plug face reveals the condition of the engine,

operating condition, method of driving and fuel
mixture. For this reason it is advisable to inspect
the spark plug at regular intervals, examining the
plug face (i.e. the part of the plug projecting into
the combustion chamber).
vmr2016-051 287
Subsection 05 (CHARGING SYSTEM)
CHARGING SYSTEM
EXTECH INDUCTIVE AMMETER .................................................. 380941 ......................................... 558
NAPA ULTRA PRO BATTERY LOAD TESTER ............................... 95260 ................................. 558–560
GENERAL – Fuse 3 30A

– Battery.
SYSTEM DESCRIPTION The voltage regulator limits voltage to prevent any
The purpose of the charging system is to keep the damage to electrical components.
battery at a full state of charge. COMPONENT VOLTAGE Vdc
NOTE: For an overview of the vehicle electrical Minimum 12.5
system, refer to ENGINE MANAGEMENT SYS- Voltage Regulator
TEM section. Maximum 15
Magneto
The magneto is the primary source of electrical
energy. It transforms a magnetic field into electric
current (AC).
The alternating current is regulated and trans-
formed into direct current (DC) by the voltage
regulator, and normally powers all of the vehicle's
systems and accessories.
The magneto has a 3 phase delta wound stator.
vmr2006-017-002
TYPICAL
Battery
The battery supplies DC power to every electri-
cal and electronic system in the vehicle as well as
all accessories. At low engine RPM operation and
high current load conditions, it supplements the
magneto's output as required, and helps to main-
tain a steady system voltage.
vmr2006-017-001
TYPICAL TROUBLESHOOTING
It is good practice to check for fault codes using
Voltage Regulator the B.U.D.S. software as a first troubleshooting
The regulator receives AC current from the mag- step. Refer to DIAGNOSTIC SYSTEM AND FAULT
neto and transforms it into direct current (DC). CODES subsection.
The voltage regulator output voltage is distributed
as follows:
– Fuse 1 30A
vmr2015-047 557
BATTERY REGULARLY DISCHARGED OR If battery voltage drops below specification dur-

WEAK ing test, replace battery and perform a CHARG-
ING SYSTEM LOAD TEST.
1. Loose or corroded battery cable connections.
- Tighten or repair battery cable connections.
CHARGING SYSTEM LOAD TEST
2. Worn or defective battery.
- Charge and test battery.
3. Defective magneto stator.
- Test stator, refer to MAGNETO AND STARTER 12V,18AH
SYSTEM subsection. RD1-1

BN4 BAT2 BAT1
4. Defective regulator/rectifier. RD RD1-3 BN1
- Test system voltage.

SS-1 BP3
5. Damaged magneto rotor or Woodruff key. BP1
- Replace magneto rotor or Woodruff key, refer to

MAGNETO AND STARTER SYSTEM subsection.
vmr2015-047-006_a
PROCEDURES 1. Remove seat.

Ensure battery is fully charged. 2. Connect a battery load tester such as the NAPA
Refer to WIRING HARNESS AND CONNECTORS ULTRA PRO BATTERY LOAD TESTER (P/N 95260).
subsection for harness layout and connector loca- 3. Start vehicle and read voltage on tester.
tions on vehicle.
SPECIFICATION
Refer to appropriate WIRING DIAGRAM for addi-
tional information. Voltage 12.5 - 15 Vdc
The magneto is covered in MAGNETO AND If voltage is above specification, replace regulator
STARTER subsection. and continue CHARGING SYSTEM LOAD TEST.
WARNING 4. Connect an ammeter such as EXTECH INDUC-
Ensure vehicle is in PARK when performing TIVE AMMETER (P/N 380941) around RD1-1 wire.
charging system tests.
BATTERY LOAD TEST

1. Remove seat.
2. Connect a battery load tester such as the NAPA
ULTRA PRO BATTERY LOAD TESTER (P/N 95260).
3. Ensure proper test conditions.
TEST CONDITIONS
Initial battery voltage‡ Above 12.5 Vdc
Engine OFF
vmr2008-138-001_a
3 times the amp-hour DC CURRENT TEST WITH INDUCTIVE AMMETER
Load
(AH) rating 1. Output connector of voltage regulator
2. Ammeter clamped over RED wire
Time 15 seconds
‡ Required for accurate testing
TEST CONDITIONS
SPECIFICATION
Battery voltage at idle‡ Above 12.6 Vdc
Battery Above 9.6 Vdc
Engine Increase to 4000 RPM
558 vmr2015-047
TEST CONDITIONS
As required to decrease
Load
battery voltage to 12 Vdc
Time 15 seconds
6. Read amperage on ammeter.

MODEL SPECIFICATION
Base models (no-DPS,
35 ± 5 Amps
not CE)
DPS models 41 ± 5 Amps
All CE models 41 ± 5 Amps
vmr2015-047-010_a
If amperage or voltage is not within specification,
verify magneto and wires. Refer to MAGNETO
AND STARTER subsection. Replace: Voltage Regulator Continuity Test
– Voltage regulator if magneto test is within spec- Due to internal circuitry, there is no static test
ifications. available.
– Magneto if magneto test is not within specifi-
cations.
Voltage Regulator Power Test
1. Check voltage at RD1-1.
VOLTAGE REGULATOR (RD) TEST CONDITIONS
RD1-1 Hot at all times
BACKPROBE PROBE SPECIFICATION

12V,18AH RD1-1 BAT2 (-) Battery voltage
RD2-1
RD1-1
BN4 BAT2 BAT1
R D2-2
RD 2. Connect a battery load tester such as the NAPA
RD1-3
RD2-3
BN1
SS-1 BP3 3. Start vehicle.
BP1
TEST CONDITIONS
vmr2015-047-001_a Engine Increase to 4000 RPM
As required to decrease
Voltage Regulator Access Load
The voltage regulator/rectifier is accessible on the Time 15 seconds
RH rear side of the vehicle.
5. Measure voltage drop.

RD1-1 BAT1 (+) Under 0.2 Vdc
If voltage drop is above specification, locate and

repair damaged connector/wire.
vmr2015-047 559
Voltage Regulator Ground Test

1. Check ground at RD1-3.
TEST CONDITIONS
RD1-3 Permanent ground

RD1-3 BAT1 (+) Battery voltage
2. Connect a battery load tester such as the NAPA

3. Start vehicle.
4. Ensure proper test conditions. vmr2012-032-002_a
TYPICAL
TEST CONDITIONS 1. Battery retaining plate
2. Retaining plate screws (3)
Engine Increase to 4000 RPM 4. Remove battery.
Load
As required to decrease Battery Cleaning
Clean the battery support, cables and battery
Time 15 seconds posts using a solution of baking soda and water.
‡ Required for accurate testing Remove corrosion (if so) from battery cable ter-
minals and battery posts using a firm wire brush.
5. Measure voltage drop. Rinse with clear water and dry well.
Battery Inspection
RD1-3 BAT2 (-) Under 0.4 Vdc Visually inspect battery casing for cracks or any
other damages. If casing is damaged, replace bat-
If voltage drop is above specification, locate and
tery and thoroughly clean battery support with a
repair damaged connector/wire.
water and baking soda solution.
BATTERY Inspect condition of battery posts, battery sup-
port, holding strap and strap attachment points
Battery Information and wire terminal lugs.
These vehicles are equipped with a VRLA battery
(Valve Regulated Lead Acid). It is a maintenance-
Battery Storage
free type battery. It is not necessary to remove the battery during
vehicle storage but it is recommended for long
Refer to battery manufacturer's instructions for
term storage.
proper filling, activation and routine charging pro-
cedures. If the battery is left in the vehicle during storage or
used infrequently, disconnect the BLACK (-) nega-
Battery Removal tive battery cable to eliminate battery current drain
1. Remove seat. from the electrical equipment.
2. Disconnect BLACK (-) cable first, then the RED Recharge the battery once a month with an ap-
(+) cable. proved battery charger as per manufacturer's rec-
ommendations.
NOTICE Always respect this order for re- Clean battery, battery support and connections as
moval; disconnect BLACK (-) cable first. required, refer to BATTERY CLEANING in this sec-
3. Remove battery retaining plate. tion.
For other recommendations during storage, refer
to battery manufacturers instructions.
560 vmr2015-047
WARNING TIGHTENING TORQUE

Ensure battery is stored in a safe place, out of
Battery retaining plate 4.5 N•m ± 0.5 N•m
reach for children. screws (40 lbf•in ± 4 lbf•in)
New Battery Activation
Refer to the instructions provided with the battery.
Battery Charging
WARNING
Always wear safety glasses and charge in a
well ventilated area. Never charge or boost a
battery while it is installed on vehicle. Do not
open the sealed cap during charging. Do not
place battery near open flame.
NOTICE If battery becomes hot, stop charg-

ing and allow it to cool before continuing.
NOTE: Sealed VRLA batteries have an internal
safety valve. If battery pressure increases due to
overcharging, the valve opens to release excess
pressure, preventing battery damage.
An automatic charger is a fast and convenient way
for error-proof charging.
Always follow the battery manufacturer's charg-
ing instructions.
When using a constant current charger, charge
battery according to the chart below.
Battery Voltage Below 12.8 V and Above 11.5
V
STANDARD CHARGING
(RECOMMENDED)
BATTERY
TIME CHARGE
TYPE
YTX20L-BS 4 - 9 HOURS 2 A
QUICK CHARGING
BATTERY
TIME CHARGE
TYPE
YTX20L-BS 50 MINUTES 10 A
Battery Installation
NOTICE Always connect RED (+) cable first
then BLACK (-) cable.
Installation is the reverse of removal procedure,
however pay attention to the following.
vmr2015-047 561
Subsection 06 (STARTING SYSTEM)
STARTING SYSTEM
SERVICE TOOLS
ECM ADAPTER TOOL (ONE CONNECTOR)................................. 529 036 085 ......................................... 565
GENERAL ENGINE TURNS

Starting system is OK.
STARTING SYSTEM OPERATION
1. Verify ignition system. Refer to IGNITION SYS-
When the START button is pressed, 12 Vdc is ap- TEM subsection.
plied through the start switch (MG1) to the starter 2. Verify EFI systems. Refer to ELECTRONIC
solenoid coil. If the engine cranking conditions are FUEL INJECTION (EFI) subsection.
met, the ECM completes the starter solenoid con-
trol circuit by providing a ground. The starter so- 3. Verify mechanical condition of engine. Refer to
lenoid then closes its contacts and battery power ENGINE, CVT AND GEARBOX section.
is applied to the starter for cranking the engine.
PROCEDURES
Engine Cranking Conditions
Ensure battery is fully charged.
The following conditions must be met to allow en-
gine cranking. Refer to applicable WIRING HARNESS AND CON-
NECTORS for harness layout and connector loca-
– Ignition switch turned ON
tions on vehicle.
– Engine stop switch to RUN
Refer to applicable WIRING DIAGRAM for addi-
– Transmission in Park, Neutral or a brake
tional information.
pedal/lever is applied
– Start button is pressed and held. WARNING
Ensure vehicle is in PARK when performing
TROUBLESHOOTING starting system tests.
Check for fault codes. Refer to: DIAGNOSTIC
AND FAULT CODES subsection. STARTING SYSTEM TESTS
Starter Solenoid
ENGINE WILL NOT TURN
If the starter cranks over the engine with the
brakes applied, check the shifter adjustment and
+
-
the gearbox position sensor and wiring. Refer

to the SHIFTER and GEARBOX AND 4X4 COU-
PLING UNIT sections.
If the “Engine cranking conditions” are met and
the starter will not crank the engine, check the fol-
lowing: M
1. Battery and connections (refer to CHARGING
SYSTEM) SS2- SS1-
2. Starter solenoid
3. Start button switch vmr2015-048-001_a
4. Starter (refer to MAGNETO AND STARTER

subsection) 1. Disconnect SS1 and SS2
5. Wiring and connections.
vmr2015-048 563
TEST CONDITION
Engine stop switch RUN
Ignition switch ON
Start button Pressed
vmr2015-048-012_a
1. SS1
2. Activate the starter solenoid.

2.1 Apply 12Vdc to SS1
2.2 Ground SS2
vmr2015-048-003_a
SS1 IS ON THE RIGHT
PROBE PROBE SPECIFICATION

SS1 SS2 Battery voltage
SS1 BAT - Battery voltage
BAT + SS2 Battery voltage
If voltage is as per specification replace starter so-

lenoid.
If voltage is not as per specification, ver-
vmr2015-048-003_c ify STARTER SOLENOID CONTROL POWER
SS1 IS ON THE RIGHT CIRCUIT or STARTER SOLENOID CONTROL
GROUND CIRCUIT as applicable.
3. If starter turns, verify STARTER SOLENOID
CONTROL CIRCUIT. Starter Solenoid Control Power Circuit
4. If starter does not turn, verify STARTER SOLE- NOTE: This procedure also tests the start button.
NOID CONTINUITY.
Starter Solenoid Control Circuit
START
OFF
L3 MG2-6
B4
START
SS2- SS1-
OFF
MG2-1
ECM
L3 HIC1-J MG2-6
B4 HIC1-A
STOP
RUN
F8
MG2-1 G2
ON WOL
ON WL
OFF
ECM
10
K3 MG1-2
MG1-1 CC-C
STOP
RUN
F8
MG2-3 A4 HIC1-B
G2 HIC1-E
ON WOL
CC-D
ON WL
OFF
10
K3 HIC2-D MG1-2 CC-C

MG1-1
MG1-3 vmr2015-048-004_a
A4 HIC1-B
CC-D
1. Disconnect MG2 connector.

vmr2015-048-002_a
564 vmr2015-048
TEST CONDITION
Engine Cranking
‡ Will prevent engine from starting
1. Measure voltage drop.
vmr2008-139-003_a
MG2 STEERING HARNESS CONNECTOR PIN-OUT
TEST CONDITION
Ignition switch ON
PROBE PROBE SPECIFICATION vmr2015-048-008_a
MG2-1 BAT - Battery voltage. PROBE PROBE SPECIFICATION
2. If voltage is not as per specification: Starter B+

BAT1 Below 0.4 Vdc
terminal
1. Check fuse(s)
2. Test engine stop switch. Refer to IGNITION If voltage drop is above specification, repair or re-
SYSTEM subsection place sources of high resistance in circuit.
3. Test ignition switch Refer toIGNITION SYS-
TEM subsection. Starter Solenoid Control Ground
3. Test start button. Circuit
TEST CONDITION
SS2- SS1-
PROBE PROBE SPECIFICATION L3 HIC1-J
B4
MG2-1 MG2-6 Close to 0
ECM
If start button does not test as specified, replace

the multifunction switch assembly. G2
If start switch tests as specified, repair wire to K3
starter solenoid SS1 terminal. A4
Starter Power Circuit Voltage Drop vmr2015-048-005_a

NOTE: Engine must be in starting condition for
this test. Do not perform on a «No Start» vehicle. 1. Disconnect SS2.
TEST CONDITION 2. Install the ECM connector onto the ECM
ADAPTER TOOL (ONE CONNECTOR) (P/N 529
Fuse F5 Removed‡ 036 085)
Ignition switch ON
vmr2015-048 565
vmr2008-139-016_a
1. ECM connector
vmr2015-048-012_a
2. ECM adapter tool
1. SS1
SS2 ECM-L3 Close to 0
If resistance is not as specified, repair or replace

wiring/connections.
If solenoid power control circuit and ground con-
trol circuit both test good, test ECM ground
circuits. Refer to ELECTRONIC FUEL INJECTION
(EFI) section.
NOTE: Supply a ground with a jumper wire if you
suspect that the ECM is not supplying a ground to vmr2015-048-003_d
the solenoid.
SPECIFICATION
PROBE PROBE
Starter Solenoid Continuity @ 20°C (68°F)
SS1 SS2 Close to 6
-
BAT2 BAT1 If resistance is not as per specification, replace the
+
solenoid.
3. Disconnect BP3.
BP3
M
SS2- SS1-
vmr2015-048-006_a
1. Disconnect the black (-) negative battery cable.

2. Disconnect SS1 and SS2
vmr2015-048-007_a

Terminal to
BP3 O.L.
starter motor
4. Jump starter solenoid.
566 vmr2015-048
Use the FLUKE 115 MULTIMETER (P/N 529 035 868)

and set it to the diode symbol as shown.
vmr2015-048-009_a
SS1 IS ON THE RIGHT

Terminal to
BP3 Close to 0
starter motor
If resistance is not as per specification, replace the vmr2006-020-005
solenoid.
Probe wires while paying attention to the diode
5. If starter power and ground circuits are good, polarity.
refer to MAGNETO AND STARTER subsection
for starter diagnosis and replacement.
Solenoid Diode Test
SS2- SS1-
vmr2015-048-011_a
FORWARD POLARITY, MUST BE AROUND 0.5 V

vmr2015-048-013_a
Disconnect SS1 and SS2 from starter solenoid.
vmr2015-048-010_a
REVERSE POLARITY, MUST BE OPEN CIRCUIT

1. SS1
vmr2015-048-012_a
1. SS1
vmr2015-048 567
If test failed, replace diode. Refer to WIRING

HARNESS AND CONNECTORS for diode loca-
tion.
NOTE: The diode is integrated in the harness near
the starter solenoid.
568 vmr2015-048
Subsection XX (RF DIGITALLY ENCODED SECURITY SYSTEM (RF D.E.S.S.))
RF DIGITALLY ENCODED SECURITY

SYSTEM (RF D.E.S.S.)
GENERAL PROCEDURES
SYSTEM DESCRIPTION D.E.S.S. KEY
The following components are specially designed D.E.S.S. Key Programming
for this system: ECM, D.E.S.S. key and engine 1. Connect the vehicle to the applicable B.U.D.S.
cut-off switch. version.
This system allows the engine to start only if a Refer to the B.U.D.S. directory on KNOWLEDGE
D.E.S.S. key is installed on engine cut-off switch CENTER for all diagnostic software related infor-
and the key is recognized as valid by the ECM. mation, including:
The D.E.S.S. key contains a magnet and a RFID – Diagnostic software version required according
chip. to the vehicle
– The magnet closes the hall effect switch inside – Current version download link
the engine cut-off switch. – User manual (programming keys, reading fault
– The RFID chip contains a unique digital code. It codes, writing data to modules etc.)
is the equivalent of the tooth-pattern cut on a – Installation instructions
conventional ignition key.
– Navigation through menus
Up to 8 D.E.S.S. keys may be programmed in the – BRP BUDS chart
ECM memory using the appropriate diagnostic
software. The keys can also be erased individu- 2. Search keyword: "BUDS".
ally.
NOTE: If desired, a D.E.S.S. key can be used on
another vehicle equipped with the D.E.S.S. sys-
tem. It only needs to be programmed for that ve-
hicle. mmr2017-025-001
D.E.S.S. Messages 3. Install a D.E.S.S. key on the post.

When starting the engine with a D.E.S.S. key on 4. Briefly press on START button. DO NOT start
the engine cut-off switch, the key is identified by the engine.
the ECM and D.E.S.S. messages will be displayed 5. Click the Read Data button in B.U.D.S.
in the multifunction gauge according to the key
recognition. See table.
MESSAGE DESCRIPTION
Displayed when a wrong
BAD KEY
key is used.
Displayed when key is not
recognized by the ECM.
DESS KEY NOT This may occur because
RECOGNIZED magnetic interference,
remove and clean key and vmr2006-012-100_aen
D.E.S.S. post.
6. Click on Keys tab.
Displayed at power up
NORMAL KEY when a normal key is
used.
Displayed at power up
PERFORMANCE KEY when a performance key
is used.
vmr2017-108 1
13. Briefly press START button. DO NOT start the

engine.
14. Click on the appropriate Add Key button.
15. Repeat to program more keys if needed.
16. Click on Write Data button to transfer new
settings and information to the ECM.
tmr2011-029-001
KEYS TAB
7. Click on Erase All Keys button.
vmr2006-012-100_ben
WRITE DATA BUTTON
17. Erase occurred fault(s) in the fault tabs.

18. Remove the D.E.S.S. key from the post and
wait for the vehicle electrical system to com-
pletely shut down.
tbl2011-001-052_a
19. Click on EXIT button to end the B.U.D.S. ses-
1. Click here to erase all keys sion.
20. Disconnect all cables and hardware from the
8. Click "YES" to confirm the action. vehicle.
9. Check the color of the key to be programmed. 21. Ensure to reinstall the connector into its hous-
KEY KEY TYPE ing.
GRAY key Performance key
DIAGNOSTIC TIPS
GREEN key Normal key
Check for fault codes as first step.
10. Click on the appropriate Add Key button. IMPORTANT: When troubleshooting an electrical
system fault, check battery condition, cables and
connections first.
RFID Pin Identification

Refer to WIRING DIAGRAM.
SPECIFICATIONS with
RFID CONNECTOR PIN RFID post connected
tbl2011-001-053_d
and key installed
TYPICAL A ECM ground
1. Add Performance Key button
2. Add Normal Key button B 12 - 15 Vdc
NOTE: The Add Work Key button is not used for C 5 Vdc
these vehicles.
D 12 Vdc
11. Remove the key.
12. Insert the next key to be programmed.
2 vmr2017-108
Stop / No Key Indicator
vmr2017-108-001
MONITORING PAGE, ECM TAB
Possible causes:
– No key installed
– Engine stop button in STOP position
– No voltage at RFID-B connector
– No ground at RFID-A connector
Condition can be duplicated by unplugging the
RFID connector.
vmr2017-108 3
Subsection XX (LIGHTS)
LIGHTS
SERVICE TOOLS
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 3–4
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ............................................. 1
GENERAL Ensure all wire terminals are properly crimped on

wires, and connector housings are properly fas-
NOTICE It is recommended to always discon- tened.
nect the battery when replacing any electric
or electronic parts. Always disconnect battery Check for signs of moisture, corrosion or dullness.
exactly in the specified order, BLACK (-) cable Clean pins properly and coat them with DIELEC-
first. TRIC GREASE (P/N 293 550 004) or other appropriate
lubricant when reassembling them, except if oth-
erwise specified such as for the ECM connector.
TROUBLESHOOTING
Pay attention to ground wires.
DIAGNOSTIC TIPS For wiring harness connector locations, refer to
WIRING HARNESS AND CONNECTORS subsec-
NOTE: It is a good practice to check for fault tion.
codes using B.U.D.S. software as a first trou-
bleshooting step. Refer to COMMUNICATION
DIAGNOSTIC GUIDELINES
IMPORTANT: When troubleshooting an electrical LOW AND HIGH BEAM HEADLIGHTS WILL
system fault, check battery condition, cables and NOT COME ON SIMULTANEOUSLY (650,
connections first. 850 AND 1000R MODELS)
1. Jumper JP1 is open circuit or missing.
Testing a Circuit
- Check jumper (fuse) JP1 in front fuse box, refer
Check the related-circuit fuse condition with a to POWER DISTRIBUTION subsection.
fuse tester or test lamp (a visual inspection could
lead to a wrong conclusion). BRAKE LIGHTS WILL NOT COME ON
NOTE: If the electrical system is left activated for WHEN BRAKES ARE APPLIED
a certain period of time, the accessory relay will 1. Defective fuse.
shut down. See ACTIVATING THE ELECTRICAL - Check fuse, refer to the appropriate BRAKE
SYSTEM in this subsection for details. LIGHT CIRCUIT PROTECTION in this subsection.
Inspecting an Electrical Connection 2. Defective brake relay.

- Test brake relay (R8), refer to POWER DISTRIBU-
When replacing an electric or electronic compo- TION subsection.
nent, always check electrical connections. Make
sure they are tight, make good contact, and are 3. Defective brake light switch(es).
corrosion-free. Dirty, loose or corroded contacts - Refer to BRAKE LIGHT SWITCHES in the BRAKE
are poor conductors and are often the source of a subsection.
system or component malfunction. 4. Defective wiring/connectors.
Pay particular attention to ensure that pins are not - Test wiring continuity, refer to applicable WIRING
bent or pushed out of their connectors. DIAGRAM.
vmr2017-109 1
TURN SIGNAL LIGHTS WILL NOT COME TURN SIGNAL/HAZARD LIGHTS

ON WHEN SELECTED (CE MODELS) INDICATOR IN MULTIFUNCTION GAUGE
WILL NOT COME ON WITH TURN SIGNAL
1. Defective fuse. OR HAZARD LIGHTS SELECTED ON,
- Check fuse, refer to the appropriate TURN SIG- IGNITION SWITCH ON (CE MODELS
NAL/HAZARD CIRCUIT PROTECTION in this sub- ONLY)
section.
2. Defective Flasher Module. 1. Signal wire from flasher module to multifunc-
tion gauge open circuit.
- Replace flasher module, refer to TURN SIG-
NALS/HAZARD in this subsection. - Test circuit continuity from flasher module
(MC2–4) to multifunction gauge (C1–8).
3. Defective wiring/connectors.
2. Defective flasher module.
- Test wiring continuity, refer to applicable WIRING
DIAGRAM. - Replace flasher module, refer to the appropriate
FLASHER MODULE in this subsection.
4. Defective Turn Signal Switch.
3. Defective multifunction gauge.
- Test switch, refer to appropriate TURN SIG-
NALS/HAZARD in this subsection and to applica- - Replace multifunction gauge, refer to GAUGE
ble WIRING DIAGRAM. subsection.
HAZARD LIGHTS WILL NOT COME ON HAZARD LIGHTS INDICATOR NOT

WHEN SELECTED (CE MODELS ONLY) WORKING WITH IGNITION SWITCH OFF
(OUTLANDER 450 / 570 CE MODELS
1. Defective fuse. ONLY)
- Check fuse, refer to TURN SIGNAL/HAZARD CIR-
CUIT PROTECTION in this subsection. 1. Defective hazard LED indicator.
- Test LED. Observe polarity.
2. Hazard lights 12 Vdc input circuit open.
- Check wiring and connectors, refer to the appro- HAZARD LIGHTS INDICATOR NOT
priate TURN SIGNAL/HAZARD in this subsection. WORKING WITH IGNITION SWITCH
Refer to WIRING DIAGRAM.
OFF (OUTLANDER 650 / 850 / 1000R CE
3. Hazard lights selector switch defective. MODELS ONLY)
- Test switch, refer to the appropriate TURN 1. Diode D10 open circuit.
SIGNAL/HAZARD in this subsection. Refer to
WIRING DIAGRAM. - Test diode, refer to applicable WIRING DIA-
GRAM.
4. Defective wiring/connector between hazard
lights selector switch and flasher module. POSITION LIGHTS WILL NOT COME ON
- Refer to applicable WIRING DIAGRAM. (CE MODELS ONLY)
5. Flasher module ground circuit open. 1. Defective fuse.
- Test wiring and connectors, refer to applicable - Check fuse, refer to the appropriate POSITION
WIRING DIAGRAM. LIGHTS in this subsection.
6. Defective flasher module. 2. Power or ground circuit wiring.
- Replace flasher module, refer to the appropriate - Check wiring continuity, refer to WIRING DIA-
TURN SIGNAL/HAZARD in this subsection. GRAM.
HAZARD LIGHTS COME ON WITHOUT 3. Defective light bulbs

BEING SELECTED (CE MODELS ONLY) - Test/replace light bulbs.
1. Hazard lights switch or wiring short circuit.

- Check for water in LH multifunction switch.
- Test hazard light switch and wiring, refer to appli-
cable WIRING DIAGRAM.
2. Flasher module parallel Resistor is open.
- Test resistor (between hazard switch output and
ground), refer to applicable WIRING DIAGRAM.
2 vmr2017-109
PROCEDURES LIGHT SWITCH

FUNCTION PIN COLOR
ACTIVATING THE ELECTRICAL
12 volt input from MG1-4
SYSTEM headlights relay MG2-4
RD/BU
NOTICE Activating the electrical system re- 12 volt output to high

MG2-5 BU
beam headlights
peatedly or using electrical equipment will
discharge the battery and you may not be able 12 volt output to low
MG2-2 GN
to start the engine. beam headlights
Models with a RF D.E.S.S. key

Headlights Circuit Protection
Press and release the START button for less than
half a second and the electrical system will turn CONDITION CIRCUIT PROTECTION
ON: Unswitched Fuse 11
– For 30 seconds, without powering any equip-
ment, if the D.E.S.S. key is NOT installed on the Testing the Headlights
D.E.S.S. post OR if the Emergency Engine Stop
switch is set to the STOP position; 1. Disconnect LOW beam and HIGH beam head-
light bulb connectors. Refer to REPLACING
– For 10 minutes, powering equipment, if the
THE HEADLIGHT BULB in this subsection.
RF D.E.S.S. key is installed on the D.E.S.S.
post AND Emergency Engine Stop is set to 2. Activate the electrical system, refer to ACTIVAT-
the RUN position. The electrical system will ING THE ELECTRICAL SYSTEM in this subsec-
be shutdown after 30 seconds if either the tion.
D.E.S.S. key is removed OR the Emergency 3. Measure the voltage on headlight connector as
Engine Stop is set to the STOP position. follows.
NOTE: If the vehicle is connected to B.U.D.S. and REQUIRED TOOL
the RF D.E.S.S. key is installed on its post, the
electrical system will not shut down.
Models with a conventional ignition key FLUKE 115
MULTIMETER
Turn the ignition key to the ON position (P/N 529 035 868)
HEADLIGHTS (MODELS WITH 4

HEADLIGHTS) LIGHT
SWITCH WIRE COLOR VOLTAGE
Headlight Wire Identification POSITION
HEADLIGHTS RELAY (R5) LO beam
HI beam GN
FUNCTION PIN COLOR (Low beam
(Models
12 volt input from fuse with a connector) Battery
C6 YE/BK BK
F11 (headlights power) DPS) voltage
12 volt input from fuse F4 BU
D6 OR/GN
(relay winding input) HI beam (Hi beam
connector)
12 volt output to light
D7 RD/BU
switch
Relay winding ground
Replacing the Headlight Bulb
C7 OR/BK
(from ECM K2) NOTICE Never touch glass portion of a halo-
gen bulb with bare fingers, it shortens its oper-
ating life. If glass is touched, clean it with iso-
propyl alcohol which will not leave a film on
the bulb.
1. Unplug connector from bulb.
vmr2017-109 3
2. Rotate bulb. Headlights Circuit Protection

CONDITION CIRCUIT PROTECTION
Supplied when relay Fuse 12 of fuse block 1
R3 is activated (from accessory relay R3)
Testing the Headlight

1. Disconnect headlight bulb connectors. Refer
to REPLACING THE HEADLIGHT BULB in this
subsection.
2. Activate the electrical system, refer to ACTIVAT-
ING THE ELECTRICAL SYSTEM in this subsec-
tion.
3. Measure the voltage on headlight connector as
follows.
vmo2012-012-060_b
REQUIRED TOOL
TYPICAL
3. Pull bulb out.

FLUKE 115
4. Properly reinstall removed parts in the reverse MULTIMETER
order of their removal. (P/N 529 035 868)
5. Validate headlight operation.
HEADLIGHTS (MODELS WITH 2 4. Measure the voltage on headlight connector as

HEADLIGHTS) follows.
LIGHT
Headlight Wire Identification SWITCH WIRE COLOR VOLTAGE
ACCESSORY RELAY (R3) POSITION
FUNCTION PIN COLOR Battery

LO beam GN
voltage
12 volt input from fusible (Low beam
E12 RD/GN connector)
link FL-2 HI beam
BK No voltage
12 volt input from F4 Lo beam
E10 OR/GN BU
(relay winding input)
(Hi beam Battery
RD/YE before HI beam connector)
12 volt output to light voltage
D10 F12 and RD/BK
switch (through F12)
after F12
Replacing the Headlight Bulb
D12 OR/BK NOTICE Never touch glass portion of a halo-
(from ECM K2)
gen bulb with bare fingers, it shortens its oper-
LIGHT SWITCH ating life. If glass is touched, clean it with iso-
FUNCTION PIN COLOR propyl alcohol which will not leave a film on
the bulb.
12 volt input from relay
MG2-4 RD/BU 1. Remove cover.
R3 (through fuse F12)
12 volt output to high 2. Unplug connector.
MG2-5 BU
beam headlights 3. Remove bulb.
12 volt output to low
MG2-2 GN
beam headlights
4 vmr2017-109
90°
A
B
vmr2006-020-002_a
TYPICAL
1. Light beam center
A. 5 m (16 ft)
B. Beam aiming specification
vmr2015-050_010_a
1. Cover
2. Connector 90°
4. Properly reinstall removed parts in the reverse
order of their removal.
5. Validate headlight operation. 1 2
HEADLAMP BEAM AIMING (ALL

MODELS) 90°
NOTE: Load vehicle as per normal use.
vmr2006-020-001_a
1. Position vehicle on a level surface 5 m (16 ft) in TYPICAL
front of a test surface ( wall or screen) as in first 1. Headlight center lines
2. Light beam center
illustration.
2. Measure the distance from the center of each Adjusting Beam Aiming (Models with
headlight to the ground (high beam and low 4 Headlights)
beam).
Turn adjustment knobs to adjust beam height and
3. Trace a line on the test surface parallel to the side orientation to specification.
ground at each measured height (one for high
beam and one for low beam).
Low beam aiming is correct when the crest of the
low beam is below the applicable horizontal cen-
ter line traced on the test surface as per specifi-
cation.
High beam aiming is correct when the center of
the high beam (focus point) is below the applica-
ble horizontal center line traced on the test sur-
face as per specification.
SPECIFICATION
Low beam crest (top vmo2012-012-059_b
of low beam) 25 mm to 125 mm
OUTLANDER LOW BEAM
(1 in to 5 in) below 1. Adjustment knobs
High beam center applicable line
(focus point)
vmr2017-109 5
BRAKE LIGHT RELAY (R8)

FUNCTION PIN COLOR
12 volt input from F4 (relay
D8 OR/GN
winding input)
12 volt output to LH and
D9 WH/OR
RH brake lights
(from brake light C9 RD/OR
switch(es))
Brake Light Circuit Protection

CIRCUIT
CONDITION
vmo2012-012-060_a PROTECTION
OUTLANDER HIGH BEAM AND RENEGADE LOW BEAM/HIGH
BEAM Supplied when:
1. Adjustment knobs Accessories relay Fuse 14 (from
R3 activated Accessories relay R3)
Adjusting Beam Aiming (Models with Brake relay R8 activated
2 Headlights)
Turn adjustment knobs to adjust beam height and Taillight Wire Identification
side orientation to specification.
CIRCUIT
FUNCTION PIN
PROTECTION
Supplied when
Accessories relay R3 3 RD/VI
activated
Ground from BK2 2 BK
Taillight Circuit Protection

Supplied when
Fuse 14 (from
Accessories relay R3
Accessories relay R3)
activated
vmr2015-050_008_a
1. Adjustment knobs
Taillight/Brake Light Bulb Replacement
1. Unplug connector from bulb.
TAILLIGHTS/BRAKE LIGHTS
(MODELS WITH 2 TAILLIGHTS) 2. Rotate light bulb counterclockwise to remove it
from taillight.
Brake Light Switch
For brake light switch location and testing, refer to
BRAKES subsection.
Brake Light Wire Identification
BRAKE LIGHT RELAY (R8)
FUNCTION PIN COLOR
12 volt input from fuse
C8 RD/VI
F14 (brake light power)
6 vmr2017-109
Taillight Wire Identification

FUNCTION PIN COLOR
Supplied when main relay
2 OR/GN
R2 activated
Ground from BN1 3 BK
Taillight Circuit Protection

Supplied when main Fuse 4 of fuse block 1
relay R2 activated (from main relay R2)
vmo2012-012-062_a Replacing the Taillight/Brake Light

ROTATE BULB COUNTERCLOCKWISE Bulb
3. Remove bulb socket from taillight. 1. Disconnect the taillight connector.
Installation is the reverse of the removal proce- 2. Rotate the socket counterclockwise to remove
dure. it from taillight.
TAILLIGHT/BRAKE LIGHT
(MODELS WITH A SINGLE
TAILLIGHT)
Brake Light Switch
For brake light switch location and testing, refer to
BRAKES subsection.
Brake Light Wire Identification vmr2015-050_014_a
BRAKE LIGHT RELAY (R8) 3. Remove the bulb from the socket.
FUNCTION PIN COLOR Installation is the reverse of the removal proce-
12 volt input from fuse F4 dure.
C8 OR/GN
(brake light power)
12 volt input from F4 (relay
D8 OR/GN
winding input)
12 volt output to brake
D9 WH/OR
light
(from brake light C9 RD/OR
switch(es))
Brake Light Circuit Protection

CIRCUIT
CONDITION
PROTECTION
Supplied when:
Fuse 4 of fuse block 1
Main relay R2 activated
(from main relay R2)
Brake relay R8 activated
vmr2017-109 7
POSITION LIGHTS (CE MODELS CONDITION CIRCUIT PROTECTION

WITH 4 HEADLIGHTS) Fuse 12 of fuse block
Supplied when relay R3
1 (from accessories
Headlight Wire Identification is activated
relay R3)
NOTE: The position lights and licence plate light
are supplied whenever the accessory relay R3 is
activated. TURN SIGNALS/HAZARD
ACCESSORY RELAY (R3)
(CE MODELS WITH 4
HEADLIGHTS)
FUNCTION PIN COLOR
12 volt input from fusible
Turn Signal/Hazard Lights Wire
link FL-2
E12 RD/GN Identification
12 volt input from F4 FLASHER MODULE
E10 OR/GN
(relay winding input) FUNCTION PIN COLOR
RD/YE before 12 volt input from
12 volt output to lights MC2-1 RD/WH
D10 F12 and RD/BK fuse F10 (unswitched)
(through F7)
after F7
12 volt input from
Relay winding ground MC1-5 RD/BK
D12 OR/BK fuse F7 (switched)
(from ECM K2)
RH turn 12 volt input
MC1-1 BE/BROWN
from turn signal switch
Position Light Circuit Protection
LH turn 12 volt input
CONDITION CIRCUIT PROTECTION MC1-2 BE/GY
Supplied when relay R3 Fuse 7 (from accessories Output to RH turn
is activated relay R3) MC2-2 BR
signal lights
Output to LH turn signal
MC2-3 GY
POSITION LIGHTS (CE MODELS lights
WITH 2 HEADLIGHTS) Output to multifunction
gauge (turn signal MC2-4 OR
Headlight Wire Identification indicator)
Ground MC1-4 BK
activated. Hazard 12 volt input
MC1-6 BE/RD
from hazard switch
ACCESSORY RELAY (R3)
FUNCTION PIN COLOR TURN SIGNAL SWITCH
(IN MULTIFUNCTION SWITCH)
12 volt input from fusible
E12 RD/GN FUNCTION PIN COLOR
link FL-2
12 volt input from F4 12 volt input from
E10 OR/GN MG3-3 RD/BK
(relay winding input) fuse F10 (unswitched)
RD/YE before RH turn 12 volt output
12 volt output to position MG3-1 BE/BR
D10 F12 and RD/BK to flasher module
lights (through F12)
after F12 LH turn 12 volt output
MG3-2 BE/GY
Relay winding ground to flasher module
D12 OR/BK
(from ECM K2)
Position Light Circuit Protection

activated.
8 vmr2017-109
HAZARD SWITCH TURN SIGNALS/HAZARD

FUNCTION PIN COLOR (CE MODELS WITH 2
12 volt input
HEADLIGHTS)
from fuse F10 MG3-3 RD/BK Turn Signal/Hazard Lights Wire
(unswitched)
Identification
12 volt output to
flasher module FLASHER MODULE
MG3-5 BE/RD FUNCTION PIN COLOR
12 volt output to
wake up gauge 12 volt input from
MC2-1 BE
fuse F8 (unswitched)
Turn Signal/Hazard Circuit Protection 12 volt input from
MC1-5 RD/BK
accessory relay R3
TURN SIGNAL CIRCUIT
RH turn 12 volt input
CONDITION CIRCUIT PROTECTION MC1-1 BE/BR
Supplied with
Fuse 7 (from Accessories LH turn 12 volt input
Accessories relay MC1-2 BE/GY
relay R3) from turn signal switch
(R3) activated
Output to RH turn
Battery power MC2-2 BR
Fuse 10 signal lights
(continuous)
Output to LH turn signal
MC2-3 GY
HAZARD CIRCUIT lights
CONDITION CIRCUIT PROTECTION Output to multifunction
gauge (turn signal MC2-4 OR
Battery power indicator)
Fuse 10
(continuous)
Ground MC1-4 BK
Flasher Module Access Hazard 12 volt input
MC1-6 BE/RD
Remove multifunction gauge. from hazard switch
TURN SIGNAL SWITCH

(IN MULTIFUNCTION SWITCH)
FUNCTION PIN COLOR
12 volt input from
MG3-3 BE
fuse F8 (unswitched)
RH turn 12 volt output
MG3-1 BE/BR
to flasher module
LH turn 12 volt output
MG3-2 BE/GY
to flasher module
HAZARD SWITCH
vmr2012-035-012_a FUNCTION PIN COLOR
TYPICAL
1. Flasher module location 12 volt input
from fuse F8 MG3-3 BE
(unswitched)
12 volt output to
flasher module
MG3-5 BE/RD
12 volt output to
hazard pilot lamp
vmr2017-109 9
Turn Signal/Hazard Circuit Protection

TURN SIGNAL CIRCUIT
Supplied when R3 is Fuse 12 of fuse block 1
activated (from accessory relay R3)
Battery power
(continuous)
HAZARD CIRCUIT
Battery power
(continuous)
Flasher Module Access

Remove multifunction gauge.
vmr2012-035-012_a
1. Flasher module location
10 vmr2017-109
Subsection XX (GAUGE)
GAUGE
SERVICE TOOLS
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 14
SERVICE PRODUCTS
GENERAL
NOTICE It is recommended to always discon-
nect the battery when replacing any electric
or electronic parts. Always disconnect battery
exactly in the specified order, BLACK (-) cable
first.
COMPACT DIGITAL
MULTIFUNCTION GAUGE vmr2007-050-002_d
1. Transmission position
Multifunction Gauge Description
DISPLAY FUNCTION
P Park
R Reverse
N Neutral
H High range
L Low range
3) Main Screen
The main screen is used to display numerous
functions of the multifunction gauge.
vmo2013-010-001_a
Refer to MULTIFUNCTION DISPLAY MODES for
1. Selector button the available display modes.
2. Transmission position display
3. Main screen 4) Fuel Level Display
4. Fuel level display
5. 4WD indicator lamp Bar gauge continuously indicates the level of fuel
6. Low fuel level indicator lamp in the fuel tank while riding.
7. Check engine indicator lamp
8. High beam indicator lamp
9. MPH, Km/h indicator lamp
10. Signal lights/hazard lights indicator lamp (CE models)
1) Selector Button
The selector button is used to navigate or change
settings in the multifunction gauge.
2) Transmission Position Display
This display will show transmission position.
vmr2017-110 1
10) Turn signal/Hazard lights Indicator Lamp
When this indicator is ON, it indicates:

– A turn signal is activated, or
– The hazard lights are activated.
Multifunction Display Modes

Speed Mode
In this mode, the display shows the speed of the
vmo2013-010-001_b
vehicle either in km/h or in MPH.
5) 4WD Indicator Lamp
When this indicator is ON, it indicates the 4WD

system is activated.
6) Low Fuel Level Indicator Lamp
vdd2008-001-084
RPM Mode
When this indicator is ON, it indicates that there is In this mode, the display shows the engine RPM.
approximately 5 L (1.3 U.S. gal.) of fuel left in fuel
tank.
7) Check Engine Indicator Lamp
When this indicator is ON, it indicates an engine

fault code, look for a message in the main screen
display.
When this indicator blinks, it indicates that LIMP vdd2008-001-089
HOME mode is activated.

Combined Mode
8) High Beam Indicator Lamp
In this mode, the display shows the speed of the
vehicle and the engine RPM.
When this indicator is ON, it indicates that high

beam is selected on the headlights switch and
that the ignition key is in the "ON with lights" po-
sition.
9) KM/H or MPH Indicator Lamp
vdd2008-001-085_a
The applicable lamp turns on to indicate the active 1. Vehicle speed
speedometer unit of display. 2. Engine RPM
2 vmr2017-110
Odometer (OD)
Odometer records the total distance travelled ei-
ther in miles or kilometers.
vsi2009-018-032
Press and HOLD the selector button for 2 seconds

to reset the hour meter.
vsi2009-018-030 Engine Hour Meter (EH)
Clock The engine hour meter records engine running
time.
Shows current time.
vsi2009-018-033
Message Display Mode

vmo2011-008-001
If an abnormal engine condition occurs, a mes-
Refer to PROCEDURES to set current time. sage may scroll across the main screen in con-
junction with a pilot lamp.
Trip Meter (TP) Refer to DIAGNOSTIC AND FAULT CODES sub-
The trip meter records the travelled distance since section.
it has been reset. Distance travelled is displayed
either in kilometers or miles. Navigating the LCD Gauge
WARNING
Never adjust or set functions on the multi-
function gauge while riding the vehicle.
Default Display Mode

After vehicle startup, the default display mode is
either:
– Vehicle speed
vsi2009-018-031
– Engine revolutions per minute (RPM)
Press and HOLD the selector button for 2 seconds – Both parameters simultaneously (combined
to reset the trip meter. mode).
To change from one display to the other, proceed
Trip Hour Meter (TH) as follows.
The trip hour meter records vehicle running time 1. Turn ignition key to ON to power-up the system.
when the electrical system is activated. It can be
used to establish traveling time between 2 places. 2. Wait until the “greeting message” has been
displayed.
vmr2017-110 3
3. Press and release selector button once to dis- FULL SIZE DIGITAL
play OD (odometer). MULTIFUNCTION GAUGE
4. Press the selector button again, this time for 2
seconds. Multifunction Gauge Description
This will change the Mode to either Speed, RPM The multifunction gauge is located in the middle
or Combined. of the handlebar.
vdd2008-001-083
5. To select another mode, repeat steps 3 and 4

until the desired mode is displayed.
Temporary Display Mode vmo2012-012-029_a
1. Display 1
In the temporary display mode, the following func- 2. Display 2
tions are available: 3. Display 3
4. Selector button
– Odometer 5. Transmission position display
– Clock 7. Indicator lamps
– Trip meter (resettable)
Speedometer
– Trip Hour meter (resettable)
– Engine hour meter. This display will show vehicle speed.
Press and release selector button to change the
default display mode to the temporary mode.
vmr2007-050-002_c
vmo2012-012-029_i
1. Selector button
1. Vehicle speed (Display 1)
The gauge will display the selected mode for 10 Tachometer
seconds then will return to the normal display
mode. Measures engine revolutions per minute (RPM).
Multiply by 1000 to obtain the actual revolutions.
While in a resettable mode, push and HOLD se-
lector button for 2 seconds to reset it. NOTE: RPM may also be displayed via Display 2
(mode) display.
4 vmr2017-110
vmo2012-012-029_k vmo2012-012-029_n
1. Tachometer 1. Fuel level display

2. Operating range
3. Tachometer via Display 2 (mode) Low fuel level Indicator Lamp
Transmission Position Display
This display will show transmission position.
When this indicator turns ON, it indicates that

there is approximately 5 L (1.3 U.S. gal.) of fuel
left in fuel tank.
4WD Indicator Lamp
When this indicator is ON, it indicates the 4WD

system is activated.
Brake Lock Indicator Lamp
vmo2012-012-029_j
1. Transmission position
DISPLAY FUNCTION
When this indicator is ON, it indicates the brake is
P Park
activated for more than 15 seconds (while riding).
R Reverse
High Beam Indicator Lamp
N Neutral
H High gear
L Low gear
When this indicator is ON, it indicates that high
NOTE: If the letter “E” is displayed in the trans- beam is selected.
mission position display, it means that there is a
electrical communication error. Contact an autho- Check Engine Indicator Lamp
rized Can-Am dealer.
Fuel Level Display
Bar gauge continuously indicates the fuel level in
the fuel tank. When this indicator is ON, it indicates an engine
fault code, look for a message at the LCD display.
Refer to DIAGNOSTIC AND FAULT CODES sub-
section.
vmr2017-110 5
Turn Signal/Hazard Lights Indicator Lamp E) Engine Hour Meter

CE Models Records engine running time.
F) Engine RPM
Measures engine revolutions per minute (RPM).
When this indicator is ON, it indicates:

– A turn signal is activated, or
– Hazard lights are activated.
Multifunction Display Modes

WARNING
Never adjust or set functions on the multi-
function gauge while riding the vehicle.
The available modes may be displayed by pressing

the selector button.
NOTE: An abbreviation of the mode selected will
also be displayed in Display 3.
vmo2012-012-029_m
1. Display 2 (mode)
2. Display 3 (mode/message)
A) Odometer
Records the total distance travelled.
B) Clock
Shows current time.
Press and HOLD selector button to set clock.
C) Trip Meter
Records the distance travelled since it has been
reset.
Press and HOLD display selection button to reset.
D) Hour Meter (Trip Time)
Records the vehicle running time when the elec-
trical system is activated since it has been reset.
Press and HOLD display selection button to reset.
6 vmr2017-110
ANALOG / DIGITAL MULTIFUNCTION GAUGE

Multifunction Gauge Description
The Multifunction Gauge (Analog/digital) is comprised of a digital gauge and two analog gauges
(speedometer and tachometer).
The engine temperature and fuel level bar graphs are comprised in the digital gauge.
The indicators lamps are comprised in both analog gauges.
1 11 2 6 3 7 4
M S
M S
5 10 12 13 9 8 5
vmo2013-007-001_c
TYPICAL
1. Analog speedometer
2. MODE (M) button
3. SET (S) button
4. Analog tachometer (RPM)
5. Indicator lamps
6. Main digital display
7. Multifunction display
8. Fuel level indicator
9. Gearbox position indicator
10. Engine temperature indicator
11. Numerical display
12. 2WD/4WD indicator
13. Secondary digital display
WARNING
Do not adjust the display while riding. You could lose control.
vmr2017-110 7
1) Analog Speedometer
Measures vehicle speed in km/h or mph.
2) MODE (M) Button
Pressing the MODE (M) button will scroll through the functions of the main digital display.
FUNCTION SEQUENCE OPTIONS
Air Suspension (LTD model only) Press ACS button to change setting (1 to 6)
Press SET (S) to scroll and select desired function
Numerical Display is flashing
and press MODE (M) to confirm
Press SET (S) to scroll and select desired function
Multifunction display is flashing
and press MODE (M) to confirm
3) SET (S) Button

Pressing the SET (S) button will scroll through the functions of the secondary digital display.
FUNCTION SEQUENCE INFORMATION DISPLAYED
XX:XX (24:00 time base)
Clock
XX:XX A or P (12:00 AM/PM time base)
Cumulative distance odometer XXXXX.X km or mi
Trip distance — odometer A (TRIP A) XXXXX.X km or mi
Trip distance — odometer B (TRIP B) XXXXX.X km or mi
Engine time chronometer (Hr) XXXXX.X
Trip time chronometer (HrTRIP) XXXXX.X
To reset any trip functions, push and hold the MODE (M) button for three seconds.
4) Analog Tachometer (RPM)
Measures engine revolutions per minute (RPM). Multiply by 1000 to obtain actual revolutions.
5) Indicator Lamps
Indicator lamps will inform you of various conditions or problems.
An indicator lamp can flash alone or in combination with another lamp.
INDICATOR LAMP(S) DESCRIPTION
All indicator lamps are activated when ignition switch is ON and
All indicator lamps On
the engine is not started
On Low Fuel
On Check Engine
On High Engine Temperature
On Headlights in the HIGH beam position
On Brake is pressed for more than 15 seconds while riding
8 vmr2017-110
6) Main Digital Display

Displays useful real-time information to the rider.
7) Multifunction Display
The vehicle speed or the engine revolutions (RPM) can be displayed. See MODE (M) BUTTON in this
section.
Important messages can also be displayed. Refer to table below.
MESSAGE DESCRIPTION
Message displayed when the brakes are applied continuously for 15
BRAKE
seconds.
NORMAL KEY Displayed at power up when a the normal key is used.
PERFORMANCE KEY Displayed at power up when a the performance key is used.
Override is displayed when the override switch is pressed and the shift
OVERRIDE
lever is set to reverse gear.
Displayed in the gauge when a periodic maintenance will soon be
MAINTENANCE REQUIRED required. To erase this message, refer to PROCEDURES in this
subsection.
If an abnormal engine condition occurs, a message can be combined with a pilot lamp. Refer to DIAG-
NOSTIC AND FAULT CODES subsection.
8) Fuel Level Indicator
Bar graph that continuously indicates the level of fuel left in the fuel tank.
9) Gearbox Position Indicator
Displays the selected gearbox position.
LTD Models
As a second function, will indicate the current ACS position setting.
10) Engine Temperature Indicator
Bar graph that continuously indicates the engine coolant temperature.
11) Numerical Display
The vehicle speed or the engine revolutions (RPM) can be displayed. See MODE (M) BUTTON in this
section.
12) 2WD/4WD Indicator
When this indicator is ON, the 4WD system is activated.
13) Secondary Digital Display
Displays useful real time information to the rider. For display function informations, refer to SET (S) BUT-
TON.
Gauge Setup
Setting Metric/Imperial Units
Use B.U.D.S. software to select metric or imperial units.
Setting Clock
Use B.U.D.S. software or do the following:
1. Press SET (S) button to select clock display.
2. Push and hold SET (S) button for three seconds.
vmr2017-110 9
3. Press SET (S) button to select 12:00 AM PM or 24:00 time base.

4. If 12:00 AM PM time base is selected, A or P flashes. Press SET (S) button to select A (AM) or P (PM).
5. Press SET (S) to select the first digit of the hour.
6. Press SET (S) to select the second digit of the hour.
7. Press SET (S) to select first digit of the minutes.
8. Press SET (S) to select second digit of the minutes.
Setting Language
The gauge display language can be changed using B.U.D.S. software.
TROUBLESHOOTING DIAGNOSTIC GUIDELINES

MULTIFUNCTION GAUGE WILL NOT
DIAGNOSTIC TIPS COME ON
NOTE: It is a good practice to check for fault 1. Multifunction gauge not powered up.
codes using B.U.D.S. software as a first trou-
- Check fuse(s), refer to CIRCUIT PROTECTION in
bleshooting step. Refer to COMMUNICATION this subsection.
- Test multifunction gauge 12 Vdc input and ground
IMPORTANT: When troubleshooting an electrical circuits as per WIRING IDENTIFICATION in this
system fault, check battery condition, cables and subsection. Refer to applicable WIRING DIA-
connections first. GRAM.
2. Defective Multifunction Gauge.
Testing a Circuit - Replace multifunction gauge.
Check the related-circuit fuse condition with a
fuse tester or test lamp (a visual inspection could MULTIFUNCTION GAUGE
lead to a wrong conclusion). COMMUNICATION ERROR
NOTE: If the ignition switch is left ON for a certain 1. Multifunction gauge CAN circuit open.
period of time, the accessory relay will shut down. - Ensure multifunction gauge is properly connected
and powered up.
Inspecting an Electrical Connection - Check for applicable fault code using B.U.D.S., re-
When replacing an electric or electronic compo- fer to DIAGNOSTIC AND FAULT CODES subsec-
nent, always check electrical connections. Make tion.
sure they are tight, make good contact, and are - Carry out TESTING THE CAN RESISTOR in this
corrosion-free. Dirty, loose or corroded contacts subsection.
are poor conductors and are often the source of a - Carry out a continuity test of the multifunction
system or component malfunction. gauge CAN wires, refer to applicable WIRING
DIAGRAM.
Pay particular attention to ensure that pins are not
bent or pushed out of their connectors. NO FUEL QUANTITY INDICATION
Ensure all wire terminals are properly crimped on 1. Defective fuel level sender or wiring.
wires, and connector housings are properly fas- - Refer to FUEL TANK AND FUEL PUMP subsec-
tened. tion.
Check for signs of moisture, corrosion or dullness. 2. Defective Multifunction Gauge.
Clean pins properly and coat them with DIELEC-
- Replace multifunction gauge, refer to PROCE-
TRIC GREASE (P/N 293 550 004) or other appropriate DURES in this subsection.
lubricant when reassembling them, except if oth-
erwise specified such as for the ECM connector.
Pay attention to ground wires.
For wiring harness connector locations, refer to
WIRING HARNESS AND CONNECTORS subsec-
tion.
10 vmr2017-110
PROCEDURES Wiring Identification

FUNCTION PIN COLOR
MULTIFUNCTION GAUGE 12 volt input from fuse F4 17 ORANGE/YELLOW
Resetting the "Maintenance Required" 12 volt input from fuse F8 16 RED/WHITE
Message Using B.U.D.S.
Ground 20 BLACK
Connect to the latest applicable B.U.D.S. software
version. Refer to COMMUNICATION TOOLS CAN LO 18 WHITE/BLACK
AND B.U.D.S. subsection. CAN HI 19 WHITE/BEIGE
Select Vehicle tab. 4
Fuel level gauge supply BROWN/PINK
Click on the Reset Service button.
Fuel level gauge ground 21 VIOLET/PINK
2WD/4WD switch
7 BLACK/BEIGE
signal (-)
HI beam signal (+) 5 BLUE
Vehicle speed sensor
9 PINK
signal (VSS)
Circuit Protection
Supplied at all times
(from fusible link 1)
tmr2011-030-014_a Fuse 4 of fuse block
Supplied with main relay
TYPICAL 1 (from main relay R2
activated
1. Reset Service button in fuse block 1)
Resetting the "Maintenance Required" Setting the Clock Using the Gauge
Message Using the Gauge Button Selector Button
1. Select display and hold button as per following
table: Compact and Full Size Digital Multifunction
Gauges
BUTTON
GAUGE TYPE DISPLAY To set current time, proceed as follows:
(HOLD)
1. Select the clock display.
Analog / digital
multifunction Odometer SET (S)
gauge
Full size digital
multifunction Odometer Selector button
gauge
Compact digital
multifunction Default Selector button
gauge
2. While holding the button, alternate between

LOW beam and HIGH beam 3 times.
NOTE: Step 2 must be started on high beam and vmo2011-008-001
completed within 2 seconds. COMPACT DIGITAL MULTIFUNCTION GAUGE
3. Release SET button.
vmr2017-110 11
9. Press SET (S) button.
Setting Using B.U.D.S.

Connect to the applicable B.U.D.S. software. Re-
fer to COMMUNICATION TOOLS AND B.U.D.S.
subsection.
Language Selection
In B.U.D.S., select the:
– Setting page tab
– Cluster page tab.
Scroll and select the desired display language in
vmo2012-012-029_o
the Cluster Language box.
FULL SIZE DIGITAL MULTIFUNCTION GAUGE
1. Time (Display 2)
2. Message (Display 3)
2. Press and HOLD selector button.

NOTE: On the full size gauge, "SET TIME" will ap-
pear on display 3.
3. Choose the 12-hour (12H) or 24-hour (24H) for-
vmr2016-137-001_a
mat by pressing button.
4. If the 12-hour format was selected, choose Am Selecting Units
(A) or Pm (P) by pressing button. In B.U.D.S., select the:
5. Choose hour first digit by pressing button. – Setting page tab
6. Choose hour second digit by pressing button. – Cluster page tab.
7. Choose minutes first digit by pressing button. Select Imperial or Metric in the Cluster Units
box.
8. Choose minutes second digit by pressing but-
ton.
9. Press button to enter settings (CLOCK will ap-
pear on display).
NOTE: The gauge will display the current time for
10 seconds then will return to the normal display
mode.
vmr2016-137-001_b
Analog / Digital Multifunction Gauge

Setting the Clock
1. Press SET (S) button to select clock display.
2. Push and hold SET (S) button for three seconds.
– Setting page tab
3. Press SET (S) button to select 12:00 AM PM or – Cluster page tab.
24:00 time base.
To set clock to the 24-hour format, check the 24 H
4. If 12:00 AM PM time base is selected, A or P box. To set it to the 12-hour format, leave the box
flashes. Press SET (S) button to select A (AM) empty.
or P (PM).
If 12-hour format was selected, check the PM box
5. Choose hour first digit by pressing SET (S) but- if required.
ton.
Set hour and minutes using the up or down ar-
6. Choose hour second digit by pressing SET (S) rows.
button.
7. Choose minutes first digit by pressing SET (S)
button.
8. Choose minutes second digit by pressing SET
(S) button.
12 vmr2017-110
Indicator Lights Monitoring

– Monitoring page
– Cluster tab.
Use the Cluster Lamp Active box to monitor dif-
ferent indicator lights outputs.
vmr2016-137-002_a
TYPICAL
1. 24 H box
2. PM box
3. Arrows
Selecting Tire Size vmr2016-137-003
Select Setting and ECM tabs. TYPICAL - CLUSTER LAMP ACTIVE BOX
Scroll and select the appropriate tire diameter (see This function confirms that the signals are broad-
inscriptions on the tires) in the Tire Size box. casting and the indicator lights should be ON in
the multifunction gauge.
Switch Input Monitoring
– Monitoring page
– Cluster tab.
Use the Switch Inputs box to monitor different
switch inputs as you activates the switches.
tmr2016-136-306_a
1. Tire Size box
Testing Using B.U.D.S.

Connect to the latest applicable B.U.D.S. software
version. Refer to COMMUNICATION TOOLS vmr2016-137-004
AND B.U.D.S. subsection. TYPICAL - SWITCH INPUTS BOX
Wow Test This function confirms that the multifunction

This function is used to check if the indicator gauge receives the inputs.
lights, display and analog indicators (if applicable)
Vehicle Parameters Monitoring
are functional.
NOTE: This function does not test the signals or
external circuits. – Monitoring page
– Cluster tab.
– Activation page In the upper area of the B.U.D.S. cluster page, the
following indications are displayed.
– Cluster tab.
– Engine speed (RPM)
Click on the WOW Test button.
– Vehicle speed
– Fuel level.
vmr2017-110 13
These indications confirm that the applicable sig- NOTE: This tests both the ECM and the Cluster
nals are transmitted and the information should be CAN resistors and wires.
displayed in the multifunction gauge.
TEST RESULT
Testing the CAN Resistor READING POSSIBLE CAUSE
Models with a 1 connector DPS Approximately ECM and CLUSTER CAN wires and
60 resistors good
Disconnect DPS connector. Refer to the appropri-
ate DYNAMIC POWER STEERING (DPS) subsec- CAN wire to CLUSTER open
Approximately CAN wire to ECM open
tion. 120 CLUSTER CAN resistor open
Models with a 3 connectors DPS ECM CAN resistor open
Disconnect DPS1 (control) connector. Refer to Infinite CAN wire to DB connector open
the appropriate DYNAMIC POWER STEERING (open circuit) circuit
(DPS) subsection.
All Models Removing the Multifunction Gauge
(Outlander 450 / 570)
1. Remove seat to access diagnostic link connec-
tor (DB). 1. Remove the gauge support by pulling it up.
2. Remove diagnostic link connector from its
holder.
vmr2015-050_011_a
2. Disconnect the gauge connector.

3. From the back of the gauge support, release
the gauge retaining tabs and remove the gauge
vmr2012-023-003_a
from its support.
3. Measure the resistance of the CAN resistors as

follows.
REQUIRED TOOL
FLUKE 115
MULTIMETER
(P/N 529 035 868)
CAN RESISTOR TEST

vmr2012-035-003_a
DIAGNOSTIC LINK GAUGE RELEASE TABS (4)

RESISTANCE
CONNECTOR
14 vmr2017-110
Removing the Multifunction Gauge Tilt gauge rearward.

(Outlander 650 / 850 / 1000R)
Remove gauge outer support.
– Push in on both sides of its leading edge to dis-
engage it.
– Lift up and pull forward to remove.
NOTE: There are a total of 6 tabs that retain the
gauge support.
vmr2017-109-002_a
Disconnect the gauge connector.

Remove gauge from the inner support by pulling
it up.
Removing the Multifunction Gauge

(Renegade)
1. Remove console panel, refer to BODY subsec-
vmr2012-035-001_a tion.
OUTER GAUGE SUPPORT REMOVAL 2. Remove the gauge support as shown.
1. Push in and lift up here (both sides)
Full Size digital Multifunction gauge

Disconnect the gauge connector.
From the back of the outer gauge support, release
the bezel retaining tabs and remove the bezel.
vmr2016-410-004_a
EXCEPT X MR MODEL
vmr2012-035-002_a
BEZEL RETAINING TABS
From the back of gauge support, rotate the gauge

clockwise to release it from its support.
Analog / Digital Multifunction Gauge
Release tabs.
vmr2017-110 15
vmr2016-410-005_a
X MR MODEL
3. From the back of the gauge support, release

the gauge retaining tabs and remove the gauge
from its support.
vmr2012-035-003_a
GAUGE RELEASE TABS (4)
Installing the Multifunction Gauge

dure.
New Multifunction Gauge Registration
(coding)
Whenever the multifunction gauge is replaced,
B.U.D.S. must be used to register it in the ECM.
Simply click Yes when the following message
appears.
vmr2006-020-058_a
16 vmr2017-110
Subsection XX (ACCESSORIES)
ACCESSORIES
SERVICE PRODUCTS
GENERAL PROCEDURES
NOTICE It is recommended to always discon-
nect the battery when replacing any electric ACTIVATING THE ELECTRICAL
or electronic parts. Always disconnect battery SYSTEM
exactly in the specified order, BLACK (-) cable
first. NOTICE Activating the electrical system re-
peatedly or using electrical equipment will
TROUBLESHOOTING discharge the battery and you may not be able
to start the engine.
DIAGNOSTIC TIPS Models with a RF D.E.S.S. key
Testing a Circuit Press and release the START button for less than
Check the related-circuit fuse condition with a half a second and the electrical system will turn
fuse tester or test lamp (a visual inspection could ON:
lead to a wrong conclusion). – For 30 seconds, without powering any equip-
ment, if the D.E.S.S. key is NOT installed on the
NOTE: If the electrical system is left activated for D.E.S.S. post OR if the Emergency Engine Stop
a certain period of time, the accessory relay will switch is set to the STOP position;
shut down. See ACTIVATING THE ELECTRICAL
SYSTEM in this subsection for details. – For 10 minutes, powering equipment, if the
RF D.E.S.S. key is installed on the D.E.S.S.
Inspecting an Electrical Connection post AND Emergency Engine Stop is set to
the RUN position. The electrical system will
When replacing an electric or electronic compo- be shutdown after 30 seconds if either the
nent, always check electrical connections. Make D.E.S.S. key is removed OR the Emergency
sure they are tight, make good contact, and are Engine Stop is set to the STOP position.
corrosion-free. Dirty, loose or corroded contacts
are poor conductors and are often the source of a NOTE: If the vehicle is connected to B.U.D.S. and
system or component malfunction. the RF D.E.S.S. key is installed on its post, the
electrical system will not shut down.
Pay particular attention to ensure that pins are not
bent or pushed out of their connectors. Models with a Conventional Ignition Key
Ensure all wire terminals are properly crimped on Turn the ignition key to the ON position
wires, and connector housings are properly fas-
tened. 12 VOLT POWER OUTLET
Check for signs of moisture, corrosion or dullness.
Clean pins properly and coat them with DIELEC-
Removing and Installing a 12 Volt
TRIC GREASE (P/N 293 550 004) or other appropriate
Power Outlet
lubricant when reassembling them, except if oth- Remove the gauge support, refer to REMOVING
erwise specified such as for the ECM connector. THE MULTIFUNCTION GAUGE in this subsection.
Pay attention to ground wires. Unplug the connectors of the power outlet.
For wiring harness connector locations, refer to Unscrew the retaining nut.
WIRING HARNESS AND CONNECTORS subsec- Reverse procedure for installation.
tion.
vmr2017-111 1
12 Volt Power Outlet Wire HORN

Identification
FUNCTION PIN COLOR
FUNCTION PIN COLOR
12 volt input from
2 BE/BK
12 volt input from fuse F12 2 RD/BR horn switch
Ground Ground 1 BK
1 BK
(to ground terminal BK3)
Horn Circuit Protection
12 Volt Power Outlet Circuit Protection
Unswitched
Supplied with from fusible link FL-1
Fuse 12
accessories relay
(from accessories relay R3)
activated
WINCH
HORN (OUTLANDER 650 / 850 Winch Wire Identification
/ 1000R AND RENEGADE CE WINCH RELAY
MODELS) FUNCTION PIN COLOR
Horn Wire Identification 12 volt input from battery
BP4 RD
(winch power)
HORN SWITCH (IN MULTIFUNCTION SWITCH)
Ground (Wire) SW4 BK
FUNCTION PIN COLOR
Ground (Cable) BN4 BK
12 volt input
from fuse F10 MG3-3 RD/WH 12 volt input from
SW1 GN/BU
(unswitched) switch (IN)
12 volt output to horn MG3-4 BE/BK 12 volt input from
SW2 LT BU
switch (OUT)
HORN Motor power (switches
RD (with blue
FUNCTION PIN COLOR polarity depending on SW3
sleeve)
rotation direction)
12 volt input from
2 BE/BK Motor power (switches
horn switch RD (with
polarity depending on SW5
Ground 1 BK yellow sleeve)
rotation direction)
Horn Circuit Protection NOTE: The small black wire at terminal SW4 con-
nected to the diodes is used to prevent electric
CONDITION CIRCUIT PROTECTION arcs in the switch. It can also be connected to
Battery power BN4.
Fuse 10
(unswitched)
HORN (OUTLANDER 450 / 570 CE

MODELS)
Horn Wire Identification
HORN SWITCH (IN MULTIFUNCTION SWITCH)
FUNCTION PIN COLOR
12 volt input from
MG3-3 BE
fuse F8
12 volt output to horn MG3-4 BE/BK
2 vmr2017-111
Removing the Winch

1. Disconnect, the battery BLACK (-) cable first,
then the RED (+) cable.
WARNING
Always respect this order for disassembly;
disconnect BLACK (-) cable first.
2. Remove the hook.

2.1 Remove and discard the cotter pin.
2.2 Remove the hook pin.
vmr2017-111-001_a
WINCH RELAY
1. To GN / BU wire
2. To LT BU wire
3. To winch motor cable with BLUE sleeve
4. To BK ground cable
5. To winch motor cable with YELLOW sleeve
6. To RD positive cable
7. BK ground wire (can also be connected with the ground cable)
WINCH SWITCH (OUTLANDER 650 / 850

/ 1000R AND RENEGADE)
FUNCTION PIN COLOR
12 volt input from fuse 7 A RD/BK
12 volt output to relay
C GN/BU
winding (IN)
B LT BU
winding (OUT) tsi2011-004-009_a
1. Hook
2. Hook pin
WINCH SWITCH (OUTLANDER 450 / 570) 3. Cotter pin
FUNCTION PIN COLOR 3. Remove the winch cable fairlead.
12 volt input from fuse 12 A RD/BK
C GN/BU
winding (IN)
B BU/GN
winding (OUT)
NOTICE Before testing, make sure the winch

is in FREESPOOL mode (Freespool clutch dis-
engaged).
Winch Relay Access

Refer to BODY and remove the RH inner fender
panel. vmr2012-035-008_a
TYPICAL
Winch Switch Circuit Protection 1. Winch fairlead
2. Fairlead retaining screws
650 / 850 / 1000R Models
Outlander 450 / 570
Supplied when Fuse 12 4. Remove the front skid plate.
accessories relay NOTE: On CE models, disconnect the turn signal
R3 is activated All models except 450 / 570
Fuse 7 lights and front marker lights.
vmr2017-111 3
vmr2012-035-009_a
1. Front skid plate

vmr2012-035-011_a
2. Retaining screws
TYPICAL
All Models 1. Front bumper support
2. Winch retaining screws
5. Disconnect both winch power cables.
7. Remove winch.
NOTE: Note the position of the power cables for
reinstallation. Installing the Winch
dure, however pay attention to the following.
Connect winch power cables as noted at removal.
NOTE: If the winch power cables are not con-
nected correctly, the winch motor will operate in
the reverse direction of selection.
TIGHTENING TORQUE
16 N•m ± 2 N•m
Winch retaining screws
7 N•m ± .5 N•m
Winch power cables
Winch fairlead elastic 16 N•m ± 2 N•m
vmr2012-035-010_a
nuts (142 lbf•in ± 18 lbf•in)
TYPICAL
1. Winch power cables
Install a new cotter pin on the hook pin.
6. Remove the four winch retaining screws from
the front bumper support.
4 vmr2017-111
Subsection XX (FRONT DRIVE)
FRONT DRIVE
SERVICE TOOLS
BACKLASH MEASUREMENT TOOL............................................. 529 035 665 ............................................. 7
CV BOOT CLAMP PLIER .............................................................. 529 036 120 ............................................. 5
CV JOINT EXTRACTOR................................................................. 529 036 005 ............................................. 5
SPANNER SOCKET ....................................................................... 529 035 649 ............................................. 9
SERVICE PRODUCTS
LOCTITE 277 ................................................................................. 293 800 073 ........................................... 11
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ........................................... 12
XPS SYNTHETIC GREASE............................................................. 293 550 010 ................................. 5, 11–12
vmr2017-127 1
FRONT DRIVE SHAFTS AND FRONT PROPELLER SHAFT
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
(M8)
NEW
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
(M10)
NEW
See
STEERING
SYSTEM
NEW
XPS
Synthetic
NEW
grease
205 ± 15 N•m
(151 ± 11 lbf•ft)
XPS
Synthetic
grease
Loctite
648
75 ± 5 N•m
(55 ± 4 lbf•ft)
vmr2017-127-100_a
2 vmr2017-127
FRONT DIFFERENTIAL
NEW XPS synthetic NEW

grease 37 ± 3 N•m
(27 ± 2 lbf•ft)
33 ± 3 N•m
(24 ± 2 lbf•ft)
22.5 ± 2.5 N•m

(17 ± 2 lbf•ft)
NEW
NEW
For backlash
adjustment
NEW
180 ± 15 N•m
(133 ± 11 lbf•ft)
Loctite 277 NEW NEW
XPS synthetic
grease
7.5 ± 0.5 N•m

NEW (66 ± 4 lbf•in)
NEW
XPS synthetic grease

vmr2015-051-101_a
vmr2017-127 3
GENERAL Installing the Wheel Hub

The procedure explained below is the same for The installation is the reverse of the removal pro-
the RH and LH sides unless otherwise instructed. cedure. However, pay attention to the following.
Install Belleville washer with its convex side out-
SYSTEM DESCRIPTION wards.
Tighten castle nut to specification.
The Visco-Lok® system constantly monitors front
wheel speed and, if it detects one wheel spinning TIGHTENING TORQUE
faster than its mate, it progressively sends more 205 N•m ± 15 N•m
power to the wheel with the better traction. Castle nut
The Visco-Lok system is comprised of two princi-
pal components, a shear pump and the controlled NOTE: Tighten castle nut further if required to
multi-plate clutch. align grooves with drive shaft hole.
A unique feature of the shear pump is that it Install a NEW cotter pin, bend as shown.
is self-contained and independent. It does not
require an external source of hydraulic fluid. The
self-contained viscous shear pump generates a
pressure proportional to wheel speed differential
- meaning the difference in rotational speed be-
tween the two wheels. This pressure engages
the friction clutch via a piston to transmit the
torque.
In the event of a failure, the Visco-Lok carrier/ring
gear and pinion gear will have to be replaced.
NOTE: The Visco-Lok shear pump is not service-
able. If the pump is disassembled, the viscous
fluid contained inside will be lost and it cannot be tmr2017-108-001_a
replaced. 1. Cotter pin correctly bent
2. Domed (convex) side here
PROCEDURES
FRONT DRIVE SHAFT
WHEEL HUB Removing the Front Drive Shaft
Removing the Wheel Hub Lift and support vehicle.
Lift and support vehicle. Remove inner fender panel(s). Refer to BODY
Select the 4WD position and place the transmis- subsection.
sion lever on "P". Remove the KNUCKLE. Refer to STEERING SYS-
Remove caliper from knuckle. Refer to BRAKES TEM subsection.
subsection. Remove shock absorber lower bolt.
Remove the following parts: Lift and attach the following parts to make room.
– Wheel cap – Shock absorber
– Cotter pin – Upper suspension arm.
– castle nut Strongly pull drive shaft out of differential.
– Belleville washer.
Remove wheel hub.
Inspecting the Wheel Hub

Check wheel hub for cracks or other damages.
Check inner splines for wear or other damages.
If any damage is detected on wheel hub, replace
it with a new one.
4 vmr2017-127
DRIVE SHAFT BOOT

Removing the Drive Shaft Boot
Remove FRONT DRIVE SHAFT. See procedure in
this subsection.
Remove drive shaft boot clamps.
REQUIRED TOOL
CV BOOT CLAMP PLIER (P/N 529 036 120)
vmr2012-036-002_a
PULL DRIVE SHAFT

529036120
Discard the stop ring at the end of the shaft.
Dislodge the large end of the boot.
Inspecting the Front Drive Shaft Separate the joint from the shaft. Two procedures
Inspect the condition of boots. If there is any dam- can be done.
age or evidence of leaking lubricant, replace them.
Refer to DRIVE SHAFT BOOT in this subsection. Without the Special Tool
Check splines for excessive wear. Replace if nec- Clamp joint housing in a vise.
essary. Align shaft with joint.
NOTE: If the splines on plunging joint are worn, a Pull hard on shaft to remove from joint.
check of differential inner splines should be done. Remove boot from drive shaft.
Installing the Front Drive Shaft Remove and discard the circlip. A new one is in-
cluded in the boot kit.
cedure. However, pay attention to the following. With the Special Tool
Install a NEW stop ring. Place drive shaft in vice with the joint downward.
Install the tool on bearing.
1
REQUIRED TOOL
CV JOINT EXTRACTOR (P/N 529 036 005)
529036005
V07H0AA
TYPICAL
1. Stop ring

the splines.
Ensure that wear ring is close to the differential.
vmr2017-127 5
vmr2007-053-010_a
TYPICAL — CV JOINT SHOWN

1. Joint extractor tool
vmr2015-074-002_a
With an hammer, hit on the tool to separate joint FROM LH SIDE

from shaft.
4. Remove screw securing the propeller shaft to
When joint and shaft are separated, remove boot the front differential.
from drive shaft.
Remove and discard the circlip. A new one is in-
Installing the Drive Shaft Boot

Install the NEW circlip.
Pack bearing area with grease (included with the
new boot kit).
NOTE: Do not use or add other grease.
Install NEW drive shaft boot clamps.
vmr2015-074-003_a
FRONT DIFFERENTIAL NOTE: Heat screw to break the threadlocker

Removing the Front Differential bond prior to removal.
1. Drain front differential. Refer to PERIODIC 5. Remove screws securing front differential to
MAINTENANCE PROCEDURES subsection. frame.
2. Remove both front drive shafts. Refer to
FRONT DRIVE SHAFT in this subsection.
3. Detach vent hose from front differential.
vmr2015-074-004_a
6. Move differential upward and rearward, and

pull it out of the frame from the RH side.
6 vmr2017-127
vmr2015-074-005_a
vmr2006-023-015_a
NOTICE Be careful not to knock or to bend 1. Tab of backlash measurement tool
vent hose fitting while removing front differen- 2. Mark on tab
tial. A. 25.4 mm (1 in)
Position the dial indicator tip against the tab at a

Inspecting the Front Differential 90° angle and right on the previously scribed mark.
(Assembled)
Gently, move the tool tab back and forth. Note the
Manually turn the pinion gear; it should turn backlash result.
smoothly. Repair if necessary.
Check if oil seals are brittle, hard or damaged. Re-
place if necessary.
Measuring the Backlash
When measuring backlash, the differential cover
should be upside down to pull the ring gear out of
mesh.
Using a dial indicator and the BACKLASH MEA-
SUREMENT TOOL (P/N 529 035 665), measure the
backlash.
Place the backlash measurement tool at the end
of pinion gear.
From center of tool bolt, measure 25.4 mm (1 in)
and scribe a mark on the tab. vmr2006-023-016
Rotate pinion gear 1/2 turn and recheck backlash.

Note the result.
Rotate pinion gear 1 turn and recheck backlash.
BACKLASH SPECIFICATION
0.1 mm (.004 in) to 0.25 mm (.01 in)
If backlash is out of specification, split final drive

housing and adjust shim thickness as per follow-
ing guideline.
vmr2017-127 7
BACKLASH ADJUSTMENT GUIDELINE

BACKLASH
WHAT TO DO
MEASUREMENT
Remove shim(s) and

Below 0.1 mm (.004 in)
recheck backlash
Add shim(s) and recheck

Above 0.25 mm (.01 in)
backlash
vmr2015-051-006_a
PRELOAD SPECIFICATION
Maximum 0.50 N•m (4 lbf•in)
If preload is out of specification, split front differ-

ential housing and check all bearings conditions.
Disassembling the Front Differential

Differential Housing
Remove front differential housing screws.
vmr2015-051-008
1. Backlash shim
Measuring the Preload

Screw the propeller shaft screw in pinion gear.
vmr2012-036-008_a
Separate half housings.

Remove oil seals.
vmr2015-051-005_a
Using a needle torque wrench, measure the

preload.
vmr2015-051-001_a
8 vmr2017-127
Visco-Lok Carrier/Ring Gear

Remove Visco-Lok carrier/ring gear out of half
housing.
vmr2015-051-010_a
1. Visco-Lok unit
2. Ring gear
Pinion Gear
vmr2015-051-002_a
Remove screw retaining front propeller shaft
adapter.
Remove screws securing ring gear to Visco-Lok
unit.
vmr2012-036-009_a
1. Retaining screw
Remove and discard oil seal.
vmr2015-051-009
Separate ring gear from Visco-Lok unit.
vmr2012-036-010_a
1. Oil seal
Unscrew the pinion nut.

REQUIRED TOOL
SPANNER SOCKET (P/N 529 035 649)
vmr2017-127 9
529035649
vmr2008-142-010_a
1. O-ring
2. Pinion gear
3. Bearing
Remove and discard the needle bearing.
vmr2012-036-011_a
Assembling the Front Differential
1. Pinion nut Adjustment is required when any of the following
part is changed.
Remove bearing and pinion gear together.
– Pinion gear
RECOMMENDED TOOLS QTY – Ring gear
Pipe: 78 mm (3-1/16 in) diameter x 127 mm – Viscolok unit
1
(5 in) in length – Housing.
Threaded rod: M10 x 1.25, 178 mm (7 in) As a preliminary setup, install shim according to
1
length the following table.
M10 x 1.25 nut 3 RECOMMENDED SHIM THICKNESS
Flat bar 1 0.5 mm (.02 in)
BACKLASH
(as a preliminary adjustment)
vmr2012-036-012_a
1. Bearing
2. Pinion gear
Remove and discard O-ring. vmr2015-051-008
Remove bearing from pinion gear. 1. Backlash shim
Prior to finalizing assembly, proceed in this order:

– Temporarily assemble final drive using recom-
mended torques.
– Do not apply thread locker product.
– Do not install a new pinion nut.
– Check backlash.
– Check preload.
10 vmr2017-127
Visco-Lok Carrier/Ring Gear

Tighten Visco-Lok / ring gear screws to specifica-
tion.
TIGHTENING TORQUE
Visco-Lok / ring gear 37 N•m ± 3 N•m
Check condition of seal. Replace if damaged.

vmr2015-051-001_a
Tighten differential housing screws to specifica-

tion.
TIGHTENING TORQUE
Differential housing 23.5 N•m ± 3.5 N•m
Pinion Gear
Install a NEW ball bearing.
Install a NEW O-ring.
Install a NEW needle bearing.
Apply LOCTITE 277 (P/N 293 800 073) to pinion nut.
vmr2015-051-003_a
Install and tighten the pinion nut to specification.
TIGHTENING TORQUE
Check bearings. Replace with NEW bearings if
necessary. 180 N•m ± 15 N•m
Pinion nut +
800 073)

NEW oil seal and install.
Tighten front propeller shaft adapter retaining
screw to specification.
TIGHTENING TORQUE
Front propeller shaft 75 N•m ± 5 N•m
adapter retaining screw (55 lbf•ft ± 4 lbf•ft)
Installing the Front Differential

vmr2015-051-004_a The installation is the reverse of the removal pro-
NEW oil seals and install. TIGHTENING TORQUE
M8 nut securing front 24.5 N•m ± 3.5 N•m
differential to frame (18 lbf•ft ± 3 lbf•ft)
M10 nuts securing front 61 N•m ± 9 N•m
differential to frame (45 lbf•ft ± 7 lbf•ft)
vmr2017-127 11
Refill front differential with recommended oil. Re- TIGHTENING TORQUE

fer to PERIODIC MAINTENANCE PROCEDURES
subsection. 75 N•m ± 5 N•m
Propeller shaft screws +
FRONT PROPELLER SHAFT LOCTITE 648 (GREEN)
(P/N 413 711 400)
Removing the Front Propeller Shaft
1. Lift and support vehicle.
2. Remove front wheel. Refer to WHEELS AND
PROPELLER SHAFT U-JOINTS
TIRES subsection. Removing the Propeller Shaft U-Joint
3. Remove inner fender panel(s). Refer to BODY Remove internal snap ring from bearing caps.
subsection.
4. Remove front differential. Refer to REMOVING
THE FRONT DIFFERENTIAL in this subsection.
5. Remove screw securing front propeller shaft to
coupling unit.
V01H0YA 1
1. Snap ring
Support inner yoke in vice and drive other yoke

down with a soft hammer.
vmr2015-074-006_a
NOTE: Heat screw to break the threadlocker

bond prior to removal.
6. Remove front propeller shaft by pulling it for-
ward.
Inspecting the Front Propeller Shaft

Inspect if propeller shaft is not bent or twisted.
Check propeller shaft splines for wear or damage.
Check if propeller shaft bellows is pierced or brit-
tle.
V01H0ZA
Installing the Front Propeller Shaft
The installation is the reverse of removal proce- Support U-joint in vice and drive inner yoke down
dure. However, pay attention to the following: to remove remaining bearing caps.
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on Remove U-joint cross.
splines.
Installing the Propeller Shaft U-Joint
Install new U-joint in inner yoke.
12 vmr2017-127
V01H10A
TYPICAL
Install bearing caps. Use a vise to push bearing

caps.
V01H11A
TYPICAL
Using a suitable pusher, fully seat bearing cap on

one side.
V01H12A
TYPICAL
Install snap ring.

Complete installation for the other bearing caps.
vmr2017-127 13
Subsection XX (REAR DRIVE (450 / 570))
REAR DRIVE (450 / 570)

SERVICE TOOLS
BACKLASH MEASUREMENT TOOL............................................. 529 035 665 ............................................. 9
CV BOOT CLAMP PLIER .............................................................. 529 036 120 ............................................. 5
CV JOINT EXTRACTOR................................................................. 529 036 005 ............................................. 5
SPANNER SOCKET ....................................................................... 529 035 649 ........................................... 12
SERVICE PRODUCTS
LOCTITE 277 ................................................................................. 293 800 073 ........................................... 14
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ............................................. 8
XPS SYNTHETIC GREASE............................................................. 293 550 010 ......................................... 4, 7
vmr2017-128 1
DRIVE SHAFTS AND PROPELLER SHAFT
XPS Synthetic NEW

grease
NEW
NEW
XPS Synthetic
205 ± 15 N•m grease
(151 ± 11 lbf•ft)
NEW
90 ± 5 N•m
(66 ± 4 lbf•ft)
NEW XPS Synthetic
XPS grease
Synthetic
grease
NEW
Loctite
648
Hi-temp bearing grease
NLGI-2 or equivalent
75 ± 5 N•m
(55 ± 4 lbf•ft)
Loctite
648
NEW
NEW XPS Synthetic

grease NEW
205 ± 15 N•m
(151 ± 11 lbf•ft)
NEW

vmr2017-128-101_a
2 vmr2017-128
REAR FINAL DRIVE
NEW XPS synthetic

grease
For preload
adjustment
32 ± 3 N•m
(24 ± 2 lbf•ft)
NEW For backlash

adjustment
22.5 ± 2.5 N•m
(17 ± 2 lbf•ft)
NEW
NEW
180 ± 15 N•m
(133 ± 11 lbf•ft) NEW NEW
LH threads
5 ± 1 N•m
(44 ± 9 lbf•in)
Loctite 277
XPS synthetic
grease
NEW NEW

vmr2015-052-102_a
vmr2017-128 3
PROCEDURES
WHEEL HUB
Removing the Wheel Hub
Lift and support vehicle.
Remove the wheel.
Remove the following parts:
– Caliper mounting bolts (if applicable), refer to
BRAKES subsection
– Hub cap
– Cotter pin
– Wheel hub nut vmr2012-037-004
– Belleville washer.
Installing the Wheel Hub Installation
drive shaft splines.
Install Belleville washer with its convex side out-
ward.
vmr2012-037-003_a
1. Caliper
2. Remove bolts
Remove wheel hub.
Inspecting the Wheel Hub

Remove disk from RH wheel hub as necessary. vmr2012-037-005_a
Check wheel hub for cracks or other damages. 1. Wheel hub

2. Washer — Convex side here
Check inner splines for wear or other damages. 3. Nut
If any damage is detected on wheel hub, replace TIGHTENING TORQUE
it with a new one.
205 N•m ± 15 N•m
Wheel hub nut
NOTE: If required, tighten castle nut further to

align grooves with drive shaft hole.
Install a NEW cotter pin, bend as shown.
4 vmr2017-128
Installing the Drive Shaft

Install a NEW stop ring.
tmr2017-108-001_a
1. Cotter pin correctly bent

2. Domed (convex) side here
DRIVE SHAFT V07H0AA
Removing the Drive Shaft TYPICAL

1. NEW stop ring
After drive shaft insertion in rear final drive, vali-

date if properly locked.
DRIVE SHAFT BOOT

Removing the Drive Shaft Boot
Remove the drive shaft from vehicle. See proce-
Remove drive shaft boot clamps using the follow-
ing tool:
REQUIRED TOOL
CV BOOT CLAMP PLIER
(P/N 529 036 120)
vmr2012-037-014_a
TYPICAL
1. Drive shafts Dislodge the large boot end.
Separate the joint from the shaft. Two procedures
can be done.
Remove the wheel hub. See procedure in this
subsection. Without the Special Tool
Remove trailing arm. Refer to REAR SUSPEN- Clamp joint housing in a vise.
SION. Align shaft with joint.
Strongly pull drive shaft out of final drive. Pull hard on shaft to remove from joint.
Remove boot from drive shaft.
Inspecting the Drive Shaft
Remove and discard the circlip. A new one is in-
Inspect the condition of boots. If there is any dam-
age or evidence of leaking lubricant, replace them.
Refer to DRIVE SHAFT BOOT. With the Special Tool
Check shaft splines. Replace drive shaft if neces- Place drive shaft in vice with the joint downward.
sary. Install the CV JOINT EXTRACTOR (P/N 529 036 005)
Check dust shield on drive shaft end. Replace if on bearing.
necessary.
vmr2017-128 5
PROPELLER SHAFT
Removing the Propeller Shaft
529036005
vmr2007-053-010_b
TYPICAL — CV JOINT SHOWN vmr2012-037-014_b

1. Joint extractor tool
TYPICAL
1. Propeller shaft
With an hammer, hit on the tool to separate joint
from shaft. 1. Lift and support rear end of vehicle.
When joint and shaft are separated, remove boot 2. Remove wheels. Refer to WHEELS AND
from drive shaft. TIRES subsection.
Remove and discard the circlip. A new one is in- 3. Drain oil from rear final drive. Refer to PERI-
cluded in the boot kit. ODIC MAINTENANCE PROCEDURES.
Remove drive shaft boot. 4. Detach brake master cylinder from frame. Re-
fer to BRAKES subsection.
Installing the Drive Shaft Boot
Pack bearing area with grease (included with the
new boot kit).
NOTE: Do not use any other grease.
vmr2012-037-006_a
1. Remove retaining screws
6 vmr2017-128
vmr2015-052-001_a
vmr2012-037-007_a LH SIDE OF VEHICLE

1. Master cylinder moved apart
7. Remove rear final drive retaining bolts. Refer to
5. From RH side of vehicle, remove propeller shaft REAR FINAL DRIVE in this subsection.
screw from gearbox output shaft. 8. Remove bolts from rear retaining plate. Refer
NOTE: Heat screw to break the threadlocker to REAR FINAL DRIVE in this subsection.
bond prior to removal. 9. Move the rear final drive rearward to allow dis-
lodging the propeller shaft.
10. Dislodge the propeller shaft from the gearbox.
11. Remove the propeller shaft.
vmr2012-037-008_a
TYPICAL — RH SIDE OF VEHICLE

1. Remove screw
6. From LH side of vehicle, remove propeller shaft

screw from rear final drive yoke. vmr2012-037-012_a
1. Pull out propeller shaft
Inspecting the Propeller Shaft

Inspect if propeller shaft is not bent or twisted.
Check propeller shaft splines for wear or damage.
Check if propeller shaft bellow is cracked, pierced
or brittle.
Installing the Propeller Shaft

Apply XPS SYNTHETIC GREASE (P/N 293 550 010) to
splines.
vmr2017-128 7
On the engine side, Install the Belleville with the

notches towards the screw head.
V01H0ZA
tmr2017-109-001
TYPICAL
Support U-joint in vice and drive inner yoke down
to remove remaining bearing caps.
TIGHTENING TORQUE Remove U-joint cross.
75 N•m ± 5 N•m
(55 lbf•ft ± 4 lbf•ft) Installing the Propeller Shaft U-Joint
Propeller shaft screws + Install a NEW U-joint in inner yoke.
LOCTITE 648 (GREEN)
(P/N 413 711 400) NOTE: Position propeller shaft U-joint as shown
for proper grease fitting location.
Refill rear final drive. Refer to PERIODIC MAINTE-
PROPELLER SHAFT U-JOINTS

Removing the Propeller Shaft U-Joint
Remove internal snap ring from bearing caps.
V01H10A
Install bearing caps. Use a vise to push bearing

caps.
V01H0YA 1
1. Snap ring
Support inner yoke in vice and drive other yoke

down with a soft hammer.
V01H11A
8 vmr2017-128
Using a suitable pusher, fully seat bearing cap on

one side.
vmr2015-052-003_a
Unplug the vent hose from final drive.

V01H12A
Install snap ring.

Complete installation for the other bearing caps.
Grease U-joint. Refer to PERIODIC MAINTE-
REAR FINAL DRIVE

Removing the Rear Final Drive
Drain oil. Refer to PERIODIC MAINTENANCE
Support rear bottom end of frame. vmr2012-037-015_a
1. Pull out
Remove drive shafts. See procedure in this sub-
section. Remove the final drive.
Remove rear propeller shaft screw from the rear
final drive yoke. Refer to PROPELLER SHAFT in Inspecting the Rear Final Drive
this subsection. (Assembled)
Remove rear final drive screws (5x). Manually turn rear final drive gear; it should turn
smoothly. Repair if necessary.
Check if oil seals are brittle, hard or damaged. Re-
place if necessary.
Measuring the Backlash
Using a dial indicator and the BACKLASH MEA-
SUREMENT TOOL (P/N 529 035 665), measure the
backlash.
Place the backlash measurement tool at the end
of pinion gear.
From center of tool bolt, measure 25.4 mm (1 in)
and scribe a mark on the tab.
vmr2015-052-002_a
Remove bolts from rear retaining plate.
vmr2017-128 9
BACKLASH ADJUSTMENT GUIDELINE

BACKLASH
WHAT TO DO
MEASUREMENT
Add shim(s) and recheck
Below 0.1 mm (.004 in)
backlash
Remove shim(s) and
Above 0.35 mm (.014 in)
recheck backlash
vmr2006-023-015_a
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 tool tab back and forth. Note the
backlash result.
vmr2015-052-004_a
1. Backlash shim
Measuring the Preload

Screw the propeller shaft screw in pinion gear.
vmr2006-023-016
Rotate pinion gear 1/2 turn and recheck backlash.

Note the result.
Rotate pinion gear 1 turn and recheck backlash.
BACKLASH SPECIFICATION
vmr2015-052-005_a
0.1 mm (.004 in) to 0.35 mm (.014 in)
Using a needle torque wrench, measure the
If backlash is out of specification, split final drive preload.
housing and adjust shim thickness as per follow-
ing guideline.
10 vmr2017-128
vmr2015-052-006_a
PRELOAD SPECIFICATION vmr2015-052-007_a
0.06 N•m (.5 lbf•in) to 0.50 N•m (4 lbf•in)

Split final drive housings.
If preload is out of specification, split final drive NOTE: Be careful to keep track of shims on ring
housing and adjust shim thickness as per follow- gear.
ing guideline.
PRELOAD GUIDELINE
PRELOAD
WHAT TO DO
MEASUREMENT
Below 0.06 N•m Add shim(s) and recheck
(.5 lbf•in) preload
Above 0.50 N•m Remove shim(s) and
(4 lbf•in) recheck preload
vmr2015-052-004_c
1. Backlash shim
2. Preload shim
3. Ring gear
Extract ring gear out of half housing.

Pinion Gear
Remove and discard oil seal.
vmr2015-052-004_b
1. Preload shim
Disassembling the Rear Final Drive

Ring Gear
Remove the final drive housing screws.
vmr2015-052-008_a
vmr2017-128 11
Unscrew the pinion nut. Use the SPANNER

SOCKET (P/N 529 035 649).
529035649
vmr2015-052-011_a
1. O-ring
2. Ball bearing
3. Pinion gear shim
4. Pinion gear
The pinion gear and bearing can be easily removed

using the following suggested tool:
PART QTY
vmr2015-052-009_a Pipe: 83 mm (3-1/4 in) diameter x 127 mm
1
(5 in)
NOTE: The pinion nut is left hand threaded. Un-
Threaded rod: M10 x 1.25 x 178 mm (7 in) 1
screw by turning clockwise.
Remove the bearing along with the pinion gear. M10 x 1.25 nut 3
Be careful to keep track of shims. Discard bear- Flat bar 1
ing.
Remove and discard the needle bearing.
vmr2015-052-010_a
vmr2015-052-012_a
Assembling the Rear Final Drive

Adjustment is required when any of the following
part is changed.
– Pinion gear
– Ring gear
– Housing.
As a preliminary setup, install shims according to
the following table.
12 vmr2017-128
RECOMMENDED SHIM THICKNESS

See procedure for pinion gear
PINION GEAR
shim thickness
BACKLASH 0.5 mm (.02 in)
PRELOAD (as a preliminary adjustment)
Procedure for pinion gear shim thickness:

1. Remove the old pinion gear and install the new
one without the ball bearing. The new pinion
will be located at the "zero" location.
2. Measure the distance "A" between outside sur-
face of the gear case and the shim surface of
pinion.
3. Measure the distance "B" between outside sur- vmr2015-052-015_a
face of the gear case and the bearing shoulder 1. Backlash side
2. Preload side
of the gear case.
4. The shim thickness will be "A-B-0.53 mm
(.021 in)".
5. Select the good combination of shim to match
the thickness calculated on step 4.
B
vmr2015-052-004_a
1. Backlash shim
vmr2015-052-016_a
vmr2015-052-004_b
1. Preload shim
Prior to finalizing assembly, proceed in this order:

– Temporarily assemble final drive using recom-
mended torques.
– Do not apply thread locker product.
– Do not install a new pinion nut.
vmr2017-128 13
– Check backlash. Install the shim(s) then a NEW ball bearing.

– Check preload. install a NEW O-ring.
Ring Gear Apply LOCTITE 277 (P/N 293 800 073) to pinion nut.
The installation is the reverse of the removal pro- Install and tighten the pinion nut as per specifica-
cedure. However, pay attention to the following: tion.
Check condition of seal. Replace if damaged. TIGHTENING TORQUE
180 N•m ± 15 N•m
Pinion nut
+
(LH THREADS)
800 073)
Lubricate and install a NEW oil seal.
Installing the Rear Final Drive

Install the lowest rear final drive retaining screws
first.
Install all screws and nuts prior to tighten.
Tighten nuts to specification.
vmr2015-052-013_a
TIGHTENING TORQUE
Install NEW bearings.
90 N•m ± 5 N•m
Final drive retaining nuts
Refill the final drive with recommended oil. Re-

fer to PERIODIC MAINTENANCE PROCEDURES
subsection.
vmr2015-052-014_a
Tighten final drive housing screws as per specifi-

cation.
TIGHTENING TORQUE
Final drive housing 32 N•m ± 3 N•m
Pinion Gear
Install a NEW needle bearing.
14 vmr2017-128
Section 08 CHASSIS
Subsection 01 (WHEELS AND TIRES)
WHEELS AND TIRES

SERVICE PRODUCTS
PROCEDURES
TIRES
WARNING
Do not rotate tires. The front and rear tires
have a different size. Respect direction of ro-
tation when applicable.
Tire Pressure
WARNING tmr2011-033-002_a
TYPICAL
Tire pressure greatly affects vehicle handling 1. Direction of rotation
and stability. Insufficient pressure may cause
tire to deflate and rotate on wheel. Excessive
pressure may burst the tire. Always follow WHEELS
recommended pressure. Wheel Removal
Loosen nuts just enough to be able to unscrew
Check pressure when tires are cold before us- them once the vehicle will be off the ground.
ing the vehicle. Tire pressure changes with tem-
perature and altitude. Recheck pressure if one of Lift and support the vehicle.
these conditions has changed. Remove nuts, then remove wheel.
TIRE PRESSURE FRONT REAR
Wheel Inspection
41.4 kPa 41.4 kPa Inspect wheel for wear or damage especially at
MIN.
(6 PSI) (6 PSI)
the mounting holes.
MAX.
Use when total 48.3 kPa 68.9 kPa Wheel Installation
load is greater than (7 PSI) (10 PSI)
At installation, it is recommended to apply LOC-
131.5 kg (290 lb)
TITE 767 (ANTISEIZE LUBRICANT) (P/N 293 800 070)
on threads.
Tire Inspection Check if tires are unidirectional.
Check tire for presence of slits, bulges, wear or
other damage. Replace if necessary.
Tire Replacement
Use an automotive tire changer to replace tires.
WARNING
– Replace tires only with the same type and
size as original tires.
– For unidirectional tread pattern, ensure
that the tires are installed in the correct
direction of rotation.
vmr2015-053 627
Section 08 CHASSIS
Subsection 01 (WHEELS AND TIRES)
tmr2011-033-002_a
TYPICAL
1. Direction of rotation
Install wheel with the tire in the right direction of

rotation.
Install lug nuts with the taper towards the wheel.
Tighten wheel lug nuts to the specified torque us-
ing the illustrated sequence.
WHEEL LUG NUTS
100 N•m ± 10 N•m
TORQUE
vmr2012-038-004_a
TYPICAL - TIGHTENING SEQUENCE
NOTICE Always use the recommended

wheel nuts for the type of wheel. Using a
different nut could cause damages to the rim
or studs.
628 vmr2015-053
Subsection XX (STEERING SYSTEM (OUTLANDER 450 / 570))
STEERING SYSTEM
(OUTLANDER 450 / 570)
SERVICE TOOLS
STEERING ALIGNMENT TOOL..................................................... 529 036 059 ............................................. 4

SMOOTHFLOW™ TAPERED TIP.................................................. 16 ga ............................................. 5
#511 rtt-b
SERVICE PRODUCTS
LOCTITE 406 (GLUE)..................................................................... 293 800 100 ............................................. 5
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ..................................... 11, 14
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ............................................. 5
vmr2017-112 1
Without DPS
Loctite
406
Europe
Loctite
406
XPS NEW
Synthetic
grease NEW
NEW
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
Loctite
243
NEW
NEW
72.5 ± 7.5 N•m

(53 ± 6 lbf•ft)
Loctite 767
72.5 ± 7.5 N•m

(53 ± 6 lbf•ft)
NEW
57.5 ± 7.5 N•m
(42 ± 6 lbf•ft)

vmr2015-054-100_a
2 vmr2017-112
With DPS
Europe
Loctite
406
Loctite
406
NEW
XPS
Synthetic NEW
grease
NEW
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
NEW
NEW
72.5 ± 7.5 N•m
(53 ± 6 lbf•ft)
NEW
72.5 ± 7.5 N•m
72.5 ± 7.5 N•m (53 ± 6 lbf•ft)
NEW (53 ± 6 lbf•ft)
72.5 ± 7.5 N•m

NEW = Component must be replaced when removed. NEW (53 ± 6 lbf•ft)
vmr2017-112-101_a
vmr2017-112 3
GENERAL
The procedures described below are the same for
the RH and LH sides, unless otherwise instructed.
ADJUSTMENT
ALIGNING THE WHEELS
1. Place vehicle on a level surface.
vmr2008-068-006_a
2. Check pressure in each tire. Adjust to recom- TYPICAL
mended pressure. 1. Steering adjustment tool
2. Angle gauge or level
3. Lift and secure vehicle off the ground so that
the suspension is fully extended. 10. At the LH front of wheel, near the front of the
4. Remove both inner fenders to have easy ac- rim, pull on the rope so that it does not touch
cess to pitman arm. the first spacer block on the alignment tool.
5. Center pitman arm by measuring equal dis-
tances, ±1mm, between the edges as per
the following illustration, on both sides of the
pitman arm.
vmr2008-068-005_a
TYPICAL
vmr2016-059-001_a
A. Equal distance ± 1 mm (1/32 in) on both sides

11. Slowly move rope back until it just makes con-
1. Steering column lower attach tact with both spacers.
2. Pitman arm
NOTE: Ensure rope remains in this position as
6. Secure handlebar without moving steering col- you carry out the following steps.
umn.
7. Remove two wheel nuts on the LH rear wheel
and install the steering alignment tool.
REQUIRED TOOL
STEERING ALIGNMENT
TOOL (P/N 529 036 059)
8. Place a rope around all four tires using an elas-

tic, link both ends together. vmr2008-068-007
NOTE: The rope must be placed at the center of TYPICAL

the wheels.
12. Measure the distance between the rope and
9. Rotate the rear wheel to position the alignment the rim, at the front and at the rear of the
tool level with the rope. Ensure rope passes wheel rim.
over the spacer blocks on the alignment tool.
4 vmr2017-112
tmr2011-034-107_a
A. Maximum unengaged length
14.3 Tighten tie-rod end lock nuts to specifica-

vmr2008-068-008
tion.
TYPICAL — FRONT OF WHEEL TIGHTENING TORQUE
34 N•m ± 2 N•m
Tie-rod end locking nut
15. Repeat procedure for other front wheel.

16. Put the vehicle back on the ground.
17. Remove the handlebar securing device.
18. Place the front wheels in straight ahead posi-
tion and adjust the handlebar in its center posi-
tion by loosening the 4 bolts clamping the han-
dlebar on the steering column.
vmr2008-068-009
TYPICAL — REAR OF WHEEL PROCEDURES

13. Calculate the difference between the front
and rear measurements and compare with HANDLEBAR GRIP
following specification. Removing the Handlebar Grip
SPECIFICATION 1. Loosen the screw at the end of handlebar grip.
0 mm to 3 mm (0 in to .118 in) toe-in 2. Remove the handlebar grip cap.
3. Cut and remove the handlebar grip.
14. If the wheel toe measurement is out of spec-
ification, carry out the following: Installing the Handlebar Grip
14.1 Loosen tie-rod end lock nuts. 1. Remove all rubber residues of the old grip be-
14.2 Adjust tie-rod length. fore installing the new.
NOTE: For a toe-in adjustment, the dis- 2. Clean the handlebar with PULLEY FLANGE
tance must be longer at the front of the CLEANER (P/N 413 711 809) or alcohol to remove
wheel. Lengthen tie-rod to increase toe-in, any greasy matter on it.
and vise-versa. 3. Install handlebar grip by blowing compressed
air between handle grip and handlebar.
WARNING
4. Install a SMOOTHFLOW™ TAPERED TIP
The maximum unengaged tie-rod
(P/N 16 GA #511 RTT-B) from EFD Inc on a
length must not exceed 32 mm
bottle of LOCTITE 406 (GLUE) (P/N 293 800 100).
(1-1/4 in) Tie rod unengaged length
must be the same at both ends of the 5. Lift a part of the grip using a small screwdriver
tie-rod. and inject glue (about 4 spots per side).
NOTE: The glue dries quickly. Do not apply it be-
fore installing grip.
6. Apply pressure on the grip for approximately
30 seconds to set the glue.
7. Install the handlebar grip cap and tighten
screws to specification.
vmr2017-112 5
TIGHTENING TORQUE STEERING CONNECTORS

Handlebar grip cap screw 0.4 N•m (3.5 lbf•in) Steering Connector Access
1. Remove gauge support, refer to GAUGE sub-
HANDLEBAR COVER section.
Removing the Handlebar Cover

Pull on plastic handlebar cover to remove it from
the handlebar.
Inspecting the Handlebar Cover

Check covers for cracks or other damages. Re-
place if necessary.
Installing the Handlebar Cover

cedure.
vmr2015-054-002_a
HANDLEBAR
2. Remove front body module, refer to body sub-
Removing the Handlebar section.
1. Remove handlebar cover. 3. Remove dash board support.
NOTE: Remove handlebar grips, throttle handle,
brake handle and multifunction switch only if the
handlebar is defective and requires replacement.
2. Remove handlebar mounting screws.
vmr2012-033-001_a
1. Dash board support
vmr2015-054-003_a
Inspecting the Handlebar

Inspect the handlebar for damage, cracks or bend-
ing. Replace if any of these problems is detected.
Installing the Handlebar

cedure.
NOTE: Ensure handlebar "U" clamps are tightened
equally (equal distance on each side of clamps).
6 vmr2017-112
Steering Connector Identification 4. Take note of the positions of the locking ties
securing the steering harness, then cut them
and remove the multifunction switch steering
harness from the vehicle.
Installing the Multifunction Switch

NOTICE Be sure to route and secure the mul-
tifunction switch steering harness as noted
prior to removal.
THROTTLE LEVER
Removing the Throttle Lever
1. Disconnect the HIC1 connector (2/4WD
vmr2015-054-001_a
switch), refer to STEERING CONNECTORS
STEERING CONNECTOR IDENTIFICATION
1. MG1 (LH multifunction switch) in this subsection.
2. MG2 (LH multifunction switch)
3. MG3 (LH multifunction switch) 2. Remove throttle lever housing retaining
4. DC3 (DC power connector) screws.
5. HIC1 (Engine interconnect)
1
MULTIFUNCTION SWITCH
Removing the Multifunction Switch
From the Vehicle
Remove gauge support. Refer to GAUGE subsec-
tion.
Carry out steps in REMOVING THE MULTIFUNC-
TION SWITCH (AT HANDLEBAR).
Removing the Multifunction Switch (At
Handlebar)
1. Remove multifunction switch screws.
V07I0FA
TYPICAL - THROTTLE LEVER HOUSING

1. Remove retaining screws
3. Separate throttle lever housing from handlebar.

4. Slide rubber protector back to expose throttle
vmr2012-039-006_a
cable adjuster.
TYPICAL - MULTIFUNCTION SWITCH
2. Separate multifunction switch from handlebar.

3. Disconnect multifunction switch steering con-
nectors, refer to STEERING CONNECTOR
IDENTIFICATION in this subsection:
– MG1
– MG2
– MG3.
vmr2017-112 7
V07I0GA 1 2 3 4
1. Cable protector
3. Lock nut
4. Throttle lever housing V07I0IA
5. Loosen lock nut and screw in the throttle cable

adjuster. 8. Remove throttle cable from housing.
6. Remove inner housing protector. Installing the Throttle Lever
cedure.
Adjust throttle cable. Refer to THROTTLE CABLE
ADJUSTMENT in ELECTRONIC FUEL INJECTION
(EFI) subsection.
BRAKE LEVER
Removing the Brake Lever From the
Vehicle
1. Carry out steps in REMOVING THE BRAKE
LEVER (AT HANDLEBAR).
NOTICE Avoid spilling brake fluid on plastic,
rubber or painted parts.
V07I0HA 1
2. Disconnect brake hose, refer to BRAKES sub-
section.
7. Slide cable in clip slot and remove the end of
the cable from clip. Removing the Brake Lever (At
Handlebar)
1. Remove brake lever retaining screws.
8 vmr2017-112
vmr2008-068-004_a
TYPICAL
1. Remove these retaining screws
2. Separate brake lever from handlebar. vmr2012-033-001_a
1. Dash board support

Installing the Brake Lever
The installation is the reverse of the removal pro- 4. Remove the air intake silencer. Refer to AIR IN-
cedure. However, pay attention to the following: TAKE SYSTEM subsection.
Tighten brake lever mounting screw to specifica- 5. Remove handlebar, refer to REMOVING THE
tion. HANDLEBAR in this subsection. Also remove
locking ties and separate wiring harnesses and
TIGHTENING TORQUE hoses from the steering column.
Brake lever mounting 9 N•m ± 1 N•m 6. Disconnect the tie-rods from the pitman arm at
screw (80 lbf•in ± 9 lbf•in) the bottom of the steering column. Refer to
TIE-ROD in this subsection.
WARNING
If brake hose was disconnected, bleed brake
system. Refer to BRAKES subsection.
STEERING COLUMN
Removing the Steering Column
(Without DPS)
section.
2. Refer to BODY subsection to remove the fol-
lowing:
– Front body module
– Inner fender panels
vmr2015-054-004_a
3. Remove dash board support. 1. Steering column
2. Pitman arm
3. Tie-rod end
4. Cotter pin
5. Tie-rod retaining nut
NOTE: When removing tie-rods from pitman arm,

take note of positions of flat washers for installa-
tion.
7. Remove lower half bushing retaining screws
and pull retainer off of half bushings.
vmr2017-112 9
vmr2012-033-001_a
vmr2015-054-005_a 1. Dash board support

1. Lower retainer mounting screws (2)
2. Lower half bushing retainer 4. Remove the air intake silencer. Refer to AIR IN-
3. Steering column
4. Pitman arm TAKE SYSTEM subsection.
5. Remove handlebar, refer to REMOVING THE
8. Remove upper half bushing retaining screws HANDLEBAR in this subsection. Also remove
and pull retainer off of half bushings. locking ties and separate wiring harnesses and
hoses from the steering column.
6. Remove steering column pinch bolt. Discard
the nut.
vmr2012-039-010_a
1. Upper steering column support

2. Half bushings vmr2017-113-007
3. Half bushing retainer
4. Retainer mounting screws (2)
7. Remove upper half bushing retaining screws
9. Pull steering column from vehicle. and pull retainer off of half bushings.
Removing the Steering Column (With

DPS)
section.
lowing:
– Front body module
– Inner fender panels
3. Remove dash board support.
10 vmr2017-112
3. Remove seal.
vmr2012-039-010_a
1. Upper steering column support

2. Half bushings
3. Half bushing retainer vmr2015-054-011_a
4. Retainer mounting screws (2)
8. Pull steering column from vehicle. 4. Install a NEW seal.

5. Install a NEW ball bearing.
Inspecting the Steering Column
1. Inspect steering column for wear, cracks or Installing the Steering Column
bending. Replace if any of these problems is The installation is the reverse of the removal pro-
detected. cedure. However, pay attention to the following:
2. Check steering column O-rings and seal for brit- PRODUCT
tleness, hardness, wear or other damage. Re-
O-rings and half XPS SYNTHETIC GREASE
place if necessary.
bushings (P/N 293 550 010)
3. Clean and check steering column half bushings.
If they show signs of wear or cracking, replace DPS output and
LOCTITE 767 (ANTISEIZE
output shaft
them. splines
LUBRICANT) (P/N 293 800 070)
Models Without a DPS
Install NEW cotter pins (as applicable per model).
4. Check if steering column lower ball bearing Both ends of cotter pins must be folded.
turns freely and smoothly. Replace if neces-
sary. Install NEW elastic nuts where used.
Torque all fasteners as specified in the applicable
Replacing the Steering Column Lower exploded view.
Ball Bearing and Seal (Without a DPS) Carry out a steering alignment, refer to ALIGNING
1. Remove the pitman arm. Refer to PITMAN THE WHEELS in this subsection.
ARM in this subsection. Reset the torque sensor offset, refer to RESET-
2. Remove ball bearing. TING THE TORQUE OFFSET in the appropriate
DYNAMIC POWER STEERING (DPS) subsection.
TIE-ROD
NOTE: Use the same procedure for RH and LH
side.
Removing the Tie-Rod

1. Place vehicle on jack stands and remove the ap-
plicable wheel.
vmr2015-054-010_a
vmr2017-112 11
2. Remove tie-rod end from steering knuckle by Installing the Tie-Rod

removing: The installation is the reverse of the removal pro-
– Cotter pin (discard) cedure. However, pay attention to the following:
– Retaining nut When installing a new tie-rod or tie-rod end, adjust
– Hardened washers. tie-rod to nominal length.
TIE-ROD NOMINAL LENGTH
Dimension "A" - 416.4 mm
center to center (16-3/8 in)
rmr2008-028-015_a
NOMINAL LENGTH
1. Pitman arm side
2. Knuckle side
A. 416.4 mm (16-3/8 in)
vmr2012-039-012_a
TIE-ROD MAXIMUM UNENGAGED LENGTH
TIE ROD AT STEERING KNUCKLE
1. Cotter pin Dimension "A" - Shoulder
2. Retaining nut 32 mm (1-1/4 in)
3. Hardened washers to tie rod end face
3. If completely removing tie-rod from vehicle, re- WARNING

peat previous step at pitman arm.
Maximum tie-rod unengaged length must
not exceed specification. Both tie-rod ends
must be engaged equally.
tmr2011-034-107_a
MAXIMUM TIE-ROD UNENGAGED LENGTH

A. 32 mm (1-1/4 in)
Install NEW cotter pins. Both ends of cotter pins

vmr2015-054-004_a must be folded.
TIE ROD AT PITMAN ARM Check the steering alignment, refer to ALIGNING
1. Steering column
2. Pitman arm THE WHEELS in this subsection.
3. Tie-rod end
4. Cotter pin Apply specified torques.
5. Tie-rod end retaining nut
TIGHTENING TORQUE
Inspecting the Tie-Rod 34 N•m ± 2 N•m
Tie-rod lock nut
Inspect tie-rod for straightness, cracks and other (25 lbf•ft ± 1 lbf•ft)
damages. Replace as required. 72 N•m ± 7 N•m
Tie rod end retaining nut
Inspect tie-rod ends for wear or excessive play. If (53 lbf•ft ± 5 lbf•ft)
excessive, replace the tie-rod end.
12 vmr2017-112
KNUCKLE Inspecting the Wheel Bearing (During

Component Removal)
Removing the Knuckle
Whenever the drive axle or knuckle is removed,
1. Safely lift and support the front of vehicle. check if wheel bearing turns freely and smoothly.
2. Remove front wheel. Replace if necessary.
3. Detach tie-rod end from knuckle, refer to TIE-
ROD in this subsection. Removing the Wheel Bearing
4. Remove brake caliper, refer to BRAKES subsec- 1. Remove knuckle from vehicle, refer to REMOV-
tion. ING THE KNUCKLE in this subsection.
5. Remove wheel hub, refer to the appropriate 2. Remove the circlip.
FRONT DRIVE subsection.
vmr2017-112-001_a
1. Circlip
vmr2015-054-006
3. Install knuckle on a press.

6. Detach upper suspension arm from knuckle, re-
fer to FRONT SUSPENSION. 4. Remove bearing from knuckle using an appro-
priate bearing remover.
7. Detach lower suspension arm from knuckle, re-
fer to FRONT SUSPENSION.
8. Remove knuckle from vehicle.
Inspecting the Knuckle

Check knuckle for cracks or other damages. Re-
place if necessary.
Check if wheel bearing turns freely and smoothly.
See WHEEL BEARINGS in this subsection.
Installing the Knuckle

cedure.
Refer to applicable subsection.
tmr2011-034-109
TYPICAL
WHEEL BEARINGS
NOTE: It may be necessary to heat the knuckle to
Inspecting the Wheel Bearing remove bearing.
(Maintenance)
Refer to PERIODIC MAINTENANCE PROCE- WARNING
DURES subsection. Clean all grease from outside and inside of
knuckle before heating it.
vmr2017-112 13
Installing the Wheel Bearing

To ease wheel bearing installation:
– Place bearing in a freezer for 10 minutes.
– Place knuckle in oven to 100°C (212°F) for
30 minutes maximum.
When knuckle is cooled down, install NEW circlip.
PITMAN ARM (WITHOUT DPS)

Removing the Pitman Arm
1. Remove tie rod ends from pitman arm. Refer vmr2015-054-009_a
to TIE ROD in this subsection.
2. Remove and discard cotter pin. Inspecting the Pitman Arm
Inspect pitman arm for cracks or other damages.
Check pitman arm splines for excessive wear. Re-
place if necessary.
Installing the Pitman Arm

Installation is the reverse of the removal. How-
PRODUCT
Steering column LOCTITE 767 (ANTISEIZE
splines LUBRICANT) (P/N 293 800 070)
Tighten the pitman arm retaining nut to specifica-

tion.
vmr2015-054-007_a
TIGHTENING TORQUE
3. Remove pitman arm retaining nut and washer.
57.5 N•m ± 7.5 N•m
Pitman arm retaining nut
Install a NEW cotter pin. Both ends of cotter pins

must be folded.
PITMAN ARM (WITH A DPS)

Refer to the appropriate DYNAMIC POWER
STEERING (DPS) subsection.
vmr2015-054-008_a
4. Remove pitman arm.
14 vmr2017-112
Subsection XX (DYNAMIC POWER STEERING (DPS) - 1-CONNECTOR TYPE)
DYNAMIC POWER STEERING (DPS) -

1-CONNECTOR TYPE
SERVICE PRODUCTS
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ..................................... 10, 12
24 ± 3.5 N•m
NEW
24 ± 3.5 N•m
(18 ± 3 lbf•ft)
Loctite 767
(antiseize lubricant)
XPS Synthetic
grease
XPS Synthetic
grease NEW
22 ± 2 N•m
(16 ± 1 lbf•ft)
24 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW
NEW NEW
24 ± 3.5 N•m 24 ± 3.5 N•m
(18 ± 3 lbf•ft) (18 ± 3 lbf•ft) XPS Synthetic
grease
vmr2017-113-101_a
vmr2017-113 1
GENERAL The greater the power steering assist, the greater

the load on the electrical system.
NOTICE Never perform arc welding in the
DPS area. Otherwise, poor DPS operation When the electrical system is under high load
might occur. (battery not at full charge, operating the vehicle
for prolonged periods of time at slow speed and
low RPM which, requires higher power steering
SYSTEM DESCRIPTION assist), the battery power reserve will gradually
(FEATURES) decrease. This further increases the load on the
charging system and the electrical system volt-
The Dynamic Power Steering (DPS) provides
age will drop. As system voltage drops, so does
a computer controlled, variable power assist,
power steering assist.
achieved by an electric motor to optimize the
amount of steering input required by the rider. NOTE: It is important to maintain the battery at
a full state of charge to ensure proper DPS oper-
ation. The magneto output is 650 watts to mini-
mize battery drain and system voltage drop.
DPS Assist Mode

The DPS system provides three rider selectable
modes of operation.
NOTE: The system automatically adjusts to the
speed of the vehicle and driving conditions. the
modes are designed to meet the preference of
the rider.
The following DPS modes are preset in the vehi-
cle.
vmr2017-113-004
DPS MODE
The DPS system uses the following parameters to
DPS MAX. Maximum steering assist
determine how much steering assist it provides:
– Engine RPM DPS MED. Medium steering assist
– Battery/electrical system voltage DPS MIN. Minimum steering assist
– Vehicle speed
– DPS shaft torque sensor input. A fourth mode of operation is available as an ac-
cessory to adjust the steering assist level for op-
– DPS internal temperature.
eration with an approved BRP track kit.
The amount of steering assist provided is depen-
dent on the handlebar effort (steering torque), DPS SYSTEM DESCRIPTION
electrical power available, and vehicle speed.
(COMPONENTS)
The greater the handlebar effort (torque), the
greater the assist will be. DPS Unit
The slower the vehicle speed, the greater the as- The DPS unit is a self contained unit that includes
sist will be. the steering gear, the DPS module, the DPS mo-
If the electrical system is activated but the engine tor, and the torque sensor.
is not running, DPS assist will be provided for ap-
proximately 30 seconds. DPS assist will resume
once the engine is started.
After turning the ignition key OFF, DPS assist will
be provided for approximately 20 seconds.
When the handlebar is in the straight ahead posi-
tion, there is no steering assist.
Steering torque may also come from the wheels
due to rough terrain. Steering kickback is reduced
while providing feedback to the driver.
2 vmr2017-113
PART ADJUSTED OR
WHAT TO DO
REPLACED
– DPS unit
– Steering column
half bushings
– Steering column
– Tie rod
– Tie rod end
Reset Torque Offset
– Knuckle in Setting, DPS
– Wheel bearing
– Ball joint
– Front suspension arm
(lower/upper)
vmr2017-113-005
– Pitman arm
DPS UNIT – Steering alignment
The DPS module provides DC power to the mo- 1. Ensure steering alignment is correct, refer to
tor. The amount and duration of that DC power is ALIGNING THE WHEELS in the appropriate
determined by the inputs to the DPS module. STEERING SYSTEM subsection.
The DPS motor does not "spin", but rather turns in 2. Connect vehicle to the latest applicable
very small increments based on the amount, du- B.U.D.S. software version.
ration, and direction of DC power delivered by the 3. In B.U.D.S., select Read Data.
DPS module.
4. Choose the Setting page tab.
NOTE: Should the DPS unit fail, the vehicle steer-
ing is still available with moderate increase in 5. At the bottom LH corner of the Setting page,
steering effort. choose the DPS tab.
NOTICE Ensure handlebar is free and cen-
Steering Torque Sensor tered within ±10 degrees of center position.
The steering column is connected to the shaft on There MUST NOT be any effort applied to the
the DPS unit. A small area of the DPS shaft is steering column.
magnetized. Inside the DPS unit, a torque sensor
surrounds the magnetized area of the DPS shaft. 6. Press Reset Torque Offset button.
When the handlebar is turned, torque is applied to
the shaft which tends to twist the shaft slightly,
deforming the magnetic field in the shaft. The
sensor detects the torque by measuring the devi-
ation of the magnetic field.
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
vmr2010-003-002_a
DPS TORQUE OFFSET RESET

RESETTING THE TORQUE 1. Setting page tab
2. DPS tab
OFFSET 3. Reset Torque Offset button
When replacing the following parts or adjust-

ing steering alignment, the sensor torque offset
MUST be reset to zero for proper system oper-
ation.
vmr2017-113 3
DPS ASSIST MODE 2. To change DPS ASSIST mode, press and hold
the OVERRIDE/DPS button for approximately 2
1. To view the active DPS ASSIST mode, momen- seconds to go to the next setting.
tarily press and release the OVERRIDE/DPS
button on the LH multifunction switch assem- The DPS system will toggle to the following avail-
bly. able mode. The newly activated DPS mode will
be briefly displayed in the multifunction gauge.
3. Repeat previous step to toggle through the
available mode.
NOTE: The DPS mode of operation cannot
be changed if the vehicle is in reverse. The
DPS/Override switch must be released between
each DPS mode selection.
PROCEDURES
DPS UNIT
DPS Unit Fuse Location
vmo2012-012-014_b
1. OVERRIDE/DPS/ACS button
The active DPS mode will be displayed in the mul-

tifunction gauge.
vmr2017-113-002_a
1. DPS (F2) fuse
DPS Wire Identification

For circuit details, refer to WIRING DIAGRAM.
LCD gauge
1. DPS mode display E K
A F
vmr2017-113-015_a
ANALOG/DIGITAL GAUGE
DPS CONNECTOR HARNESS SIDE
1. DPS mode display
4 vmr2017-113
DPS CONNECTOR NOTE: This test may also be carried out by con-
necting a 12 Vdc test light between connector
FUNCTION PIN COLOR pins (C, D and E), and the battery (-) negative
12 volt input (from terminal. The test light must come on bright.
C RD/PK
fuse F2)
12 volt input (from
Testing the DPS Ignition Signal
fuse F2)
D RD/PK Voltage
12 volt input (from
1. Disconnect DPS connector.
E RD/PK
fuse F2)
12 volt switched input
G OR/GN
(from fuse F4)
CAN HI J WH/BE
CAN LO K WH/BK
Ground A BK
Ground B BK
Ground F BK
Testing the DPS Input Voltage vmr2017-113-001_a

1. Disconnect the DPS connector. 1. DPS connector
2. Set the ignition switch to ON.

3. Set the engine RUN/STOP switch to RUN.
4. Test for 12 Vdc power at the DPS connector as
MULTIMETER PROBE POSITIONS VOLTAGE
DPS connector
Battery
(harness side) Battery ground
voltage
pin G
If NO voltage is measured, check wires and con-

nector pins from the DPS unit to the fuse (F4) in
vmr2017-113-001_a
the front fuse box (PF1-F4). Replace or repair de-
1. DPS connector
fective parts and reset fault codes.
2. Test for 12 Vdc DPS motor power at DPS con- If battery voltage is measured, test the DPS
nector as per following table. ground circuit.
MULTIMETER PROBE POSITIONS VOLTAGE NOTE: This test may also be carried out by con-
necting a 12 Vdc test light between the DPS con-
DPS connector
nector (pin G), and the battery (-) negative termi-
pin C
nal. The test light must come on bright.
DPS connector Battery
Battery ground
pin D voltage Testing the DPS Ground Circuit
DPS connector 1. Disconnect the DPS connector.
pin E
If NO voltage is measured, test the 40 A DPS

fuse (F2). If good, check wires and connector
pins. Replace or repair defective parts and reset
fault codes.
If battery voltage is measured, test the DPS igni-
tion signal voltage.
vmr2017-113 5
MULTIMETER PROBE
POSITIONS
DPS RESISTANCE
CONNECTOR DIAGNOSTIC @ 20°C (68°F)
(HARNESS CONNECTOR
SIDE)
Pin J Pin 1
Less than 1
Pin K Pin 2
If resistance measured is out of specification,

check wires and connector pins. Carry out re-
vmr2017-113-001_a
pairs as required and reset fault codes using
1. DPS connector
B.U.D.S software.
2. Test for continuity between DPS connector and If resistance measured is good, replace the DPS
battery ground. unit and reset fault codes using B.U.D.S software.
MULTIMETER PROBE
POSITIONS
READING Testing the DPS System Load
If the charging system cannot sustain normal volt-
DPS connector
(harness side)
age when the DPS is operating, DPS ASSIST may
pin A be greatly reduced or nonexistent. Carry out the
following steps.
DPS connector
(harness side) Battery ground
Continuity 1. Measure the battery voltage.
(close to 0 )
pin B NOTE: If battery voltage is low, recharge battery.
DPS connector 2. Ensure the vehicle transmission is set to PARK.
(harness side) 3. Start the engine.
pin F
4. Note the voltage on the multimeter with the en-
If there is NO continuity or a high resistance is gine running (charging system voltage).
measured, check wires and connector pins from 5. Press the RANGE button repeatedly to select
DPS unit to chassis ground post. Replace or re- Manual Range 6 0.
pair defective parts and reset fault codes.
If there is good continuity, carry out: TESTING
THE DPS UNIT COMMUNICATION LINK (CAN)
CONTINUITY.
NOTE: This test may also be carried out by con-
necting a 12 Vdc test light between each GDN
connector pin and the battery (+) positive termi-
nal. The test light must come on bright.
Testing the DPS Communication Link

(CAN) Continuity
NOTE: DPS unit must receive an RPM signal to
provide power steering assist.
1. Disconnect the DPS connector and the diagnos-
tic connector.
2. Test continuity of CAN Bus Wires as per follow-
ing table.
mmr2009-023-027_a
VDC SELECTED TO MANUAL RANGE 6 0
6 vmr2017-113
6. Press the MIN MAX button on the multimeter

to engage the MIN function.
vmr2010-003-007
If the electrical system cannot sustain at least

12 Vdc, check the following:
– Battery
– Battery connections
mmr2009-023-027_e
1. MIN function selected – DPS unit power and ground connections

– Charging system
7. Turn the handlebar momentarily against the – Chassis and engine ground studs.
steering frame stops to each side.
If the previously listed items are correct, , carry
NOTE: Do not hold steering against frame stops out: TESTING THE DPS UNIT CURRENT.
for an extended period of time.
8. Read the MIN charging system voltage Testing the DPS Unit Current
recorded while the handlebar was turned 1. Connect vehicle to the latest applicable
against each stop. B.U.D.S. software version.
DPS SYSTEM LOAD TEST 2. Click on the Read Data button.
STEERING VOLTAGE 3. Choose the Monitoring page tab.
PROBE POSITIONS
POSITION READING 4. At the bottom of the Monitoring page, choose
Battery (-) DPS fuse LH stop At least the DPS tab.
terminal holder pin B RH stop 12 Vdc
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.
vmr2010-003-008_a
Step 1: Press Data button

Step 2: Select Monitoring page tab
Step 3: Select DPS tab
vmr2017-113 7
5. With the vehicle engine running in PARK, turn – Reset the torque sensor offset, refer to RESET-
the handlebar side to side, momentarily against TING THE TORQUE OFFSET in this subsection.
each stop and observe the indications on the – Replace DPS unit.
B.U.D.S. DPS Monitoring page.
The DPS Torque Sensor Nm increase with torque Removing the DPS Unit
applied to handlebar. 1. Lift and support the front of the vehicle.
The DPS Current ammeter should increase pro- 2. Remove the front wheels.
portionately to the torque applied, and decrease 3. Remove the inner fender panels, refer to BODY
with the torque as steering assist is provided. subsection.
4. Remove the CVT front duct, refer to CONTINU-
OUSLY VARIABLE TRANSMISSION (CVT) sub-
section.
vmr2010-003-009_a
TYPICAL - LH TURN
1. Torque sensor indication (negative)
2. DPS current indication (positive)
vmr2017-113-006_a
1. CVT front duct
5. Remove the steering column pinch bolt.
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- vmr2017-113-007

rent readings is very brief as steering assist is
quickly provided. Current draw should remain 6. Disconnect the electrical connector.
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.
If current draw tends to remain high, carry out the
following:
– Steering alignment check.
8 vmr2017-113
10. Remove the RH DPS unit support.

NOTE: The support must be removed from the
DPS unit, otherwise it will exert tension on the
unit at reinstallation.
vmr2017-113-001_a
1. DPS connector
NOTE: There is no need to mark the parts index-

ation. There is a master spline on the assembly.
7. Remove the inner tie-rod ends from the pitman
arm. Discard the cotter pins. vmr2017-113-010
8. Remove the half bushing retainer that secures

the pitman arm to the chassis. 11. Remove the DPS unit by lowering it.
NOTE: Remove the unit by the left hand side of
the vehicle.
If DPS unit is to be replaced, remove the following
from it:
– Lower support
– Pitman arm (see procedure in this subsection)
vmr2017-113-008_a
1. Half bushing retainer
9. Remove the LH DPS unit support.
vmr2017-113-011_a
1. Lower support
2. Pitman arm
Installing the DPS Unit

1. If applicable, install:
– Lower support (tighten screw to the speci-
fied torque)
– Pitman arm (see procedure in this subsec-
tion)
vmr2017-113-009_a
LH SUPPORT SCREWS
1. Loosen
2. Remove
vmr2017-113 9
TIGHTENING TORQUE
Lower support screws

22 N•m ± 2 N•m 3
(16 lbf•ft ± 1 lbf•ft) 1
(P/N 293 800 070) to the DPS input splines.
3. Position the DPS unit in the chassis and engage
the input splines on the steering column.
4. Install the steering column pinch bolt. Tighten
it to the specified torque.
NOTE: Make sure to engage the pinch bolt in the
DPS input shaft groove properly. 2
TIGHTENING TORQUE vmr2017-113-017_a
1. RH support
Steering column 24.5 N•m ± 3.5 N•m 2. Rear of RH support
pinch bolt (18 lbf•ft ± 3 lbf•ft) 3. LH support
5. Install the RH and LH support but do not

tighten yet.
NOTICE The DPS unit must be free of any
strain at this step. 7 5
6. Install the half bushings retainer. Tighten bolts 3
to the specified torque. 8 6
4
1
1 vmr2017-113-016_a
3 TIGHTENING SEQUENCE
2 TIGHTENING TORQUE
vmr2017-113-014_a RH and LH support 24.5 N•m ± 3.5 N•m
PARTS REMOVED FOR CLARITY fasteners (18 lbf•ft ± 3 lbf•ft)
1. RH support
2. Half bushings retainer 8. Connect the electrical connector.
3. LH support
9. Install the inner tie-rod ends, refer to the appro-
TIGHTENING TORQUE priate STEERING SYSTEM subsection.
Half bushings retainer 24.5 N•m ± 3.5 N•m 10. Install other removed parts.
bolts (18 lbf•ft ± 3 lbf•ft)
Updating the Electronic Module
7. Tighten the RH support and LH support fasten-
ers to the specified torque, in the illustrated se- New DPS units do not come with the required
quence. 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.
To update the software, proceed as follows:
1. Connect the ATV to the latest applicable
10 vmr2017-113
2. Select the Read Data button. NOTICE Do not pry between the DPS unit and
3. In the Module menu, choose the DPS sub- the pitman arm to avoid damage to the output
menu and install the latest DPS software and shaft seal.
calibration Update file. The correct file will 3. Remove the half bushings.
be automatically selected by B.U.D.S. for the
vehicle configuration.
vmr2017-113-013_a
1. Half bushings
vmr2010-003-040
4. Inspect the O-rings and replace if required.
DPS SOFTWARE UPDATE
4. Once the correct DPS file is installed, go to the

Faults page and clear the fault codes.
5. Carry out: RESETTING THE TORQUE OFFSET
procedure as described in this subsection.
6. Test drive the ATV to ensure proper DPS oper-
ation.
PITMAN ARM
Removing the Pitman Arm vmr2017-113-003_a
1. Remove the pinch bolt. 1. O-rings
Installing the Pitman Arm

1. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
to:
– The inside half bushings
– The pitman arm contact surface and "O"
rings.
vmr2017-113-012_a
1. Pinch bolt
NOTE: There is no need to mark the parts index-

ation. There is a master spline on the assembly.
2. Remove the pitman arm by hand or using a soft
hammer.
vmr2017-113 11
vmr2012-039-017_a
A. Apply grease here
vmr2017-113-003_b
1. Apply grease here

(P/N 293 800 070) to the DPS outout shaft
splines.
3. Install pitman arm. Tighten the pinch bolt to the
specified torque.
NOTE: Make sure to engage the pinch bolt in the
DPS input shaft groove properly.
TIGHTENING TORQUE
Steering column 24.5 N•m ± 3.5 N•m
pinch bolt (18 lbf•ft ± 3 lbf•ft)
12 vmr2017-113
Subsection XX (FRONT SUSPENSION)
FRONT SUSPENSION
SERVICE TOOLS
BALL JOINT REMOVAL TOOL...................................................... 529 036 310 ........................................... 9
vmr2017-115 1
UPPER SUSPENSION ARMS AND COMPONENTS (OUTLANDER 450 /

570)
NEW
NEW
65 ± 5 N•m
Suspension
3.0 ± 0.5 N•m Grease
(27 ± 4 lbf•in) 90° from arm axis
Suspension
Grease
3.0 ± 0.5 N•m

(27 ± 4 lbf•in)
65 ± 5 N•m
(48 ± 4 lbf•ft) NEW
NEW
45 ± 5 N•m
(33 ± 4 lbf•ft)

vmr2017-115-102_a
2 vmr2017-115
UPPER SUSPENSION ARMS AND COMPONENTS (OUTLANDER 650 /

850 / 1000R AND RENEGADE)
65 ± 5 N•m
(48 ± 4 lbf•ft)
3.0 ± 0.5 N•m
Suspension (27 ± 4 lbf•in)
Grease
90° from arm axis
NEW
NEW
NEW
3.0 ± 0.5 N•m

(27 ± 4 lbf•in)
NEW
65 ± 5 N•m
(48 ± 4 lbf•ft)
Suspension
Grease
NEW
NEW 45 ± 5 N•m
(33 ± 4 lbf•ft)

vmr2017-115-101_a
vmr2017-115 3
LOWER SUSPENSION ARMS AND COMPONENTS (ALL MODELS)
NEW
NEW
4.5 ± 0.5 N•m
(40 ± 4 lbf•in)
NEW
3.0 ± 0.5 N•m

(27 ± 4 lbf•in)
Suspension
Grease
NEW
3.0 ± 0.5 N•m 65 ± 5 N•m

(27 ± 4 lbf•in) (48 ± 4 lbf•ft)
65 ± 5 N•m
(48 ± 4 lbf•ft) Suspension
Grease
90° from arm axis

vmr2017-115-103_a
4 vmr2017-115
GENERAL ACTION RESULT

The procedure explained below is the same for Increasing compression Firmer compression
the RH and LH sides unless otherwise noted. damping force damping
Decreasing compression Softer compression
ADJUSTMENT damping force damping
SHOCK DAMPING WARNING

ADJUSTMENTS (APPLICABLE Make sure compression damping setting is
MODELS) the same on both sides.
Compression damping controls how the shock ab- PROCEDURES

sorber reacts when riding.
POSITION SETTING
RESULT ON BIG SHOCK ABSORBER
BUMPS
Removing the Shock Absorber
Softer compression
1 Soft 1. Safely lift and support the vehicle off the
damping
ground.
Medium
Medium 2. Remove screws and nuts retaining the shock
2 compression
(Factory) absorber.
damping
Firmer
3 Hard compression
damping
219001682-007_a
1. Position 1
2. Position 2
3. Position 3
vmr2015-056-001_a
3. Remove shock absorber.
Inspecting the Shock Absorber

Remove spring from shock absorber. Refer to
SPRINGS in this subsection.
Secure the end of shock eyelet in a vise with its
rod upward.
219001727-010_a
COMPRESSION DAMPING
1. Increases damping (stiffer)
2. Decreases damping (softer)
Turn adjuster clockwise to increase shock damp-

ing action (stiffer).
Turn adjuster counterclockwise to decrease
shock damping action (softer). vsi2015-143-003_a
TYPICAL
vmr2017-115 5
NOTICE Do not clamp directly on shock

body.
Extend and compress the piston several times
over its entire stroke. Check that it moves
smoothly and with uniform resistance with its
rod upward.
Check the following conditions that will denote a
defective shock:
– A skip or a hang back when reversing stroke at
mid travel.
– Seizing or binding condition except at extreme
end of either stroke.
– Oil leakage. vmr2015-056-002_a
– A gurgling noise, after completing one full com-

pression and extension stroke. 4. Remove screws and nuts securing suspension
arm to frame.
Replace if any faults are present.
Installing the Shock Absorber

Install shock absorber screws from front towards
rear of vehicle.
Tighten shock absorber nuts to specification.
TIGHTENING TORQUE
Shock absorber nut 61 N•m ± 9 N•m
(450 / 570) (45 lbf•ft ± 7 lbf•ft)
Shock absorber nut (650 73 N•m ± 7 N•m
/ 850 / 1000R) (54 lbf•ft ± 5 lbf•ft)
vmr2012-040-003_a
1. Suspension arm screws

SHOCK ABSORBER BUSHINGS
5. Remove suspension arm.
Refer to SHOCK ABSORBER BUSHINGS in
REAR SUSPENSION subsection for complete
procedures.
SPRINGS
Refer to SPRINGS in REAR SUSPENSION subsec-
tion for complete procedures.
LOWER SUSPENSION ARM

Removing the Lower Suspension Arm
1. Safely lift and support the vehicle off the
ground.
2. Remove wheel, refer to WHEELS AND TIRES vmr2012-040-004_a
MOVE OUTWARDS
subsection.
3. Remove screw and nut securing lower ball joint
to knuckle.
6 vmr2017-115
Installing Lower Suspension Arm

Lubricate suspension arm. Refer to PERIODIC
Tighten ball joint nut to specification.
TIGHTENING TORQUE
Nut securing ball joint 45 N•m ± 5 N•m
to knuckle (33 lbf•ft ± 4 lbf•ft)
Perform steering alignment procedure. Refer to

STEERING ALIGNMENT subsection.
vmr2015-056-004_a
UPPER SUSPENSION ARM

5. Remove ball joint nut and washer.
Removing the Upper Suspension Arm
ground.
2. Remove wheel, refer to WHEELS AND TIRES
subsection.
3. Remove fasteners retaining brake hose to vehi-
cle.
vmr2015-056-005_a
6. Carefully move brake hose aside.

7. Using a plastic hammer, carefully hit on the
knuckle side to separate ball joint from knuckle.
NOTE: A ball joint remover can be used if the ball
joint is jammed into knuckle.
vmr2015-056-003_a NOTICE Never hit on suspension arm to
avoid damaging it permanently.
4. Remove and discard cotter pin retaining ball
joint.
vmr2017-115 7
Installing the Upper Suspension Arm

Install a NEW cotter pin to secure ball joint nut.
Both end of cotter pin must be folded.
Tighten shock absorber nut to specification.
TIGHTENING TORQUE
Shock absorber nut 61 N•m ± 9 N•m
(450 / 570) (45 lbf•ft ± 7 lbf•ft)
tmr2011-035-020
TYPICAL - CAREFULLY HIT ON KNUCKLE SIDE

Shock absorber nut (650 73 N•m ± 7 N•m
/ 850 / 1000R) (54 lbf•ft ± 5 lbf•ft)
8. Remove screw and nut securing suspension
arm to shock absorber. Tighten ball joint nut to specification.
TIGHTENING TORQUE
45 N•m ± 5 N•m
Ball joint nut
Perform steering alignment procedure. Refer to

STEERING ALIGNMENT subsection.
SUSPENSION ARM BUSHINGS

Removing the Suspension Arm
Bushings
1. Remove wear plates, bushings and sleeves
from suspension arm.
vmr2015-056-006_a
TYPICAL
9. Remove screws and nuts securing suspension

arm to frame.
vmr2015-056-009_a
LOWER SUSPENSION ARM

1. Wear plates
2. Bushings
3. Sleeves
vmr2015-056-007_a
TYPICAL
10. Remove suspension arm.
8 vmr2017-115
vmr2015-056-011
UPPER BALL JOINT

vmr2015-056-008_a
3. Install suspension arm on a press.
TYPICAL - UPPER SUSPENSION ARM
1. Wear plates
2. Bushings NOTICE Pressing on the center or on the lip
3. Sleeves of the ball joint will damage it.
Installing Suspension Arm Bushings
BALL JOINTS
Removing the Ball Joint
1. Remove suspension arm from vehicle. Refer to
REMOVING SUSPENSION ARM in this subsec-
tion.
2. Remove circlip from ball joint. vmr2015-056-012_a
DO NOT PRESS THERE
NOTE: The BALL JOINT REMOVAL TOOL (P/N 529

036 310) is design to apply force only on the out-
side edge of the ball joint.
vmr2015-056-010
LOWER BALL JOINT
529036310
vmr2017-115 9
vmr2015-056-013
vmr2015-056-014_a
CONTACT BETWEEN TOOL AND BALL JOINT ON THE OUTSIDE

EDGE ONLY
4. Remove ball joint from suspension arm.

NOTICE Make sure that suspension arm is
properly supported on the press during ball
joint removal.
Installing Ball Joint

Install a NEW circlip to secure ball joint.
10 vmr2017-115
Subsection XX (REAR SUSPENSION (OUTLANDER 450 / 570))
REAR SUSPENSION (OUTLANDER 450 /

570)
SERVICE TOOLS
SPRING COMPRESSOR ............................................................... 529 036 184 ........................................... 4
SERVICE PRODUCTS
SUSPENSION GREASE ................................................................. 293 550 033 ........................................... 7
vmr2017-116 1
TRAILING ARMS AND STABILIZER BAR
53 ± 3 N•m
(39 ± 2 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
NEW
NEW
Suspension
grease
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
Suspension
grease
NEW
NEW
Suspension
Loctite 271 grease
255 ± 10 N•m 3.0 ± 0.5 N•m
(188 ± 7 lbf•ft) (27 ± 4 lbf•in)
NEW
Suspension
grease
3.0 ± 0.5 N•m
(27 ± 4 lbf•in)
vmr2017-116-101_a
2 vmr2017-116
GENERAL Check the following conditions that will denote a

defective shock:
The procedure described below is the same for
– A skip or a hang back when reversing stroke at
the RH and LH sides, unless otherwise instructed.
mid travel
– Seizing or binding condition except at extreme
PROCEDURES end of either stroke
– Oil leakage
SHOCK ABSORBERS – A gurgling noise, after completing one full com-
Removing the Shock Absorber pression and extension stroke.
1. Safely lift and support the vehicle off the Replace if any faults are present.
ground.
Installing the Shock Absorber
2. Remove screws and nuts retaining shock ab-
sorber. The installation is the reverse of the removal pro-
Tighten shock absorber nuts to specification.
TIGHTENING TORQUE
53 N•m ± 3 N•m
Shock absorber nut
SHOCK ABSORBER BUSHINGS

Replacing the Shock Absorber Bushing
1. Remove shock absorber from vehicle. Refer to
SHOCK ABSORBERS in this subsection.
2. Install shock absorber on a press.
3. Use an appropriate socket to push bushing.
vmr2015-057-001_a
3. Remove shock absorber.
Inspecting the Shock Absorber

Remove spring from shock absorber. Refer to
SPRINGS in this subsection.
Secure the shock eyelet in a vise with its rod up-
ward.
tmr2011-036-021
TYPICAL
4. Remove bushing from shock absorber.

vsi2015-143-003_a
TYPICAL
NOTICE Do not clamp directly on shock

body.
Extend and compress the piston several times
over its entire stroke. Check that it moves
smoothly and with uniform resistance with its
rod upward.
vmr2017-116 3
tmr2011-036-020
TYPICAL vmr2017-117-004_a
1. Built-in washer
5. Install a NEW bushing as the reverse of re- 2. Spring cap
moval. 3. Spring stopper
6. Install shock absorber on vehicle. Orient the openings 180° apart.
SPRINGS
Removing the Spring
1. Remove shock absorber from vehicle. Refer to
SHOCK ABSORBERS in this subsection.
2. Place the SPRING COMPRESSOR (P/N 529 036
184) in a vise.
vmr2015-057-018_a
OPENINGS 180° APART
529036184 STABILIZER BAR

3. Position the shock absorber in the tool. Removing the Stabilizer Bar
4. Install the spring compressor pins. 1. Safely lift and support the vehicle off the
ground.
5. Tighten spring remover screw until the spring is
sufficiently compressed to remove spring cap. 2. Remove rear wheels, refer to WHEELS AND
6. Remove spring cap from shock absorber. TIRES subsection.
3. Refer to EXHAUST SYSTEM and remove:
7. Release spring remover screw.
– Muffler
8. Remove spring from shock absorber.
– Exhaust pipe.
Inspecting the Spring 4. Remove the following inner heat shield.
Inspect the spring for damage.
Installing the Spring

Install the spring stopper and cap underneath the
built-in washer.
4 vmr2017-116
vmr2015-057-013_a vmr2015-057-006
SOME PARTS REMOVED FOR CLARITY

Tighten stabilizer bar retaining screws to specifi-
5. Remove fasteners and stabilizer bar bushing cation.
holders.
TIGHTENING TORQUE
Screws securing 24.5 N•m ± 3.5 N•m
stabilizer bar to frame (18 lbf•ft ± 3 lbf•ft)
Screws securing 48 N•m ± 6 N•m
stabilizer bar to link arm (35 lbf•ft ± 4 lbf•ft)
Lubricate stabilizer bar. Refer to PERIODIC MAIN-

TRAILING ARM
Removing the Trailing Arm
vmr2015-057-003
ground.
6. Remove stabilizer bar. 2. Remove wheel hub, refer to REAR DRIVE sub-
section.
Inspecting the Stabilizer Bar
3. Remove protective plate from trailing arm.
Check stabilizer bar for cracks, bending or other
damages.
Installing the Stabilizer Bar

Install all retaining screws of stabilizer bar loosely
first.
Position link arm screws with their heads towards
the inside.
vmr2015-057-005
NOTE: If applicable, remove fasteners retaining

brake hose to vehicle.
4. Remove nut and washer securing trailing arm
pivot shaft.
vmr2017-116 5
Disassembling the Trailing Arm

Removing Drive Shaft Bearing
1. Remove circlip securing bearing into trailing
arm.
vmr2015-057-007
5. Detach trailing arm from link arm and remove

vmr2015-057-012
lower nut retaining shock absorber.
2. Install trailing arm on a press.
3. Use an appropriate bearing remover.
4. Remove drive shaft bearing from trailing arm.
Removing the Link Arm Inner Bushing
Remove both bushings and sleeve from trailing
arm.
vmr2015-057-008
6. Firmly hold trailing arm then remove:

– Shock absorber lower screw
– Trailing arm pivot shaft (pull from opposite
side).
NOTE: If only one trailing arm is removed, pull
pivot shaft just enough to clear trailing arm. vmr2015-057-011_a
1. Bushings
2. Sleeve
Removing the Trailing Arm Pivot Bearing

1. Remove both spacers and seals from trailing
arm pivot.
vmr2015-057-010
vmr2015-057-014_a
7. Remove trailing arm from vehicle.
1. Spacer
2. Seal
6 vmr2017-116
2. Remove bearing with an appropriate bearing re-

mover.
NOTE: Remove one bearing at a time.
3. Remove inner spacer from trailing arm.
vmr2015-057-016_a
vmr2015-057-015_a
TYPICAL - LH TRAILING ARM
Step 1: Insert bearing on RH side
1. Pivot bearings Step 2: Center inner spacer with RH side bearing using a shaft
2. Inner spacer Step 3: Insert bearing on LH side
Inspecting the Trailing Arm Lubricate trailing arm pivot seals.

Check trailing arms for: LUBRICATION
– Cracks SUSPENSION GREASE
– Bending. Pivot seals
(P/N 293 550 033)
Check seals condition.
Install trailing arm pivot seal with its cavity facing
Check inner race of each pivot bearing with your inwards.
finger. Bearings should turn smoothly and quietly.
Assembling and Installing the Trailing

Arm
Install the following NEW parts:
– Trailing arm pivot nuts
– Pivot bearings
– Pivot seals
– Circlip.
vmr2015-057-017_a
Use an appropriate shaft to center trailing arm in- 1. Seal cavity
ner spacer during pivot bearings installation. 2. Trailing arm
Install pivot bearings and inner spacer as per the Center trailing arm pivot shaft.
following sequence.
Install the spacers.
Tighten trailing arm pivot nuts as per the following
sequence.
TIGHTENING SEQUENCE
Tighten nut until
RH side nut it reaches end of
Trailing arm threads
pivot nuts
255 N•m ± 10 N•m
LH side nut
Position link arm bolts with their heads towards

the inside.
vmr2017-116 7
vmr2015-057-006
Tighten trailing arm fasteners to specification.

TIGHTENING TORQUE
Bolts securing trailing 48 N•m ± 6 N•m
arm to link arm (35 lbf•ft ± 4 lbf•ft)
53 N•m ± 3 N•m
Shock absorber nuts
Protective plate retaining 10 N•m ± 2 N•m
nuts (89 lbf•in ± 18 lbf•in)
8 vmr2017-116
Section 08 CHASSIS
Subsection 06 (BRAKES)
BRAKES
SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 692
SERVICE PRODUCTS
XPS BRAKES AND PARTS CLEANER (USA) ................................. 219 701 705 ......................................... 695
XPS BRAKES AND PARTS CLEANER ........................................... 219 701 776 ......................................... 695
vmr2015-058 685
Section 08 CHASSIS
OUTLANDER L (FRONT CIRCUIT)

All Except CE Models
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW
450 engine only
NEW
To rear circuit
5.5 ± 1.5 N•m
(49 ± 13 lbf•in) NEW
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW

vmr2015-058-100_a
686 vmr2015-058
Section 08 CHASSIS
OUTLANDER L (REAR CIRCUIT)

All Except CE Models
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
MAX models
28.5 ± 1.5 N•m
(21 ± 1 lbf•ft)
0.7 ± 0.1 N•m
(6 ± 1 lbf•in)
NEW
NEW
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
To front circuit
27.5 ± 2.5 N•m
(20 ± 2 lbf•ft)
NEW

vmr2015-058-101_a
vmr2015-058 687
Section 08 CHASSIS
OUTLANDER L (FRONT CIRCUIT)

CE Models
NEW
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
450 engine only
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW To rear circuit

5.5 ± 1.5 N•m
(49 ± 13 lbf•in) NEW
NEW
28.5 ± 1.5 N•m
(21 ± 1 lbf•ft)
5.5 ± 1.5 N•m

(49 ± 13 lbf•in)
To rear circuit NEW

33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
28.5 ± 1.5 N•m
(21 ± 1 lbf•ft)

vmr2015-058-102_a
688 vmr2015-058
Section 08 CHASSIS
OUTLANDER L (REAR CIRCUIT)

CE Models
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
NEW
MAX models 61 ± 9 N•m
(45 ± 7 lbf•ft)
0.7 ± 0.1 N•m 28.5 ± 1.5 N•m

(6 ± 1 lbf•in) (21 ± 1 lbf•ft)
NEW
NEW
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
To front circuit
27.5 ± 2.5 N•m

(20 ± 2 lbf•ft)
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft) XPS synthetic grease
NEW
To front circuit

vmr2015-058-103_a
vmr2015-058 689
Section 08 CHASSIS
CALIPERS AND BRAKE LEVERS

All Models
FRONT REAR
Brake caliper 8.5 ± 1.5 N•m
synthetic grease (75 ± 13 lbf•in)
Brake caliper
synthetic
grease
8.5 ± 1.5 N•m
(75 ± 13 lbf•in)
LH SIDE
1.3 ± 0.1 N•m
(12 ± 1 lbf•in)
Cover +
gasket
RH SIDE
8.5 ± 1.5 N•m On applicable models 1.3 ± 0.1 N•m
(75 ± 13 lbf•in) (12 ± 1 lbf•in)
XPS synthetic Cover + gasket

grease
XPS synthetic
grease
8.5 ± 1.5 N•m
(75 ± 13 lbf•in)
vmr2013-044-100_a
690 vmr2015-058
Section 08 CHASSIS
GENERAL
WARNING
Always check brake system operation after
removing or servicing a brake component.
NOTICE Avoid spilling brake fluid on plastic,

rubber or painted parts. Protect these parts
with a rag when servicing brake system.
NOTE: Sealing washers must be discarded and
replaced with new ones every time a Banjo bolt
is unscrewed.
NOTE: Always clean the area around a brake com- tmr2011-037-110
ponent before servicing. TYPICAL
SYSTEM DESCRIPTION Brake Lever Verification

A disc brake system with twin-piston sliding NOTE: Do not pump up the brakes repeatedly be-
calipers is used. fore doing the validation.
1. Position force gauge perpendicularly on brake
Disc Brake Configurations lever edge.
OUTLANDER L 2. Position a ruler perpendicularly to handlebar
grip.
NUMBER OF DISC BRAKES
MODELS 3. Push brake lever at distance A from handlebar
FRONT REAR grip using force gauge.
All models 2 1
Brake Controls and Circuit

Configurations
OUTLANDER L
LH BRAKE
MODELS BRAKE PEDAL
LEVER
All except CE Controls front Controls rear
models and rear brakes brakes
Controls front Controls front
CE models vmr2012-042-006_a
and rear brakes and rear brakes A. Distance from handlebar (refer to table)
4. Read load recorded by the force gauge.

INSPECTION
5. Load reading must be as per the following table.
BRAKE SYSTEM PRESSURE BRAKE LEVER VERIFICATION
VALIDATION LEVER
DISTANCE MINIMUM
A LOAD
Required Tools
LH side lever 25 mm (1 in) 150 N (34 lbf)
Use an appropriate compression force gauge such
as MARK-10 EG-200 and a ruler. RH side lever
25 mm (1 in) 130 N (29 lbf)
(if applicable)
vmr2015-058 691
Section 08 CHASSIS
6. If load reading is not in accordance with the PROCEDURES

specification:
6.1 Perform a brake system inspection and BRAKE LIGHT SWITCHES
cleaning.
Brake Light Switch Location
6.2 Bleed brake system.
The brake light switch is located on the brake
NOTE: Refer to PERIODIC MAINTENANCE pedal master cylinder.
Brake Pedal Verification
NOTE: Do not pump up the brakes repeatedly be-
fore doing the validation.
1. Position force gauge perpendicularly on brake
pedal edge.
2. Position a ruler perpendicularly to brake pedal.
3. Push brake pedal from distance A using force
gauge.
vmr2012-035-004_a
BRAKE PEDAL MASTER CYLINDER

1. Brake light switch
2. Brake light switch connector
Brake Light Switch Resistance Test

1. Disconnect brake light switch connector.
2. Check switch operation as follows.
BRAKE LIGHT
PIN RESISTANCE
SWITCH POSITION
vmr2012-042-007_a
A. Distance to push (refer to table) Firmly pushed Close to 0

1 2
4. Read load recorded by the force gauge. Released Infinite (OL)
5. Load reading must be as per the following table. If switch is defective, replace with a new one.
BRAKE PEDAL VERIFICATION If the switch tests good, verify wire continuity
DISTANCE MINIMUM between harness connector and ECM connector.
MODELS Refer to BRAKE SYSTEMS WIRING DIAGRAM.
A LOAD
All Outlander L 35 mm REQUIRED TOOL
180 N (40 lbf)
except CE (1-3/8 in) ECM ADAPTER TOOL (P/N 529 036 166)
55 mm
Outlander L CE 180 N (40 lbf)
(2-5/32 in)
6. If load reading is not in accordance with the

specification:
6.1 Perform a brake system inspection and
cleaning.
6.2 Bleed brake system.
NOTE: Refer to PERIODIC MAINTENANCE
529036166
692 vmr2015-058
Section 08 CHASSIS
Brake Light Switch Replacement

1. Disconnect brake light switch connector.
2. Drain brake line.
3. Remove brake light switch.
NOTE: Use shop rags to catch any spilled brake
fluid.
4. Install NEW sealing washers.
5. Install brake light switch.
TIGHTENING TORQUE
28.5 N•m ± 1.5 N•m
Brake light switch
(21 lbf•ft ± 1 lbf•ft) vmr2015-058-005_a
6. Connect brake light switch connector. 5. Remove brake pedal.

7. Refill and bleed brake system, refer to PERI-
tion.
BRAKE PEDAL
Brake Pedal Removal
1. Drain brake system, refer to PERIODIC MAIN-
2. Remove RH footrest panel. Refer to BODY
subsection.
NOTE: Loosen brake pedal bolt before removing
support from frame.
3. Remove master cylinder support from frame. vmr2015-058-006_a
Brake Pedal Installation

Install NEW brake pedal O-ring.
Lubricate brake pedal pivot.
LUBRICATION
XPS SYNTHETIC
Brake pedal pivot GREASE
(P/N 293 550 010)
Tighten brake pedal nut as per the following se-

quence.
TIGHTENING SEQUENCE
vmr2015-058-004_a
STEP Brake pedal bolt 10 N•m ± 2 N•m

Step 1: Loosen brake pedal pivot 1 (pivot) (89 lbf•in ± 18 lbf•in)
Step 2: Remove nuts
STEP 27.5 N•m ± 2.5 N•m
4. Remove brake pedal spring. Brake pedal nut
2 (20 lbf•ft ± 2 lbf•ft)
vmr2015-058 693
Section 08 CHASSIS
TIGHTENING TORQUE
Brake hose screw 28.5 N•m ± 1.5 N•m
(banjo fitting) (21 lbf•ft ± 1 lbf•ft)
8.5 N•m ± 1.5 N•m
Bleeder
Install NEW sealing washers.

Refill and bleed brake system, refer to PERIODIC
CALIPER
vmr2015-058-007_a
Caliper Removal
TIGHTENING SEQUENCE 1. Safely lift and support the vehicle.
Step 1: Tighten bolt
Step 2: Hold bolt then tighten nut 2. Remove wheel, refer to WHEELS AND TIRES
subsection.
MASTER CYLINDER 3. If caliper is removed from vehicle for replace-
ment:
Master Cylinder Removal
3.1 Drain brake system, refer to PERIODIC
1. Remove BRAKE PEDAL. See procedure in this MAINTENANCE PROCEDURES subsec-
subsection. tion.
2. Remove master cylinder from support. 3.2 Unscrew brake hose from caliper.
vmr2015-058-008_a
vmr2015-058-001_a
3. Remove hoses and bleeder from master cylin- 1. Brake hose

2. Sealing washers
der.
4. Remove fasteners retaining brake hose.
Master Cylinder Inspection
5. Remove screws securing caliper support.
Check boot for crack.
Check rod for wear and scratch.
Check master cylinder housing for leak or dam-
age.
Master Cylinder Installation

Tighten brake hoses and bleeder to specification.
694 vmr2015-058
Section 08 CHASSIS
vmr2015-058-002_a vmr2015-058-003_a
1. Caliper screws 1. Pin retainer
6. Place caliper assembly onto a support. 3. Remove brake pad pin from caliper.
NOTICE Do not let caliper hangs by the hose
and do not stretch or twist hose.
Caliper Installation
If caliper was removed for replacement:
– Refill and bleed brake system, refer to PERI-
tion.
– Install NEW sealing washers.
Install NEW caliper retaining screws.
Tighten caliper retaining screws to specification.
vmr2012-042-010_a
TIGHTENING TORQUE 1. Brake pad pin
61 N•m ± 9 N•m
Caliper retaining screws
(45 lbf•ft ± 7 lbf•ft) 4. Carefully remove brake pads.
5. Clean pistons end using XPS BRAKES AND
PARTS CLEANER (P/N 219 701 776) or XPS
BRAKE PADS BRAKES AND PARTS CLEANER (USA) (P/N 219
Brake Pads Replacement 701 705).
1. Remove caliper, refer to CALIPER REMOVAL in 6. Push caliper pistons inward.

this subsection. NOTE: To avoid damaging pistons, use an old pad
2. Remove pin retainer securing brake pad pin. to push it into the caliper using a C-clamp.
7. Ensure brake pad spring is properly positioned
onto caliper and not damaged.
vmr2015-058 695
Section 08 CHASSIS
vmr2012-042-014_a
1. Caliper support
vmr2012-042-011_a
13. Install caliper, refer to CALIPER INSTALLA-
BRAKE PAD SPRING
TION in this subsection.
8. Ensure pad stopper is properly aligned with
caliper support protrusion. BRAKE DISC
Brake Disc Inspection
1. Check disc surfaces for scratches or grooves on
both sides.
2. Measure thickness of the disc.
DISC MINIMUM THICKNESS
FRONT 4.0 mm (.157 in)
REAR 4.0 mm (.157 in)
NOTICE Brake discs must never be ma-

chined.
3. Check warpage of the disc.
vmr2012-042-012_a MAXIMUM DISC WARPAGE
1. Pad stopper
2. Caliper support protrusion FRONT
0.2 mm (.01 in)
NOTICE Prior to installing brake pads, pad REAR
stopper must be properly positioned and not
damaged. Brake Disc Replacement
9. Install NEW brake pads. 1. Remove caliper, refer to CALIPER REMOVAL in
this subsection.
10. Clean and install brake pad pin on caliper.
2. Remove wheel hub, refer to FRONT DRIVE or
11. Install pin retainer to secure brake pad pin. REAR DRIVE subsection.
12. Slide caliper support completely into caliper. 3. Remove screws securing brake disc to wheel
hub.
696 vmr2015-058
Section 08 CHASSIS
vmr2012-042-013_a
1. Brake disc screw
4. Replace brake disc.

5. Install NEW brake disc screws.
6. Tighten brake disc screws to specification.
TIGHTENING TORQUE
33.5 N•m ± 3.5 N•m
Brake disc screws
7. Install wheel hub then caliper.

8. Install NEW cotter pin to secure wheel hub nut.
vmr2015-058 697
Section 08 CHASSIS
Subsection 07 (BODY)
BODY
SERVICE TOOLS
OETIKER PLIERS........................................................................... 295 000 070 ......................................... 709
vmr2015-059 699
Section 08 CHASSIS
BODY PARTS NOMENCLATURE (SHORT MODEL)
14 1 2 3 4 5
6
13
12
11 10 9 8
vmr2015-059-100_a
1. Gauge support 8. Footrest panel

2. Console 9. Side panel extension
3. Seat 10. Side panel
4. Rear fender 11. Inner fender panel
5. Rear rack 12. Front fascia
6. Rear storage compartment 13. Front fender
7. Rear fascia 14. Front rack
700 vmr2015-059
Section 08 CHASSIS
BODY PARTS NOMENCLATURE (MAX MODEL)
16 1 2 3 4 5
15
14
13 12 11 10 9
vmr2015-059-101_a
1. Gauge support 9. Footrest panel

2. Console 10. Rear side panel extension
3. Seat 11. Side panel extension
4. Passenger seat 12. Side panel
5. Rear rack 13. Inner fender panels
6. Rear storage compartment 14. Front fascia
7. Rear fascia 15. Front fender
8. Rear Fender 16. Front rack
vmr2015-059 701
Section 08 CHASSIS
FRONT AND REAR BODY MODULES (SHORT MODEL)
vmr2015-059-102_a
1. Front body module

2. Rear body module
702 vmr2015-059
Section 08 CHASSIS
FRONT AND REAR BODY MODULES (MAX MODEL)
vmr2015-059-103_a
1. Front body module

2. Rear body module
vmr2015-059 703
Section 08 CHASSIS
Subsection 07 (BODY (450)
BODY PARTS (SHORT MODEL)

Please note that unless indicated, the procedure is the same for both sides.
CE Models
vmr2015-059-104_a
704 vmr2015-059
Section 08 CHASSIS
BODY PARTS (SHORT MODEL)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
CE models
4.5 ± 0.5 N•m
(40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
vmr2015-059-105_a
vmr2015-059 705
Section 08 CHASSIS
BODY PARTS (MAX MODEL)

4.5 ± 0.5 N•m
(40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in) 4.5 ± 0.5 N•m
(40 ± 4 lbf•in)
vmr2015-059-108_a
706 vmr2015-059
Section 08 CHASSIS
RACKS AND BODY PARTS
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
CE Models
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
15 ± 2 N•m
(133 ± 18 lbf•in)
15 ± 2 N•m
(133 ± 18 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
CE Models
vmr2015-059-107_a
vmr2015-059 707
Section 08 CHASSIS
PASSENGER SEAT
25 ± 3 N•m
(18 ± 2 lbf•ft)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
vmr2015-059-109_a
708 vmr2015-059
Section 08 CHASSIS
PROCEDURES FRONT BODY MODULE

Front Body Module Removal
PLASTIC RIVET
NOTE: Unless indicated, RH side shown on illus-
Plastic rivets are used in the riveting of the vari- trations.
ous body parts. Plastic rivets can be reused many
1. Disconnect battery negative (-) cable.
times. Use the OETIKER PLIERS (P/N 295 000 070)
to remove them. 2. Remove the following panels, see procedure in
this subsection:
– SIDE PANELS
– INNER FENDER PANELS.
3. Remove front skid plate retaining screws.
V06L08A 2 1
TYPICAL
1. Pliers
2. Plastic rivet
vmr2015-059-001_a
DECALS
4. Remove locking ties securing headlights har-
Decal Removal ness to subframe.
Using a heat gun warm up one end of decal for a
few seconds until decal can roll off when rubbing
with your finger.
Pull decal slowly and when necessary apply more
heat to ease removal on the area that has to be
peeled off.
If decal tears while pulling off, it has to be heated
for a few seconds longer. If decal tends to stretch
while pulling off, stop heating and wait a few sec-
onds to let it cool, then peel it off.
Decal Installation
Using isopropyl alcohol, clean the surface and dry
thoroughly.
Apply liquid soap to new decal and carefully posi- vmr2015-059-002_a
tion it. Using a sponge or a squeegee, remove the

air bubbles and surplus water working from the 5. Disconnect headlights connectors.
center toward the edges. Allow to air dry.
NOTICE Do not apply isopropyl alcohol or
solvent directly on decals. Use these products
in a well ventilated area.
vmr2015-059 709
Section 08 CHASSIS
vmr2015-059-003_a vmr2015-059-006_a
1. Locking tie
2. Headlight connectors
6. Remove screw securing front fender to footrest

panel (on both sides).
vmr2015-059-007_a
LH SIDE
9. Remove screws securing front rack to frame.
vmr2015-059-004_a
7. Detach front fender from footrest panel by re-

leasing retaining tabs (on both sides).
vmr2015-059-008_a
10. With the assistance of a person, pull front

body module forward.
vmr2015-059-005_a
11. Install front body module on a stable and clean
support.
8. Remove screws securing front body module to
frame.
710 vmr2015-059
Section 08 CHASSIS
Front Body Module Installation

Tighten front fender screws to specification.
TIGHTENING TORQUE
Screws securing footrest 4.5 N•m ± 0.5 N•m
panels to front fender (40 lbf•in ± 4 lbf•in)
REAR BODY MODULE

Rear Body Module Removal
1. Remove seat.
2. Remove the following panels, see procedure in vmr2015-059-013_a
this subsection:
– PASSENGER SEAT HOLDER (MAX MOD- 5. Disconnect taillight connector.
ELS)
– SIDE PANELS.
3. On Short Models, remove rear storage com-
partment retaining screws.
vmr2015-059-015_a
REAR VIEW
6. Disconnect connectors from voltage regulator

rectifier.
vmr2015-059-009_a
TOP VIEW
4. Release taillight harness from the rear fender

tabs.
vmr2015-059-014_a
7. Remove rear rack upper retaining screws.
vmr2015-059 711
Section 08 CHASSIS
vmr2015-059-012_a
LH SIDE SHOWN vmr2015-059-017_a
SHORT MODEL SHOWN

8. Remove rear rack lower retaining screws and
nuts. 11. Remove fuel tank cap.
12. Place a clean rag into fuel tank filler tube.
13. With the assistance of a person, pull rear body
module rearward.
14. Install rear body module on a stable and clean
support.
15. Remove rag and reinstall fuel tank cap.
WARNING
Fuel vapors are flammable and explosive
under certain conditions. Unless otherwise
noted, the fuel tank cap must always be in-
stalled on vehicle.
vmr2015-059-011_a
REAR VIEW
Rear Body Module Installation
9. Remove screw securing rear fender to footrest The installation is the reverse of the removal pro-
panel (on both sides). cedure. However, pay attention to the following.
Tighten rear body module retaining screws to
specification.
TIGHTENING TORQUE
15 N•m ± 2 N•m
Rear rack lower screws
Tighten rear fender screws to specification.

TIGHTENING TORQUE
Screws securing footrest 4.5 N•m ± 0.5 N•m
panels to rear fenders (40 lbf•in ± 4 lbf•in)
Tighten rear storage compartment to specifica-

tion.
vmr2015-059-016_a
SHORT MODEL SHOWN
10. Detach rear fender from footrest panel by re-

leasing retaining tabs (on both sides).
712 vmr2015-059
Section 08 CHASSIS
TIGHTENING TORQUE INNER FENDER PANELS

Rear storage 4.5 N•m ± 0.5 N•m Inner Fender Removal and Installation
compartment screws (40 lbf•in ± 4 lbf•in)
Remove plastic rivets from inner fender panels.
CONSOLE
Console Removal
1. Remove seat.
2. Lift rear portion of console upwards.
3. Pull console rearwards.
vmr2015-059-020_a
WHEEL REMOVED FOR CLARITY
vmr2015-059-018_a
Console Installation
Align console front tabs with slots, then push con-
sole forward.
vmr2015-059-021_a
LH SIDE SHOWN, WHEEL REMOVED FOR CLARITY

cedure.
SIDE PANELS
Side Panel Removal
1. Remove following panels, see procedures in
this subsection:
vmr2015-059-019_a
– CONSOLE
– PASSENGER SEAT HOLDER (MAX models).
GAUGE SUPPORT 2. Remove GAUGE SUPPORT. Refer to LIGHTS,
Refer to LIGHTS, GAUGE AND ACCESSORIES
subsection. 3. Remove plastic rivet securing side panel to in-
ner fender panel.
vmr2015-059 713
Section 08 CHASSIS
6. Lift rear portion of side panel assembly then pull

it towards outside.
vmr2015-059-022_a
4. Remove plastic rivet securing side panel to air

filter housing. vmr2015-059-023_a
MAX Models
7. Remove plastic rivet securing rear side panel
extension to rear fender.
vmr2012-043-024_a
1. Plastic rivet securing side panel
Short Models vmr2012-043-025_a
5. Remove plastic rivet securing side panel to rear 1. Plastic rivet securing side panel
fender.
8. Remove passenger seat holder. See procedure
in this subsection.
9. Detach rear side panel extension from footrest
panel by releasing retaining tab.
vmr2012-043-025_a
1. Plastic rivet securing side panel
714 vmr2015-059
Section 08 CHASSIS
BACK OF PANEL SHOWN
5. Remove panel extension.
vmr2015-059-024_a Panel Extension Installation

FRAME AND ENGINE REMOVED FOR CLARITY
Installation is the reverse of removal.
10. Lift rear portion of side panel assembly then
pull it towards outside. PASSENGER SEAT HOLDER
(MAX MODELS)
Passenger Seat Holder Removal
1. Remove driver and passenger seats.
2. Remove retaining screws securing passenger
seat holder and rear storage compartment to
frame.
3. Remove plastic rivets securing passenger seat
holder to rear side panel extensions.
vmr2015-059-037_a
Side Panel Installation

Align side panel front tab with slot, then push side
panel forward.
PANEL EXTENSIONS
Panel Extension Removal
1. Remove seat.
1. Screws
2. Remove GAUGE SUPPORT. Refer to LIGHTS, 2. Plastic rivets
3. Remove following panels, see procedures in Passenger Seat Holder Installation
this subsection: Installation is the reverse of removal. However
– CONSOLE pay attention to the following:
– PASSENGER SEAT HOLDER (MAX models) Tighten passenger seat holder retaining screws to
– SIDE PANEL. specification.
4. Undo tabs securing panel extension to side
panel.
vmr2015-059 715
Section 08 CHASSIS
TIGHTENING TORQUE
Passenger seat holder 4.5 N•m ± 0.5 N•m
REAR SIDE PANEL EXTENSIONS

(MAX MODEL)
Rear Side Panel Extension Removal
1. Remove driver and passenger seats.
2. Remove the following panels, see procedures
in this subsection:
– PASSENGER SEAT HOLDER vmr2015-059-026_a
BOTTOM UP VIEW OF THE STORAGE COMPARTMENT

– SIDE PANEL. Step 1: Gently pull on taillight harness from rear fascia clip
Step 2: Push on the taillight from behind the fascia towards the rear
3. Unclip retaining tab securing rear side panel ex-
tension to side panel.
Rear Side Panel Extension Installation

Installation is the reverse of removal.
REAR STORAGE COMPARTMENT

Rear Storage Compartment Removal
1. Remove seat.
2. Remove rear body module. Refer to REAR
BODY MODULE.
3. Remove rear rack. Refer to REAR RACK RE- vmr2015-059-027_a
MOVAL.
6. Remove retaining screws securing rear fascia
4. Remove retaining screws and plastic rivets se-
to rear storage compartment.
curing rear storage compartment to rear fend-
ers.
vmr2015-059-028_a
Rear Storage Compartment

Installation
Installation is the reverse of removal. However
vmr2015-059-025_a
pay attention to the following:
5. Remove taillight from rear fascia. Tighten rear storage compartment retaining
screws to specification.
716 vmr2015-059
Section 08 CHASSIS
TIGHTENING TORQUE
Rear storage
4.5 N•m ± 0.5 N•m
compartment retaining
screws
FOOTREST PANELS
Footrest Panel Removal
Short Models
1. Remove footrest panel retaining screws.
3. Remove both plastic rivet securing inner fender

panel to footrest panel.
vmr2015-059-029_a
SHORT MODELS
vmr2015-059-020_b
WHEEL REMOVED FOR CLARITY
4. Remove screw securing rear fender to footrest

panel.
vmr2015-059-030_a
MAX MODELS
2. Remove screw securing front fender to footrest

panel.
vmr2015-059-016_a
SHORT MODEL SHOWN
5. Remove screw securing footrest panel to

frame.
vmr2015-059 717
Section 08 CHASSIS
Footrest Panel Installation

Tighten footrest panel screws to specification.
TIGHTENING TORQUE
Footrest panel retaining 4.5 N•m ± 0.5 N•m
PASSENGER GRIPS
Passenger Grips Removal
vmr2012-043-028_a 1. Remove retaining screw securing passenger
1. Screw securing footrest panel grips and remove passenger grips.
6. Detach front fender from footrest panel by re-

leasing retaining tabs.
vmr2015-059-031_a
Passenger Grips Installation

vmr2015-059-005_a Installation is the reverse of removal. However
pay attention to the following:
7. Detach rear fender from footrest panel by relea-
Tighten passenger grips retaining screw to speci-
sing retaining tabs.
fication.
TIGHTENING TORQUE
Passenger grips 25 N•m ± 3 N•m
retaining screw (18 lbf•ft ± 2 lbf•ft)
RACK (FRONT AND REAR)

Front Rack Removal
1. Remove screws securing front fenders to rack.
vmr2015-059-017_a
SHORT MODEL SHOWN
8. Remove footrest panel from vehicle.
718 vmr2015-059
Section 08 CHASSIS
TIGHTENING TORQUE
Screws securing fender 4.5 N•m ± 0.5 N•m
to front rack (40 lbf•in ± 4 lbf•in)
Rear Rack Removal

1. Remove screws securing rear fenders and stor-
age compartment to rack.
vmr2015-059-033_a
BOTTOM UP VIEW
2. Remove screws securing rack to frame.
vmr2015-059-032_a
2. Remove upper screws securing rack to frame.
vmr2015-059-008_a
3. Remove screws securing rack to subframe.
vmr2015-059-012_a
3. Remove lower screws securing rack to frame.
vmr2015-059-034_a
4. Remove rack from vehicle.
Front Rack Installation

Tighten front rack retaining screws to specifica-
vmr2015-059-011_a
tion.
vmr2015-059 719
Section 08 CHASSIS
4. Remove rack from vehicle.
Rear Rack Installation

Tighten rear rack retaining screws to specification.
TIGHTENING TORQUE
Screws securing rear
4.5 N•m ± 0.5 N•m
fenders and storage
compartment to rack
Lower screws securing 15 N•m ± 2 N•m
rear rack to frame (133 lbf•in ± 18 lbf•in)
720 vmr2015-059
Section 08 CHASSIS
Subsection 09 (FRAME)
FRAME
BLIND THREADED INSERT INSTALLER....................................... model 9600 ......................................... 744
MAX
Models
NEW
Rear frame 24.5 ± 3.5 N•m
extension (18 ± 3 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
Upper frame
support (welded)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
Lower frame
support

vmr2015-060-100_a
vmr2015-060 743
Section 08 CHASSIS
PROCEDURES
FRAME
Frame Inspection
Check frame for bending, cracks, weld damages
or any other damage. Replace frame as neces-
sary.
Frame Welding
No welding should be done on frame except if
mentioned or required on an approved BRP Bul-
letin. vmr2015-060-001_a
INSERT FOR M6 BOLT SHOWN

A. 9 mm ± 0.5 mm (.354 in ± .02 in)
Frame Insert Replacement
To install a new blind threaded insert, use the fol- Frame Replacement
lowing tool: BLIND THREADED INSERT INSTALLER Blind threaded inserts are not installed on replace-
(P/N MODEL 9600) from Textron. See their web
ment frames. Make sure to order enough inserts
site at: www.textronfasteningsystems.com. when replacing frame. Refer to ELECTRONIC
PARTS CATALOG.
Footrest Bracket Replacement
A footrest bracket replacement kit (P/N 703 500
852) is available trough regular channel.
Order a replacement kit for each bracket to be re-
placed.
tmr2011-039-004
Replacing footrest bracket request to cut the
After insert installation, ensure insert can hold the original welded one. Cut the damaged bracket at
torque applied to the screw it retains and measure 111 mm (4-3/8 in) from the square tube.
the compressed length of the frame insert. Oth- NOTICE Do not cut shorter than dimension
erwise, install a new insert. specified.
COMPRESSED
INSERT
LENGTH
9 mm ± 0.5 mm
Insert for M6 bolt
(.354 in ± .02 in)
11.5 mm ± 0.5 mm
Insert for M8 bolt
(.453 in ± .02 in)
vmr2015-060-002_a
A. 111 mm (4-3/8 in)
Install the new footrest bracket and tighten nuts

to specification.
744 vmr2015-060
Section 08 CHASSIS
vsi2014-017-003
REPLACEMENT KIT
TIGHTENING TORQUE
24.5 N•m ± 3.5 N•m
Footrest bracket nuts
vmr2015-060 745
Section 08 CHASSIS
FRAME
BLIND THREADED INSERT INSTALLER....................................... model 9600 ......................................... 290
MAX
Models
NEW
Rear frame 24.5 ± 3.5 N•m
extension (18 ± 3 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
Upper frame
support (welded)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
Lower frame
support
Base and DPS series PRO serie

vmr2016-066-100_a
vmr2016-066 289
Section 08 CHASSIS
PROCEDURES
FRAME
Frame Inspection
Check frame for bending, cracks, weld damages
or any other damage. Replace frame as neces-
sary.
Frame Welding
No welding should be done on frame except if
mentioned or required on an approved BRP Bul-
letin. vmr2015-060-001_a
INSERT FOR M6 BOLT SHOWN

A. 9 mm ± 0.5 mm (.354 in ± .02 in)
Frame Insert Replacement
To install a new blind threaded insert, use the fol- Frame Replacement
lowing tool: BLIND THREADED INSERT INSTALLER
Blind threaded inserts are not installed on replace-
(P/N MODEL 9600) from Textron. See their web
ment frames. Make sure to order enough inserts
site at: www.textronfasteningsystems.com.
when replacing frame. Refer to ELECTRONIC
PARTS CATALOG.
Footrest Bracket Replacement
A footrest bracket replacement kit (P/N 703 500
852) is available trough regular channel.
Order a replacement kit for each bracket to be re-
placed.
tmr2011-039-004
Replacing footrest bracket request to cut the
After insert installation, ensure insert can hold the original welded one. Cut the damaged bracket at
torque applied to the screw it retains and measure 111 mm (4-3/8 in) from the square tube.
the compressed length of the frame insert. Oth- NOTICE Do not cut shorter than dimension
erwise, install a new insert. specified.
COMPRESSED
INSERT
LENGTH
9 mm ± 0.5 mm
Insert for M6 bolt
(.354 in ± .02 in)
11.5 mm ± 0.5 mm
Insert for M8 bolt
(.453 in ± .02 in)
vmr2015-060-002_a
A. 111 mm (4-3/8 in)
Install the new footrest bracket and tighten nuts

to specification.
290 vmr2016-066
Section 08 CHASSIS
vsi2014-017-003
REPLACEMENT KIT
TIGHTENING TORQUE
24.5 N•m ± 3.5 N•m
Footrest bracket nuts
vmr2016-066 291
Subsection XX (ENGINE 450)
ENGINE 450
ENGINE
ROTAX 450, 4-stroke, Single Over Head
Engine type
Camshaft (SOHC), liquid cooled
Number of cylinder 1
Number of valves 4 valves (mechanical adjustment)
Bore 94 mm (3.7 in)
Stroke 61.5 mm (2.42 in)
Displacement 426.8 cm³ (26.04 in³)
Compression ratio 10.3:1
Maximum HP RPM 7500
Intake valve opening 5° BTDC
Intake valve closing 45° ABDC
Exhaust valve opening 55° BBDC
Exhaust valve closing 5° ATDC
Intake 0.06 mm to 0.14 mm (.0024 in to .0055 in)
Valve clearance
Exhaust 0.11 mm to 0.19 mm (.0043 in to .0075 in)
New 5.472 mm to 5.486 mm (.2154 in to .216 in)
Intake
Valve stem diameter
Exhaust
New 0.005 mm (.0002 in)
Valve out of round Intake and Exhaust
Valve guide diameter Intake and Exhaust
New 40.41 mm (1.591 in)
Valve spring free length
Service limit 39.00 mm (1.535 in)
Intake
Valve seat contact width
Exhaust
New 93.950 mm to 93.966 mm (3.6988 in to 3.6994 in)
Piston measurement
Piston/cylinder clearance
1st Upper compression ring, rectangular
Piston ring type 2nd Lower compression ring, taper-face
3rd Oil scraper ring, standard
vmr2017-118 1
ENGINE
Upper compression ring 0.20 mm to 0.35 mm (.008 in to .014 in)
Lower compression ring New 0.35 mm to 0.55 mm (.014 in to .022 in)
Oil scraper ring 0.20 mm to 0.70 mm (.008 in to .028 in)
Piston ring end gap
Upper compression ring 0.60 mm (.024 in)
Lower compression ring Service limit 0.85 mm (.033 in)
Oil scraper ring 1.00 mm (.039 in)
Upper compression ring 0.03 mm to 0.07 mm (.0012 in to .0028 in)
Lower compression ring New 0.02 mm to 0.06 mm (.0008 in to .0024 in)
Oil scraper ring 0.01 mm to 0.18 mm (.0004 in to .0071 in)
Ring/piston groove clearance
Upper compression ring 0.150 mm (.0059 in)
Lower compression ring Service limit 0.150 mm (.0059 in)
Oil scraper ring 0.250 mm (.0098 in)
Rocker arm bore diameter
Rocker arm shaft diameter
Cylinder bore Nominal new 93.993 mm to 94.007 mm (3.7005 in to 3.7011 in)
Maximum new 0.038 mm (.0015 in)
Cylinder taper
Maximum new 0.015 mm (.0006 in)
Cylinder out of round
Spark plug side
Camshaft main bearing Service limit 21.950 mm (.8642 in)
journal New 34.959 mm to 34.975 mm (1.3763 in to 1.377 in)
Timing chain side
Spark plug side
Camshaft main bearing Service limit 22.040 mm (.8677 in)
journal bore New 35.000 mm to 35.025 mm (1.378 in to 1.3789 in)
Timing chain side
Intake
Camshaft lobe
Exhaust
Crankshaft axial clearance
Crankshaft deflection MAG/PTO side New 0.05 mm (.002 in)
Crankshaft pin diameter
2 vmr2017-118
ENGINE
Crankshaft main journal New 42.016 mm to 42.040 mm (1.6542 in to 1.6551 in)

MAG/PTO side
diameter Service limit 42.000 mm (1.6535 in)
Crankcase plain bearing
MAG/PTO side Service limit 42.100 mm (1.6575 in)
diameter
Crankshaft radial play MAG/PTO side Service limit 0.07 mm (.0028 in)
Connecting rod big end diameter Service limit 40.100 mm (1.579 in)
Connecting rod big end radial play Service limit 0.09 mm (.0035 in)
Connecting rod big end axial play
Connecting rod small end diameter
Piston pin diameter
Connecting rod/piston pin clearance Service limit 0.080 mm (.0031 in)
LUBRICATION SYSTEM
Type Wet sump with replaceable oil filter
Oil filter Replaceable cartridge
Engine oil pressure Minimum 350 kPa (51 PSI) at 6000 RPM
Capacity
3 L (3.2 qt (U.S. liq.)) (engine/transmission)
(oil change with filter)
Lubrication
For the summer season use XPS 4-stroke
synth. blend oil (summer) (P/N 293 600 121).
Engine oil For the summer season use XPS 4-stroke
Recommended synthetic oil (All climate) (P/N 293 600 112).
If not available, use a 4-stroke SAE 5W 40
engine oil that meets the requirements for
API service classification SG, SH or SJ
Oil pressure regulator compression spring free New nominal 64 mm (2.52 in)
length Service limit 62 mm (2.441 in)
Oil pump inner and outer rotor clearance Service limit 0.25 mm (.0098 in)
Oil pump axial clearance Service limit 0.10 mm (.0039 in)
vmr2017-118 3
COOLING SYSTEM
Finland,
Norway and Use Long life antifreeze (P/N 619 590 204)
Sweden
All other
Type Use Long life antifreeze (P/N 219 702 685)
Coolant countries
Coolant specifically designed
Alternative, or
for aluminum engines
if not available
Ethyl glycol/distilled water mix (50%/50%).
Capacity 2.9 L (3.1 qt (U.S. liq.))
Starts to open 65°C (149°F)
Thermostat
Fully open 75°C (167°F)
TRANSMISSION
Type CVT (Continuously Variable Transmission)
Engagement RPM 2000 ± 100 RPM
Drive belt width Service limit 30.00 mm (1.181 in)

Governor cup roller outer diameter
Governor cup roller inner diameter
Centrifugal lever pivot bolt diameter
Centrifugal lever bore diameter
Centrifugal lever pivot bolt bore diameter
Drive pulley sliding sheave large bushing
Drive pulley sliding sheave small bushing
Drive pulley spring free length Service limit 75 mm (2.953 in)
Drive pulley spring squareness Service limit 4 mm (.157 in)
Spring sleeve length
Driven pulley sliding sheave bushing
Driven pulley fixed sheave bushing
Torque gear on driven pulley Service limit 7.500 mm (.295 in)
Cam width on top surface Service limit 6.000 mm (.236 in)
4 vmr2017-118
TRANSMISSION
Driven pulley sliding sheave wear on contact surface Service limit 2.000 mm (.079 in)
Driven pulley spring free length Service limit 164 mm (6.457 in)
Driven pulley spring squareness Service limit 3.8 mm (.15 in)
GEARBOX
Dual range (HI-LO) with park, neutral
Type
and reverse
Output shaft axial clearance
Bevel gear axial clearance
Gear groove width
MAG side 17.990 mm (.708 in)
Counter shaft Service limit
PTO side 24.950 mm (.982 in)
Bevel gear shaft PTO side Service limit 24.990 mm (.984 in)
Shift fork claw thickness
High 3.700
PRO Low 7.509
Reverse 7.863
Overall gear ratio
High 3,545
All other Low 6,769
Reverse 7,608
ELECTRICAL SYSTEM
Without DPS 400 W @ 6000 RPM
Magneto generator output With DPS 500 W @ 6000 RPM
CE version 500 W @ 6000 RPM
Stator resistance (20°C (68°F)) 0.15 to 0.30
Ignition system type IDI (Inductive Discharge Ignition)
Ignition timing Not adjustable
Quantity 1
Spark plug Make and type NGK LMAR8D-J
Gap 0.7 mm to 0.9 mm (.028 in to .035 in)
Forward 8000 RPM
Engine RPM limiter setting
Reverse 15 km/h (9 MPH) without Override)
vmr2017-118 5
FUEL SYSTEM
Electronic Fuel Injection (EFI), 46 mm throttle
Fuel delivery Type
body, 1 injector per cylinder
Idle speed 1250 RPM ± 50 (not adjustable)
6 vmr2017-118
ENGINE 570
ENGINE
ROTAX® 570, 4-stroke, 2 cylinders
Engine type
(V-twin), liquid cooled
4 valves/cylinder (mechanical
Valve train adjustment), single over head
camshaft (SOHC) with timing chain
Bore 84 mm (3.31 in)
Displacement 570 cm³ (34.8 in³)
Compression ratio 10.6:1
Maximum HP RPM 8000 RPM
Spark arrestor approved by USDA
Exhaust system
Forest Service
Air filter Synthetic paper filter with foam
Intake valve opening 3° BTDC
Intake valve closing 34 ABDC
Exhaust valve opening 39° BBDC
Exhaust valve closing 2° BTDC
0.06 mm to 0.14 mm
Intake
(.0024 in to .0055 in)
Valve clearance
0.11 mm to 0.19 mm
Exhaust
(.0043 in to .0075 in)
4.966 mm to 4.980 mm
New
Intake (.1955 in to .1961 in)
Valve stem diameter
4.956 mm to 4.970 mm
New
Exhaust (.1951 in to .1957 in)
Intake and New 0.005 mm (.0002 in)

Valve out of round
exhaust Service limit 0.06 mm (.0024 in)
4.998 mm to 5.018 mm
New
Valve guide diameter (.1968 in to .1976 in)
New 40.81 mm (1.607 in)
Valve spring free length
1.05 mm to 1.35 mm
New
Intake (.041 in to .053 in)
Valve seat contact width
1.25 mm to 1.55 mm
New
Exhaust (.049 in to .061 in)
Service limit 2 mm (.079 in)
vmr2017-119 1
ENGINE
12.036 mm to 12.050 mm
New
Rocker arm bore diameter (.4739 in to .4744 in)
12.000 mm to 12.018 mm
New
Rocker arm shaft diameter (.4724 in to .4731 in)
83.950 mm to 83.966 mm
New
Piston diameter (3.3051 in to 3.3057 in)
0.057 mm to 0.087 mm
New
Piston/cylinder clearance (.0022 in to .0034 in)
1st Upper compression ring, rectangular
Piston ring type 2nd Lower compression ring, tapered face
3rd Oil scraper ring
0.10 mm to 0.30 mm
New
Rectangular (.004 in to .012 in)
0.35 mm to 0.55 mm
New
Ring end gap Tapered face (.014 in to .022 in)
0.20 mm to 0.70 mm
New
Oil scraper ring (.008 in to .028 in)
0.025 mm to 0.070 mm
New
Rectangular (.001 in to .0028 in)
0.020 mm to 0.060 mm
New
Ring/piston groove clearance Tapered face (.0008 in to .0024 in)
0.010 mm to 0.180 mm
New
Oil scraper ring (.0004 in to .0071 in)
84.023 mm to 84.037 mm
Cylinder bore New
(3.308 in to 3.3085 in)
Maximum
0.038 mm (.0015 in)
Cylinder taper new
Maximum
0.015 mm (.0006 in)
Cylinder out of round new
2 vmr2017-119
ENGINE
34.959 mm to 34.975 mm
Timing chain New
(1.3763 in to 1.377 in)
side
Camshaft main bearing journal
21.959 mm to 21.980 mm
Spark plug New
(.8645 in to .8654 in)
side
35.000 mm to 35.025 mm
Timing chain New
(1.378 in to 1.3789 in)
side
Camshaft main bearing journal bore
22.000 mm to 22.021 mm
Spark plug New
(.8661 in to .867 in)
side
Wear limit 22.040 mm (.8677 in)
31.830 mm to 32.030 mm
New
Intake valve (1.2531 in to 1.261 in)
Camshaft lobe
31.730 mm to 31.930 mm
New
Exhaust valve (1.2492 in to 1.2571 in)
42.016 mm to 42.040 mm
Crankshaft main bearing journal diameter New
(1.6542 in to 1.6551 in)
(MAG/PTO side)
Crankshaft radial play (MAG/PTO side) Service limit 0.07 mm (.0028 in)
34.004 mm to 34.020 mm
New
Crankshaft bearing journal diameter (in PTO cover) (1.3387 in to 1.3394 in)
Crankshaft radial play (PTO cover bearing) Service limit 0.10 mm (.0039 in)
0.200 mm to 0.500 mm
New
Crankshaft axial play (.0079 in to .0197 in)
40.001 mm to 40.025 mm
New
Crankshaft pin diameter (1.5748 in to 1.5758 in)
MAG/PTO
Crankshaft deflection New 0.050 mm (.002 in)
side
MAG/PTO
Crankcase plain bearing Service limit 42.100 mm (1.6575 in)
side
PTO cover plain bearing Service limit 34.120 mm (1.3433 in)
Connecting rod big end diameter Service limit 40.100 mm (1.5787 in)
Connecting rod big end radial play Service limit 0.09 mm (.0035 in)
0.200 mm to 0.500 mm
New
Connecting rod big end axial play (.008 in to .02 in)
vmr2017-119 3
ENGINE
20.010 mm to 20.020 mm
New
Connecting rod small end diameter (.7878 in to .7882 in)
19.996 mm to 20.000 mm
New
Piston pin diameter (.7872 in to .7874 in)
Connecting rod/piston pin clearance (radial play) Service limit 0.080 mm (.0031 in)
LUBRICATION SYSTEM
Wet sump. Replaceable cartridge
Type
oil filter
Engine oil pressure Minimum 300 kPa (44 PSI) at 6000 RPM
Capacity (oil change with
2.0 L (2.1 qt (U.S. liq.))
filter)
For the summer season,
use XPS 4-stroke synth.
Engine oil blend oil (P/N 293 600 121).
For the all seasons, use XPS 4-stroke
Recommended
synthetic oil (P/N 293 600 112).
If not available, use a 5W40 motor oil
that meets the requirements for API
service classification SG, SH or SJ
COOLING SYSTEM
Finland,
Use Long life antifreeze (P/N 619
Norway and
590 204)
Sweden
All other Use long life antifreeze (P/N 219
Type countries 702 685)
Coolant
Alternative,
or if not
Ethyl glycol/distilled water mix
available
(50%/50%).
Capacity 3.4 L (.9 U.S. gal.)
Starts to
65°C (149°F)
Thermostat open
Fully open 75°C (167°F)
TRANSMISSION
CVT (Continuously Variable
Type
Transmission)
Engagement RPM 1800 RPM
Drive belt width Service limit 30.00 mm (1.181 in)
13.80 mm to 14.00 mm
New
Governor cup roller outer diameter (.543 in to .551 in)
4 vmr2017-119
TRANSMISSION
8.025 mm to 8.175 mm
New
Governor cup roller inner diameter (.316 in to .322 in)
6.078 mm to 6.100 mm
New
Centrifugal lever pivot bolt diameter (.239 in to .24 in)
6.035 mm to 6.078 mm
New
Centrifugal lever bore diameter (.2376 in to .2393 in)
6.113 mm to 6.171 mm
Drive pulley sliding half centrifugal lever pivot bolt bore New
(.241 in to .243 in)
diameter
55.000 mm to 55.040 mm
New
Drive pulley sliding half large bushing (2.165 in to 2.167 in)
32.000 mm to 32.040 mm
New
Drive pulley sliding half small bushing (1.26 in to 1.261 in)
Drive pulley spring free length Service limit 85 mm (3.35 in)
Drive pulley spring free squareness Service limit 4 mm (.157 in)
Spring sleeve length
30.060 mm to 30.100 mm
New
Driven pulley sliding half bushing (1.183 in to 1.185 in)
30.060 mm to 30.100 mm
New
Driven pulley sliding fixed bushing (1.183 in to 1.185 in)
Torque gear on driven pulley Service limit 7.500 mm (.295 in)
Driven pulley spring free length Service limit 125 mm (4.92 in)
Driven pulley spring free squareness Service limit 3.8 mm (.15 in)
Cam width in top surface Service limit 4.50 mm (.177 in)
vmr2017-119 5
GEARBOX
Dual range (HI-LO) with park,
Type
neutral and reverse
Angle drive
37/15 = 2.467
sub-transmission
Intermediate 45/40 = 1.125
PRO
High 36/27 = 1.33
Low 46/17 = 2.706

Gear ratios Reverse 34/12 = 2.833
Angle drive
32/13 = 2.462
sub-transmission
All other High 38/28 = 1.357

Low 46/20 = 2.300
Reverse 31/14 = 2.214
High 3.700
PRO Low 7.509
Reverse 7.863
Overall gear ratio
High 3.341
All other Low 5.662
Reverse 5,451
Capacity Approximately 450 ml (15.2 U.S. oz)
Gearbox oil XPS synthetic gear oil (75W 140)
Recommended (P/N 293 600 140) or a 75W140
API GL-5 synthetic gear oil
0.10 mm to 0.20 mm
New
Output shaft backlash (.004 in to .008 in)
5.25 mm to 5.35 mm
New
Coupling sleeve groove width (.207 in to .211 in)
4.95 mm to 5.05 mm
New
Coupling fork claw thickness (.195 in to .199 in)
4.80 mm to 4.90 mm
Shift fork claw thickness New
(.189 in to .193 in)
(high gear shift fork)
5.10 mm to 5.20 mm
Shift fork claw thickness New
(.201 in to .205 in)
(low and reverse gear shift fork)
6.92 mm to 6.97 mm
New
Shift fork pin diameter (.272 in to .274 in)
6 vmr2017-119
GEARBOX
5.30 mm to 5.40 mm
Width of shift fork engagement groove New
(.209 in to .213 in)
(low and reverse gear)
5.00 mm to 5.10 mm
Width of shift fork engagement groove New
(.197 in to .201 in)
(high gear)
29.000 mm to 29.013 mm
New
Diameter free pinions (1.1417 in to 1.1422 in)
24.979 mm to 25.000 mm
New
Intermediate gear shaft (.9834 in to .9843 in)
New N.A.
MAG side
New N.A.
Countershaft CVT side
Free New N.A.
pinion
bearing Service limit 24.970 mm (.9831 in)
Free
Bevel gear shaft pinion Service limit 24.984 mm (.9836 in)
bearing
ELECTRICAL SYSTEM
Without
400 W @ 6000 RPM
DPS
Magneto generator output
With DPS 500 W @ 6000 RPM
CE version 500 W @ 6000 RPM
Stator resistance (20°C (68°F)) 0.15 to 0.30
Quantity 2
Make and
Spark plug NGK DCPR8E
type
Gap 0.7 mm to 0.8 mm (.028 in to .031 in)
Forward 8000 RPM
FUEL SYSTEM
Electronic Fuel Injection (EFI), 46 mm
Fuel delivery
throttle body, 1 injector per cylinder
Idle speed 1400 ± 50 (not adjustable)
vmr2017-119 7
Subsection XX (OUTLANDER)
OUTLANDER
COOLING SYSTEM
Ethyl glycol and distilled
water (50%/50%).
Use BRP LONG LIFE
ANTIFREEZE (P/N 219
Type 702 685) or (P/N 619 590
204) (Finland, Norway
and Sweden) or coolant
Coolant specifically formulated for
aluminum engines
450 2.9 L (.77 U.S. gal.)
570
3.4 L (.9 U.S. gal.)
Quantity 650
850
3.5 L (.92 U.S. gal.)
1000R
Radiator cap opening pressure 110 kPa (16 PSI)
EXHAUST SYSTEM
Spark arrestor approved by
Exhaust system
USDA Forest Service
ELECTRICAL SYSTEM (650 / 850 / 1000R)

Type Maintenance free
Voltage 12 volts
Battery
Nominal rating 18 A•h
Power starter output 0.7 KW
High 2 x 60 W (HB3)
Headlight
Low 2 x 55 W (H1)
Taillight 2 X 5/21 W
Turn signal lights (CE models only) 4 x 10 W
Position lights (CE models only) 2 x 5 W
Licence plate light (CE models only) 1 x 10 W
Main FL-1 16 gauge
Fusible links Fan
FL-2 16 gauge
Main accessories power
vmr2017-124 1
ELECTRICAL SYSTEM (650 / 850 / 1000R)

Accessory relay control
Brake lights relay control
Communication connector
F4 5 A
Gauge
Brake relay
DPS control
Ignition coils
Fuel injectors F5 5 A
Vehicle speed sensor
Engine control module power (ECM)
F6 5 A
Fan relay control
Position lights (Europe)
Winch control F7 5 A
2W/4W control
ECM (wake up signal)
Fuses F8 5 A
Ignition switch
(fuse box 1)
Fan motor F9 25 A
Clock
Hazard lights
F10 5 A
Hazard/Signal lights/Horn
(Europe)
Headlights power F11 30 A
Connector DC3
12 V power outlet
F12 15 A
Communication connector
(DB6)
Connectors DC5 and DC6
Taillights F14 15 A
License plate light
Fuel pump relay F15 5 A
Fuse in fuse box 2 DPS / ACS F3 40 A
ELECTRICAL SYSTEM (450 / 570)

Voltage 12 volts
Battery
Nominal rating 18 A•h
Power starter output 0.7 KW
Headlight High / Low HS1 35 W
Taillight 5/21 W
Turn signal lights (CE models only) 4 x 10 W
Position lights (CE models only) 2 x 5 W
Licence plate light (CE models only) 1 x 10 W

Main FL-1 16 gauge
Fusible links Fan
FL-2 16 gauge
Main accessories power
2 vmr2017-124
ELECTRICAL SYSTEM (450 / 570)

Gauge
F4 10 A
Diagnostic connector
Injectors/Ignition,
ECM,
Fuel Pump, F5 10 A
VSS
F an relay control
Fuses Key Switch,
(fuse box 1) Engine control
module power (ECM), F8 10 A
Starter Solenoid,
Clock
Fan motor F9 20 A
DC Outlet/Light/Accessories,
Euro Control (CE), F12 20 A
2WD/4WD
Fuse in fuse box 2 DPS / ACS F3 40 A
FUEL SYSTEM
Fuel delivery Electronic Fuel Injection (EFI)
Type Electrical (in fuel tank)
Fuel pump Operating
350 kPa (51 PSI)
pressure
Type Regular unleaded gasoline
Inside North
87 (R+M)/2 or higher
Fuel America
Octane rating
Outside North
92 RON or higher
America
Fuel tank capacity 20.5 L (5.4 U.S. gal.)
Fuel remaining when low fuel light turns ON ± 5 L (1.3 U.S. gal.)
DRIVE SYSTEM
Base models Visco-lok† front differential
Front drive All other
Visco-lok † QE front differential
models
Front drive ratio 3.6:1
Straight bevel gear / Shaft

Rear drive
driven final drive
Rear drive ratio 3.6:1
Capacity 500 ml (17 U.S. oz)
XPS synthetic gear
Front differential oil oil (P/N 293 600 043)
Recommended
or synthetic gear oil 75W90
API GL-5
vmr2017-124 3
DRIVE SYSTEM
Capacity 250 ml (8.45 U.S. oz)
XPS synthetic gear oil (75W
Rear final drive oil 140) (P/N 293 600 140)
Type
or synthetic gear oil 75W140
API GL-5
CV joint grease (P/N 293 550
CV joint grease
062) or an equivalent
Propeller shaft grease (P/N 293

Propeller shaft grease for spline connections
550 063) or an equivalent
STEERING
1-UP 450 / 570 212.1 cm (83.5 in)
X mr 650 256.5 cm (101 in)
X mr 850 294 cm (115.7 in)
MAX X mr
Turning radius 431.8 cm (170 in)
1000R
2-UP 650 /
850 / 1000R 233.7 cm (92 in)
Except X mr
2-UP 450 / 570 239 cm (94 in)
Total toe (vehicle on the ground) 0.1° to 0.5° toe-in
Camber angle (vehicle on the ground) 0°
Tie-rod maximum length unengaged threads 348.5 mm (13.72 in)
FRONT SUSPENSION
Double suspension-arm with
Suspension type
dive-control geometry
X mr 850
149 mm (5.9 in)
MAX X mr 1000R
Suspension travel X mr 570 137 mm (5.4 in)
All others 216 mm (8.5 in)
Qty 2
HPG shock with piggy back
XT-P
reservoir. QS3† compression
X mr 1000R
and preload adjustments
Shock absorber
Type X mr 570
HPG
X mr 850
All other
Oil
models
4 vmr2017-124
FRONT SUSPENSION
DPS 650
DPS 850 340 mm (13.39 in)
DPS 1000R
450
326 mm (12.83 in)
570
X mr 850 322.5 mm (12.7 in)
1-UP X mr 570
370 mm (14.57 in)
X mr 650
STD 650 350 mm (13.78 in)
STD 850 340 mm (13.39 in)
XT 350 mm (13.78 in)
Spring free length
XT-P 320 mm (12.6 in)
X mr 1000R 322.5 mm (12.7 in)
DPS 650
DPS 850 354 mm (13.94 in)
DPS 1000R
STD 354 mm (13.94 in)
2-UP
LTD
362 mm (14.25 in)
XT 1000R
XT 650
362 mm (14.25 in)
XT 850
XT-P 320 mm (12.6 in)
HPG Variable positions
Preload adjustment type
Oil 5 positions cam
REAR SUSPENSION
Torsional Trailing arm Independant
Suspension type
(TTI) with external stabilizer bar
X mr 850
180 mm (7.1 in)
MAX X mr 1000R
450
216 mm (8.5 in)
Suspension travel 570
650
850 (except X mr) 227 mm (8.9 in)
1000R (except X mr)
Qty 2
X mr 570
HPG
850 X mr
HPG shock with piggy back
XT-P
Shock absorber QS3† compression and preload
Type X mr 1000R
adjustments
LTD ACS
All other
Oil
models
vmr2017-124 5
REAR SUSPENSION
XT-P 306 mm (12.05 in)
450
315.6 mm (12.43 in)
570
Outlander 570 X mr
1-UP 650 X mr 366.7 mm (14.44 in)
850 X mr
All other
355.9 mm (14.01 in)
Spring free length models
STD 354 mm (13.94 in)
DPS
366.4 mm (14.43 in)
XT 1000R
Outlander
2-UP XT Except
1000R 370 mm (14.57 in)
X mr 1000R
XT-P 306 mm (12.05 in)
0.35 bar to
6.90 bar
ACS pneumatic pressure range LTD
(5 PSI to
100 PSI)
LTD 6 Presets
Preload adjustment type XT-P Variable positions
Oil 5 position cam
BRAKES
Qty 2
Front brake 214 mm cross drilled disc brakes

Type
with hydraulic twin-piston calipers
Qty 1
Rear brake 214 mm cross drilled disc brake
Type
with hydraulic twin-piston caliper
Brake fluid
Type DOT 4
Caliper Floating twin pistons (2 x 26 mm)
Brake pad material Organic
Minimum brake pad thickness 1 mm (.04 in)
Minimum brake disc thickness 4 mm (.157 in)
Maximum brake disc warpage 0.2 mm (.01 in)
6 vmr2017-124
TIRES
UP TO 164 kg
41.4 kPa (6 PSI)
(360 lb)
1-UP FROM 164 kg
(360 lb) TO 48.2 kPa (7 PSI)
235 kg (517 lb)
Front
UP TO 132 kg
41.4 kPa (6 PSI)
(290 lb)
2-UP FROM 132 kg
(290 lb) TO 48.2 kPa (7 PSI)
272 kg (600 lb)
Pressure
UP TO 164 kg
41.4 kPa (6 PSI)
(360 lb)
1-UP FROM 164 kg
(360 lb) TO 68.9 kPa (10 PSI)
235 kg (517 lb)
Rear
UP TO 132 kg
41.4 kPa (6 PSI)
(290 lb)
2-UP FROM 132 kg
(290 lb) TO 68.9 kPa (10 PSI)
272 kg (600 lb)
Minimum tire thread depth 3 mm (.118 in)
X mr 1000R 762 x 229 x 355 mm (30 x 9x 14 in)
X mr 570 711 x 203 x 305 mm (28
X mr 650 x 8 x 12 in)
450 / 570
635 x 203 x 305 mm (25
Except X mr and Mossy
x 8 x 12 in)
Oak Hunting edition
Front
STD 650
STD 850
660 x 203 x 305 mm (26
STD 1000R
x 8 x 12 in)
All Mossy Oak Hunting
edition
Size All other models 660 x 203 x 356 (26 x 8 x 14)
X mr 1000R 762 x 229 x 355 mm (30 x 9x 14 in)
X mr 570 711 x 254 x 305 mm (28

X mr 650 x 10 x 12 in)
450 / 570
635 x 254 x 305 mm (25
Rear Except X mr and Mossy
x 10 x 12 in)
Oak Hunting edition
Standard 650 / 850
660 x 254 x 305 mm (26
/ 1000R models
x 10 x 12 in)
All Mossy Oak Hunting edition
All other models 660 x 203 x 356 (26 x 10 x 14)
vmr2017-124 7
WHEELS
Standard models Steel
Type XT-P Aluminium beadlocks
All other models Cast aluminum
X mr 1000R 355 x 165 mm (14 x 6.5 in)
Standard models
Mossy Oak Hunting edition
305 x 152 mm (12 x 6 in)
Front X mr 570
X mr 650
XT-P 356 x 165 (14 x 6.5)
All other models 356 x 152 (14 x 6)
Rim size
X mr 1000R 355 x 165 mm (14 x 6.5 in)
Standard models
Mossy Oak Hunting edition
305 x 191 mm (12 x 7.5 in)
Rear X mr 570
X mr 650
XT-P 356 x 165 (14 x 8)
All other models 356 x 152 (14 x 8.5)
100 N•m ± 10 N•m
Wheel nut torque
DIMENSION
1-UP 450 / 570 211 cm (83 in)
1-UP 650 / 850 / 1000R 218.4 cm (86 in)
2-UP 450 / 570 231 cm (91 in)
Overall length 2-UP 650 / 850 / 1000R exept
238.8 cm (94 in)
X mr
X mr 650
224 cm (88 in)
X mr 850
X mr 1000R 246 cm (97 in)
X mr 650 118 cm (46 in)

X mr 850
Overall width 127 cm (50 in)
X mr 1000R
All other models 117 cm (46.1 in)
1-UP 450 / 570 124 cm (49 in)

1-UP 650 / 850 / 1000R
126 cm (49.5 in)
Except X mr
2-UP 450 / 570 133 cm (52.5 in)
Overall height 2-UP 650 / 850 / 1000R
135 cm (53 in)
Except X mr
X mr 650 128 cm (50.5 in)
X mr 850
131 cm (51 in)
X mr 1000R
8 vmr2017-124
DIMENSION
1-UP 129.5 cm (51 in)
Wheel base
2-UP 149.9 cm (59 in)
X mr 850
103.5 cm (40.7 in)
Front X mr1000R
All other models 97.5 cm (38.4 in)
X mr 650 94.5 cm (37.2 in)
Wheel track X mr 850
100 cm (39.4 in)
X mr 1000R
Rear
650 / 850 / 1000R
93 cm (36.6 in)
Except X mr
450 / 570 92.3 cm (36 in)
X mr 650 30 cm (11.8 in)
X mr 850
33 cm (13 in)
X mr 1000R
650 / 850 / 1000R
28 cm (11 in)
Ground clearance Except X mr
570 Mossy Oak Hunting Edition 29.2 cm (11.5 in)
450 / 570
Except Mossy Oak Hunting 26.7 cm (10.5 in)
Edition
WEIGHT AND LOADING CAPACITY

450 308 kg (678 lb)
570 except X mr 319 kg (704 lb)
X mr 570 382 kg (843 lb)
1-UP
1000R 361 kg (795 lb)
X mr 650 396 kg (874 lb)
X mr 850 437 kg (963 lb)
Dry weight
450 324 kg (715 lb)
570 336 kg (741 lb)
650 372 kg (820 lb)
XT 650 361 kg (796 lb)
2-UP
850 372 kg (820 lb)
1000R except X mr 381 kg (840 lb)
X mr 1000R 449 kg (990 lb)
450
54 kg (120 lb)
Front rack 570
All other models 45 kg (100 lb)
450
109 kg (240 lb)
Rear rack 570
All other models 90 kg (200 lb)
vmr2017-124 9
WEIGHT AND LOADING CAPACITY

450 11 L (2.9 U.S. gal.)or
Rear storage compartment loading 570 10 kg (22 lb)
capacity
All other models 21.4 L (5.7 U.S. gal.)
Total vehicle load allowed (including driver, X mr 189 kg (417 lb)

passenger, all other loads and added 1-UP except X mr 235 kg (517 lb)
accessories) 2-UP except X mr 272 kg (600 lb)
Except CE version 590 kg (1,300 lb)
Towing capacity
CE version 135 kg (300 lb)
Except CE version 23 kg (50 lb)
Tongue capacity
CE version 13.5 kg (30 lb)
10 vmr2017-124
Section 10 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM INFORMATION)
WIRING DIAGRAM INFORMATION

GENERAL 22
WIRING DIAGRAM
INFORMATION VT/BG 22 MG2-1
NOTE: The wiring diagrams are in the manual vmr2016-068-003_a
back cover pocket.
The wiring diagrams use the following codes. Connector Identification
Indicates the connector individually. If there are
1 2 many connectors in the same area, this helps to
3 4
identify which wire is in which connector.
MG2-1
VT/BG 22 MG2
vmr2016-068-001_a
1. Wire colors
VT/BG 22 MG2-1
2. Wire gauge
3. Connector identification
4. Terminal location in connector vmr2016-068-004_a
Wire Colors Terminal Location in Connector

It identifies the color of a wire. When a 2-color This is the terminal position in the connector. The
scheme is used, the first color is the main color number or letter given refers to the physical iden-
while the second color is the tracer color. tification stamped on the connector.
NOTE: If no letter or number is indicated on the
VT/BG connector, they are indicated where there is a spe-

cific test using this connector.
VT/BG 22 MG2-1
1
vmr2016-068-002_a
Example: VT/BG is a VIOLET wire with a BEIGE VT/BG 22 MG2-1

stripe.
vmr2016-068-005_a
COLOR CODE
BG — BEIGE OG — ORANGE PROCEDURES
BK — BLACK RD — RED
This section gives the procedures in order to
BU — BLUE VT — VIOLET quickly repair electrical harness splices.
BN — BROWN WH — WHITE 1. Make sure to perform the usual tests described
in ELECTRICAL SYSTEM sections before inves-
GN — GREEN YE — YELLOW
tigating the harness splices.
GY — GRAY PK — PINK 2. If an electrical issue can not be found with the
LT prefix means a "light" color. E.g: LT GN = Light usual tests, locate the main harness splice that
green. is involved in the faulty circuit and repair it as
per the SPLICES REPAIR PROCEDURE.
Wire Gauge 3. To repair a splice, we recommend the use of a
The number after wire color indicates the gauge tin solder meeting the followings requirements
of a wire. or an equivalent.
vmr2016-068 315
TIN SOLDER REQUIREMENTS

SN 60
PB 40
DIA 0.062
FLUX RA 2%
SPLICES REPAIR PROCEDURE

mmr2010-043-003
CASE 1: Wire Detached from Splice
1. Locate splice. Refer to splices location dia- 4.3 Remove the shrink tube with long nose pli-
grams. ers.
2. Remove wires from protector tube. 5. Locate detached wire from splice.
3. Locate the shrink tube protecting the defective
splice.
mbg2008-021-116_a
mmr2010-043-001_a
1. Detached wire
1. Shrink tube 2. Splice
4. Remove the shrink tube. 6. Twist detached wire around splice.

4.1 Using a blade, cut the shrink tube.
mmr2010-043-002
NOTICE Be careful with the blade to

mbg2008-021-117_a
avoid cutting wires insulation.
1. Twisted wire
4.2 Slightly heat the shrink tube using a heat
gun. 7. Perform a tin solder on twisted wire.
8. Apply electrical tape to cover splice.
NOTE: Make sure tape overlaps on wire insula-
tion, approximately 13 mm (1/2 in) each side.
9. Reinstall wires into protector tube.
316 vmr2016-068
CASE 2: Wire Broken from Splice

1. Locate splice. Refer to splices location dia-
grams.
2. Remove wires from protector tube.
3. Locate the shrink tube protecting the defective
splice.
mbg2008-021-118_a
1. Broken wire
2. Splice
6. Strip wire insulation at the end of broken wire.

7. Strip wire insulation below the splice.
mmr2010-043-001_a
1. Shrink tube
4. Remove the shrink tube.

4.1 Using a blade, cut the shrink tube.
mbg2008-021-119_a
1. Broken wire stripped

2. Splice wire stripped
mmr2010-043-002
8. Twist wire around stripped wire.
NOTICE Be careful with the blade to
avoid cutting wires insulation.
4.2 Slightly heat the shrink tube using a heat
gun.
mbg2008-021-120_a
1. Twisted wire
9. Perform a tin solder on twisted wire.

mmr2010-043-003
10. Apply electrical tape to cover splice.
NOTE: Make sure tape overlaps on wire insula-
4.3 Remove the shrink tube with long nose pli- tion, approximately 13 mm (1/2 in) each side.
ers.
11. Reinstall wires into protector tube.
5. Locate broken wire from splice.
NOTE: Always perform a solder on a bigger wire
(lower gage).
vmr2016-068 317
1 2 3 4 5 6 7 8 9 10
Outlander 450/570 MAIN HARNESS

A FUELINK FUSELINK
A
Key switch FUSE
Main RELAY INJ/ IGN FUSE
FAN RELAY FAN FUSE
FUEL PMP RELAY RELAY/SPEEDO FUSE ACC RELAY
RD/GN-14
JT-RD/GY
ACC FUSE
BRAKE RELAY
JT-RD/BE
F8 R2 OR/GN-22
RD/GY-12
OR/GN-22
RD/GN-14
RD/GY-16
RD/GY-16
RD/GY-16
RD/BE-18
RD/BE-18
R8
VI/BU-18
VI/BU-18
VI/BU-18
OR/GN-22
OR/GN-22
FL-2 FL-1 BR/RD-16 RD/YL-16
F4 R3 F12
A12
A11
PF1
PF1
PF1
PF1
D2
D1
E6
B1
A1
B3
E3
E10
E12
PF1
PF1
PF1
C8
D8
B5
E9
F5 R1 F9 R4
PF1
16awg 16awg
RD/GY-16
RD/BE-18
86 30 86 30 86 30
10A 10A 20A 86 30 30 86
10A 20A
85 87 85 87 85 87
RD-12
RD-12
85 87 87A 87 85
PF1
PF1
PF1
PF1
B B
PF1
PF1
PF1
PF1
E5
A2
B2
B4
E1
E2
E4
B11
B12
B6
D12
D10
E8
D9
C9
BR/WH-16
BK/RD-20
RD/BK-16
VI/BU-18
WH/OR-22
BK-16
RD/OR-22
C ACC RELAY
B
JT VI/BU JT-RD/OR
OG/WH-22
FT
OR/BK-22
FP-3 (-E-5) RD/OR-22 RD/OR-22
L BRAKE_SW SIGNAL TO ECM
RD/BK-18 BD-5 (-G-3)
RD/GY-16
HIC1_F
OR/GN-20
BK/BU-22
A B BK-22
HIC1_F
RD/BK-18
(-H-2)
JT BK3
A VBR
FRR
VI/BU-18 JT-RD/BK
M
FAN HIC1_F
DC_2
BE-22
VI/BU-18
C 12V COIL_VSS_INJ JT OR/GN
M 2 1
OR/BU-22
B P_LATCH
RD/BK-18
H FP_RELAY P
RD/BK-18
(-G-2)
BN1
DC
FT DB BRK
BK-18
G FAN_RELAY
HIC2_F OG/WH-22 DC
C JT-BE
A VBD 4 HOT AT KEY ON OUTLET C
BE-22 BE-22 OR/GN-20 GN-18
BRK
(-H-2)
JT BK3
DC3
DC_1
5 ALWAYS HOT
2
BE-22 CI-16 (-D-5) BE-22 BU-18
DIAGNOSTIC
18
CC
6
MG2
B
5
JT GN
CONNECTOR
BK-18
DC3_CAP
B F A E C D
GND1 3 GND
OFF
RD/YL
710004570
GN
BU
2 CAN LO
GND1
MG2-4
MG2-2
MG2-5
JT-RD ON/
W LIGHT
1 CAN HI
+ G ND D ES S OFF JT-BU
(-H-2)
JT BK3
LO
GN-20
RD-12
CC
-7104957
HIC2_F HI
OR/GN-22
(-G-2)
BN1
F
C
A
BK-12 (-C-2) JT-BE BE-22

MG-4 OF 4
RD1
BK/WH-22
BK/BR-22
3
WH/OR-22
OR/GN-22
D STOP_SW -7104957
MG_1_OF_4 BK/WH-22
WH/BE-20
JT VI/BE (-F-3) JT-VI/GY VI/GY-22 BU-20
WH/BK-20
RD 1
- 3 +
VI/BE-22
OR/VI-22
16
17
6
5
D JT BK/BR
HIC1_F D
CI
RD-12
MG2
6
RECTIFIER/
20
GN-20
GN-20
BU-20
BU-20
D
OR/RD-22 DESS BK-20 BK-22
YL/RD-20
REGULATOR JT BK/WH
VI/BE-22
B VBK
MG2-6
MG2-1
PG
PD
PR
3
1
RD2-1
RD2-2
RD2-3
BK/BR-22
E ECU GND CI
BK/WH-22
YL YL YL
FREE
BK/BR-22
CAN HI
VI/BE-22
S
START
BK-20
CI
BP1 R CAN LO
MA G NE T O L H L H P B
18
19
21
20
C C
B-SS MG_2_OF_4 CAN LO JT-WH/BK
BK-22
MG1
MG2
YL/RD-20 WH/BK-22 M
WH/BK-22
SS
2
JT-WH/BE
CAN HI
(-H-1)
(-H-1)
(-G-2)
JT BK3
JT BK3
BN1
LT-1
1
WH/BE-22 WH/BE-22 TL
SS1
LT-2
MG1-3 BK/WH
MG1-1 BN
MG1-2 YL
K
MG2-3 BK
BK/BE-22
D2
(-G-1)
BN1
PK-22
BR/PK-22
VI/PK-22
RUN
A
-7104957
E STOP E
BAT1 B N VEH SPEED SENSOR
(-B-4) PF1-B12 BK/RD-20
SS2
BAT F 4WD_SW BK-20

1
J STARTER SOL FP
FP
OR/BR-20 OR/BR-20
BATTERY
4 3 2 1
BAT2 MG_3_OF_4 VI/GY-22
K OVR-SW A B
+
C
+
D
-
(-G-1)
BN1
SM JT-VI/GY
VI/GY-22 VI/GY-22 CI-6 (-D-5) FUEL L
PMP
STARTER
BK-22
-
MG1
FUEL LEVEL
M M 4WD_CTRL_4
5
WH-22
BN1
MG1-6 WH
MG1-5 OR
HIC1_F
F FREE F
OVR
BODY
GND
BK-18
E PGND1
BK-18
F PGND2
BK-22
BK-20
BK-16
BK-22
BK-22
WH/BU-22
H 4WD_CTRL_2
WH/BK-22
G 4WD_CTRL_1
CI-20 FP-4 DB-3 FRR-1 PR-3
(-E-6) (-E-5) (-D-4) (-C-9) (-E-8) -7104957
(-B-7) JT-RD/BK RD/BK-18 BK-20
HIC2_F
BD
BD
5
2
WH/BU
WH
BU
RD
BK
G 2 1 3 6 5 G
(-H-2)
JT BK3
BK-14
2WD
4WD
BD ==> 2WD, 4WD SWITCH

HIC1_F, HIC2_F ==>INTERCONNECT TO ENGINE HARNESS
JT BK3
M
DB ==> DIAGNOSTIC CONNECTOR

DC3, ==>ACCESSORY CONNECTORS
HICA ==> CE OPTION ONLY
FT ==> RADIATOR FAN
H H
BK-20
BK-20
BK-20
BK-18
BK-18
BK-16
MODEL TITLE
All rights reserved.
No parts of this document
MAIN HARNESS 710004957
PD-3 PG-3 BD-2 DC_1- DC3-1 FT-A may be reproduced in any
(-E-7) (-E-7) (-G-3) (-C-7) (-C-6) (-B-3) form without the prior
MY
219001865-003
DRAWED BY DESIGN BY REV DATE
written permission
REV
of Bombardier Recreational
DATE DATE
Products Inc. (BRP). P. SIZE
C PAGE
02
1 2 3 4 5 6 7 8 9 10
A
Outlander 450/570 CE HARNESS A
MAIN HARNESS SIDE CE HARNESS SIDE

INTERCONNECT
JT-19
B B
FROM ACC RELAY/HOT AT KEY ON E
RD/BK-20
BE-20
JT-18
FLASHER HAZARD HORN
OFF OFF
LH
RH
OFF
RUN
HANDLEBAR SW RUN
RD/BK-20
C C
BE/RD-20
BE/GY-20
BE/BR-20
BE/RD-20
BE/BK-20
20
R-3
B
BE/RD-20
MC1-5 MC1-1 MC1-2 MC2-3 A
LS-3
JT-19-
D
FROM MAIN/HOT ALL TIME BE-20 BE-20 MC2-1
BB-2 FLASHER UNIT
JT-21-1
D B D
TO CLUSTER, FLASHER SIGNAL OR-20 MC2-4
MC2-3 MC1-4 MC2-2

LT-18
HAZARD PILOT LAMP

BN-20
GY-20
JT-20-1
JT-21 JT-22 BN-20
E E
GY-20
GY-20
BN-20
BN-20
RD/BK-20
JT-14-2
JT-13-2
JT-12-2
LFF-1
RD/BK-20
LT-14 LT-15 LT-17 RD/BK-20

LT-16
JT-17-1
JT-15-2
LEFT REAR FLASHER
LT-19
LEFT FRONT FLASHER
LT-20 LT-21
RIGHT FRONT FLASHER
RIGHT REAR FLASHER

JT-14-1
JT-13-1
JT-12-1
F F
LEFT POS LAMP
RIGHT POS LAMP
LICENCE LIGHT
JT-16-1
JT-18-1
JT-15-1
BK-20
BK-20
BK-20
BK-20
BK-20
BK-20
BK-20
BK-20
BK-20
G G
TO MAIN VEHICLE GROUND A
BK-20
JT-20
HICA_M
MODEL TITLE
H
may be reproduced in any
FLASHER 710003561 H
form without the prior
MY REV DATE
DRAWED BY DESIGN BY
219001865-004
written permission
REV
of Bombardier Recreational
DATE DATE
Products Inc. (BRP). P. SIZE
B PAGE
09
1 2 3 4 5 6 7 8 9 10
A Outlander 450/570 DPS A
always hot RD-14
BP2
PF2
A
F2
B 40A B
PF2
B
RD/PK-14
C C
JT-RD/PK
RD/PK-18
RD/PK-18
RD/PK-18
DPS
C
E
D D
DPS2-A DPS2-B
Outlander 450/570
JT OR/GN
OR/GN-22
G
HOT AT KEY ON M DPS1
A
JT-WH/BK K DPS1
CAN lo
M
WH/BK-22 C
JT-WH/BE J DPS1
CAN hi
M
WH/BE-22 D
E DPS DPS3-A DPS3-B E
DPS
F
A
B
BK-18
BK-18
BK-18
F
ground F
BN2
G G
MODEL TITLE
DPS 710004898
H MY
DRAWED BY DESIGN BY REV DATE H
written permission
REV PR1
219001865-005 of Bombardier Recreational
Products Inc. (BRP). DATE DATE
2015-07-09
P. SIZE
A PAGE
07
1 2 3 4 5 6 7 8 9 10
A A
Outlander 450/570 Winch Harness
B B
1 1
C BK-20 C
2 2
RD/BK-20 RD/BK-20
DC3F DC3M -
TO 12v Bat
JT-8
BU/GN-20
D D
GN/BU-20
SW1
SW2
1
1
BU/GN-20
GN/BU-20
RD/BK-20
BP4 S-1
K
K
IN OUT
D6
D5
A
RD
A
E SWW-1 E
WINCH RELAY
BK-18
C
A
B
SWW
SW4 BK BU YL
BK-18
WM1
A B C
OUT WINCH
WM-1
F
OFF
IN
M F
WM2
to body
G G
MODEL TITLE
WINCH 710005246
H MY
written permission DRAWED BY DESIGN BY
REV
REV DATE H
219001865-006 of Bombardier Recreational
Products Inc. (BRP). DATE DATE
P. SIZE
A PAGE
08
INTRODUCTION
This publication governs all warranty labor 4. JOB REQUIREMENTS
allowances for 2017 BRP ATV. All the flat rate times mentioned in the following pages
1. HOW DOES IT WORK include the required operations such as: engine timing
(rotary valve and ignition), connecting rod(s) alignment,
We follow the procedures detailed in the BRP cylinder head(s) torque or use of parallel bar, use of ig-
ATV Shop Manual. The flat rate time is the maximum nition tester, piston clearance/ring end gap measure-
time allowed for a repair involving any given part. ment, crankshaft to crankcase measurement, cylinder
FLAT RATE TIME IS NOT CUMULATIVE. You must honing, engine leak test.
use the flat rate time given for the longest lasting
operation. 5. ILLUSTRATIONS
NOTE: The Flat Rate Time Schedule was prepared by The illustrations contained in this manual do not neces-
skilled mechanics using the hand tool usually found in sarily show every components of a given system as
workshops and all the special tools mentioned in the Parts Catalog do. Their purpose is to facilitate recogni-
Shop Manual. tion of parts related to a flat rate time. Item numbers
on illustrations correspond to the four digit Job
2. COMPILATION Code.
The Flat Rate Time Schedule is compiled as follows:
The actual required time to perform the repair plus (+) 6. FLAT RATE TIME SUGGESTION
30% correction factor up to 3.0 hours or (+) 15% over SEND A WARRANTY CASE ON BOSSWeb INFO
hours time
–3.0Vehicle to take into account, among others:
handling CENTER
– Obtaining the parts In the case, you must provide the following information:
– Diagnosis Section Subject:
– Cleaning – Flat rate time suggestion
– Special compensation (rusted bolts).
Section Your Question:
3. HOW TO USE IT – Model year;
Refer to the system you need, locate part of series of – Model description;
parts replaced. List JOB CODE in the appropriate col- – Description job code;
umn on claim. – Job code;
SYSTEM PAGE – Present flat rate;
– Suggested flat rate;
01 ENGINE 04 – Detailed repair procedure;
02 CARBURETOR AND FUEL SYSTEM 24 To ensure that your case will be promptly and efficiently
processed please indicate the step by step repair pro-
03 IGNITION SYSTEM 27 cedure you performed.
04 STARTER 30
05 TRANSMISSION SYSTEM 31
06 BRAKE SYSTEM 36
STEERING SYSTEM AND FRONT
07 38
SUSPENSION
REAR SUSPENSION SYSTEM AND
08 TRACK 44
09 BODY 48
10 ELECTRICAL SYSTEM 53
NOTE: Unless otherwise specified, dismantling order

is: top to bottom, exterior to interior, front to rear.
All fractions of hours are in tenths:
0.1 = 6 minutes
0.2 = 12 minutes, and so on
LEGEND:
* REQUIRES PRIOR AUTHORIZATION BY DISTRIBUTOR.
INDICATE LABOUR TIME ON LINE “LABOUR ONLY“ OF
**
CLAIM.
INDICATE $$$ AMOUNT ON “SUB-CONTRACTED
***
LABOUR“ OF CLAIM.
IMPORTANT: Always use the longest flat rate time ap-
plicable to the repair performed.
Volume 1- Can-Am 1
2016 VTF2016-001_OUTLANDER
INTRODUCTION
Cette publication détermine le temps de main-d’oeuvre LÉGENDE:
couvert par la garantie pour les VTT BRP 2016. * AUTORISATION REQUISE AVANT LE REMPLACEMENT.
** INSCRIRE LE TEMPS À LA LIGNE «MAIN-D’OEUVRE
1. UTILISATION DU MANUEL SEULEMENT».
INSCRIRE LE MONTANT $$$ À LA LIGNE «OUVRAGE
En procédant de la façon indiquée dans le Manuel de *** SOUS-CONTRACTÉ».
réparation VTT BRP, chaque temps donné représente
le maximum permis pour une réparation portant sur IMPORTANT: Toujours utiliser le temps donné à l’opé-
cette pièce. LES TEMPS NE SONT PAS CUMULA- ration qui nécessite le plus de temps.
TIFS. On doit inscrire le temps donné pour l’opération
qui prend le plus de temps. 4. TRAVAUX REQUIS
REMARQUE: Le Barème de temps à taux fixe a été Tous les temps mentionnés dans les pages suivantes
préparé par des mécaniciens compétents utilisant les incluent les opérations telles que: réglage du moteur
outils que l’on retrouve normalement dans les ateliers (valve rotative et allumage), alignement de la ou des
de réparation, en plus de tous les outils spéciaux men- bielles, couple de serrage de la ou des culasses ou l’uti-
tionnés dans le Manuel de réparation. lisation de barres parallèles, utilisation du vérificateur
d’allumage, mesure du jet des pistons/jeu en bout des
2. COMPILATION segments, mesure de l’écart entre le vilebrequin et le
Le Barème de temps à taux fixe a été établi en compi- carter, rectification du cylindre, vérification de fuite du
lant le temps nécessaire pour faire la réparation plus (+) moteur.
un facteur de correction de 30% lorsqu’un travail dure 5. ILLUSTRATIONS
3.0 heures et moins, ou (+) 15% lorsqu’un travail dure
plus de 3.0 heures. Cette compilation comprend, entre Contrairement aux Catalogues de pièces, les illustra-
autres, les étapes suivantes: tions de ce manuel ne montrent pas nécessairement
chacune des pièces qu’elles représentent, leur raison
– Manutention du véhicule
d’être étant plutôt de faciliter la reconnaissance des
– Nettoyage pièces reliées à un barème de temps à taux fixe. Les
– Aller chercher les pièces, essais physiques numéros d’items sur les illustrations correspondent
– Compensation spéciale (boulons rouillés) aux quatre derniers chiffres du code de travail.
– Diagnostic. 6. SUGGESTION DE BARÈME DE TEMPS À
3. UTILISATION DU BARÈME TAUX FIXE
Se reporter à la section désirée, repérer la pièce ou l’en- ENVOYEZ UNE REQUÊTE GARANTIE BOSSWeb
semble de pièces remplacées et inscrire le CODE DE DEPUIS LA SECTION INFO CENTRE
TRAVAIL dans la colonne appropriée sur la formule de Dans cette requête, vous devez fournir les informations
réclamation. suivantes:
Section Objet:
SYSTÈME PAGE – Suggestion de barème de temps à taux fixe
01 MOTEUR 4 Section Votre Question:
CARBURATEUR ET SYSTÈME – L'année modèle;
02 24 – Description du modèle;
D’ALIMENTATION D’ESSENCE
– Description du code de travail;
03 SYSTÈME D’ALLUMAGE 27
– Code de travail;
04 DÉMARREUR 30 – Temps actuel;
– Temps suggéré;
05 SYSTÈME DE TRANSMISSION 31
– Détails de la marche à suivre;
06 SYSTÈME DE FREIN 36 Pour s'assurer que votre demande sera traitée dans les
SYSTÈME DE DIRECTION ET plus brefs délais et efficacement, s.v.p. nous fournir
07 38 toutes les étapes de réparation dans les détails de la
SUSPENSION AVANT
marche à suivre.
SYSTÈME DE SUSPENSION ARRIÈRE ET
08 44
CHENILLE
09 CARROSSERIE 48
10 SYSTÈME ÉLECTRIQUE 53
REMARQUE: Sauf indication contraire, le démontage

doit s’effectuer de haut en bas, de l’extérieur vers l’in-
térieur, de l’avant vers l’arrière.
Toutes les fractions d’heures sont exprimées en dixiè-
mes:
0.1 = 6 minutes
0.2 = 12 minutes, et ainsi de suite
2 Can-Am - Volume 1
2016
2016
ATV / VTT
COOLING SYSTEM/
MODEL/ ENGINE TYPE/
TABLE DESCRIPTION SYSTEME DE
MODÈLE TYPE DE MOTEUR REFROIDISSEMENT
5AGA/5AGB
OUTLANDER L450 5AGC/5AGD
5AGE
2WGA/2WGB Liquid cooled/
1 OUTLANDER L DPS 450 450 CVT
2WGC/2WGD Refroidi par liquide
3NGA/3NGB
OUTLANDER L PRO 450 3NGC/3NGD
3NGE
OUTLANDER L MAX 450 5CGA/5CGB
2XGA/2XGB Liquid cooled/
2 450 CVT
OUTLANDER L MAX DPS 450 2XGC/2XGD Refroidi par liquide
2XGE
2TGA/2TGB
OUTLANDER L 570
2TGC
2CGA/2CGB
2CGC/2CGD
OUTLANDER L DPS 570 Liquid cooled/
3 2CGE/2CGF 570 CVT
2CGG Refroidi par liquide
OUTLANDER L LE 570 4AGA

OUTLANDER L MOSSY OAK
3ZGA
HUNTING EDITION 570
OUTLANDER L MAX 570 2EGA
2FGA/2FGB Liquid cooled/
4 570 CVT
OUTLANDER L MAX DPS 570 2FGC/2FGD Refroidi par liquide
2FGE/2FGF
Liquid cooled/
5 OUTLANDER L XRM 570 3MGA/3MGB 570 CVT
Refroidi par liquide
Volume 1- Can-Am 3
2016
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
NO LABOR INVOLVED
01 00 AUCUNE MAIN D’OEUVRE 0 0 0 0 0
01 01 REMOVE AND REPLACE ENGINE (ASS’Y) 4.5 4.5 4.7 4.7 5.0
* REMPLACEMENT DU MOTEUR (COMPLET)
OIL PRESSURE SWITCH
01 03 INTERRUPTEUR DE PRESSION D’HUILE 0.3 0.3 0.3 0.3 0.3
HEAT SHIELD AND/OR RUBBER MOUNT

01 04 0.4 0.4 0.4 0.4 0.4
DÉFLECTEUR DE CHALEUR ET/OU BUTÉE DE CAOUTCHOUC
FAN AND/OR FAN SUPPORT
01 08 VENTILATEUR ET/OU SUPPORT DE VENTILATEUR 1.3 1.3 1.3 1.3 0.6
CYLINDERS AND/OR GASKETS (ALL)

01 17 CYLINDRES E/O JOINTS (TOUS) 4.5 4.5 4.5 4.5 4.5
SENDER TEMPERATURE (ENGINE)

01 18 CAPTEUR DE TEMPÉRATURE (MOTEUR) 0.9 0.9 0.9 0.9 0.9
THERMOSTAT
01 19 THERMOSTAT 0.5 0.5 0.5 0.5 0.5
RADIATOR INLET HOSE

01 37 0.5 0.5 0.5 0.5 0.5
BOYAU D’ENTRÉ DU RADIATEUR
WATER PUMP SHAFT (ALL PARTS)
01 38 ARBRE DE POMPE À L'EAU (TOUTES LES PIÈCES) 5.3 5.3 5.5 5.5 5.5
ENGINE RUBBER MOUNT

01 45 3.8 3.8 4.0 4.0 4.0
TAMPONS D'ANCRAGE DU MOTEUR
RADIATOR AND/OR GROMMMET
01 46 RADIATEUR ET/OU PASSE-FILS 1.6 1.6 1.6 1.6 1.0
CRANKSHAFT AND/OR BEARINGS (FRONT/REAR)

01 50 VILEBREQUIN ET/OU ROULEMENTS (AVANT/ARRIÈRE) 7.0 7.0 7.3
CRANKCASE COVER GASKET

01 56 JOINT DE COUVERCLE DE CARTER 1.3 1.3 1.3
PTO CRANKCASE COVER

01 57 COUVERCLE DE CARTER PDM 1.3 1.3 1.3
INTAKE OR EXHAUST VALVE GUIDE (1)

01 58 2.3 2.3 2.8 2.8 2.8
GUIDE DE SOUPAPE D'ADMISSION OU D'ÉCHAPPEMENT (1)
INTAKE OR EXHAUST VALVE GUIDES (2)
01 59 GUIDES DE SOUPAPE D'ADMISSION OU D'ÉCHAPPEMENT (2) 2.4 2.4 2.9 2.9 2.9
MUFFLER AND/OR EXHAUST GASKET AND/OR CLAMP

01 70 SILENCIEUX D’ÉCHAPPEMENT ET/OU JOINT D’ÉCHAPPEMENT ET/OU 0.3 0.3 0.3 0.3 0.3
BRIDE DE SERRAGE
EXHAUST MANIFOLD (REAR)
01 73 CONNECTEUR D'ÉCHAPPEMENT (ARRIÈRE) 0.5 0.5 0.5
ANTI-VIBRATION RUBBER MOUNT (1 OR 2) (TOP)

01 77 TAMPON D’ANCRAGE ANTI-VIBRATION (1 OU 2) (HAUT) 1.0 1.0 1.0 1.0 1.0
4 Can-Am - Volume 1
2016
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
COOLANT HOSE (ENGINE TO TANK)
01 79 BOYAU DU SYSTÈME DE REFROIDISSEMENT (RÉSERVOIR AU MOTEUR) 0.4 0.4 0.4 0.4 0.4
EXHAUST MANIFOLD (FRONT)

01 83 CONNECTEUR D'ÉCHAPPEMENT (AVANT) 0.5 0.5 0.5 0.5 0.5
TUNE PIPE HEAT SHIELD (1)

01 84 DÉFLECTEUR DE CHALEUR TUYAU D'ÉCHAPPEMENT (1) 0.3 0.3 0.3 0.3 0.3


RUBBER MOUNT (MUFFLER)

01 88 0.3 0.3 0.3 0.3 0.3
TAMPON D'ANCRAGE (SILENCIEUX)
ENGINE OIL FILTER
01 90 FILTRE À HUILE DU MOTEUR 0.3 0.3 0.3 0.3 0.3
OIL SIEVE AND/OR O-RING AND/OR COLLECTOR AND/OR RUBBER RING

AND/OR COVER
01 96
CRIBLE D’HUILE ET/OU JOINT TORIQUE ET/OU COLLECTEUR ET/OU ANNEAU DE
2.0 2.0 6.7 6.7 7.0
CAOUTCHOUC ET/OU COUVERCLE
COOLING RESERVOIR
01 98 1.0 1.0 1.0 1.0 1.0
RÉSERVOIR D’ANTIGEL
RADIATOR OUTLET HOSE
01 100 BOYAU DE SORTIE DU RADIATEUR 0.4 0.4 0.4 0.4 0.4
PISTON, PIN, CIRCLIP, RINGS (1)

01 101 PISTON, GOUPILLE, CIRCLIP, SEGMENTS (1) 3.0 3.0 3.0 3.0 3.0
PISTONS, PINS, CIRCLIPS, RINGS (2)

01 102 PISTONS, GOUPILLES, CIRCLIPS, SEGMENTS (2) 4.7 4.7 4.7
VALVE COVER AND/OR GASKET

01 109 COUVERCLE DE SOUPAPE ET/OU JOINT D’ÉTANCHÉITÉ 0.5 0.5 0.5 0.5 0.5
TIMING GEAR
01 111 1.2 1.2 1.2 1.2 1.2
PIGNON DE DISTRIBUTION
ROCKER ARM AND/OR PUSH ROD AND/OR ROCKER ARM SHAFT
01 113 CULBUTEUR ET/OU TIGE POUSSOIR ET/OU ARBRE DE CULBUTEUR 1.3 1.3 1.3 1.3 1.3
CYLINDER HEAD
01 114 CULASSE 3.5 3.5 3.5 3.5 3.5
EXHAUST AND/OR INLET VALVE AND/OR SPRING AND/OR SEAL

01 116 VALVE ADMISSION ET/OU ÉCHAPPEMENT ET/OU RESSORT ET/OU ANNEAU 2.7 2.7 2.7 2.7 2.7
D’ÉTANCHÉITÉ
CYLINDER AND/OR GASKET
01 117 CYLINDRE ET/OU JOINT D’ÉTANCHÉITÉ 2.8 2.8 2.8 2.8 2.8
WATER PUMP HOUSING AND/OR IMPELLER

01 119 0.4 0.4 0.4 0.4 0.4
CARTER DE LA POMPE À EAU ET/OU ROUE À AILETTES
SHIFT SHAFT ASS’Y
01 122 ARBRE D’EMBRAYAGE COMPLET 5.3 5.3
Volume 1- Can-Am 5
2016
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
OIL PUMP GEAR
01 132 ENGRENAGE DE LA POMPE À HUILE 5.2 5.2 1.5 1.5 1.5
CAMSHAFT
01 134 ARBRE À CAME 2.3 2.3 2.3 2.3 2.3
OIL PUMP COVER AND/OR SHAFT AND/OR ROTOR

01 137 COUVERCLE DE LA POMPE À HUILE ET/OU ARBRE ET/OU ROTOR 5.2 5.2 1.5 1.5 1.5
CRANKCASE RESEAL OR GASKET

01 138 RECELLEMENT DU CARTER ET/OU JOINT D’ÉTANCHÉITÉ 6.1 6.1 6.9 6.9 7.2
CRANKCASE REPLACEMENT
01 139 REMPLACEMENT DU CARTER 6.6 6.6 7.2 7.2 7.5
CRANKSHAFT A/O BALANCE SHAFT

01 140 6.1 6.1
VILEBREQUIN E/O ARBRE D’EQUILIBRAGE
DRIVE SHAFT AND/OR BEARINGS AND/OR SEALS
01 152 ARBRE D’ENTRAÎNEMENT ET/OU ROULEMENT À BILLES ET/OU ANNEAUX 6.3 6.3 6.9 6.9 7.2
D’ÉTANCHÉITÉ
GEARS BOX ASS’Y / MAIN SHAFT
01 153 BOITE D’ENGRENAGE COMPLET / ARBRE PRINCIPAL 6.3 6.3
TIMING CHAIN
01 154 4.3 4.3 3.1 3.1 3.1
CHAÎNE D’ENGRENAGE
OUTPUT SHAFT
01 155 ARBRE DE SORTIE 6.3 6.3
SHIFT DRUM
01 172 6.4 6.4
TAMBOUR D’EMBRAYAGE
CHAIN GUIDE
01 179 GUIDE DE CHAÎNE 1.0 1.0 1.0 1.0 1.0
CHAIN TENSION GUIDE

01 191 GUIDE DE TENSION DE CHAÎNE 3.1 3.1 3.1 3.1 3.1
CHAIN TENSIONER (ASS’Y)

01 192 TENDEUR DE CHAÎNE (COMPLET) 0.3 0.3 0.3 0.3 0.3
HEAT SHIELD (RH OR LH)

01 196 DÉFLECTEUR DE CHALEUR (DR OU GA) 0.5 0.5
WATER PUMP GEAR

01 200 5.1 5.1 1.6 1.6 1.6
ENGRENAGE DE LA POMPE À EAU
REAR OUTPUT SHAFT SEAL
01 205 ANNEAU D’ÉTANCHÉITÉ DE L’ARBRE DE SORTIE ARRIÈRE 3.0 3.0 5.2 5.2 5.5
OUTPUT CRANKSHAFT SEAL

01 209 ANNEAU D’ÉTANCHÉITÉ SORTIE VILBREQUIN 0.8 0.8
MAIN SHAFT SEAL

01 210 JOIN D’ÉTENCHÉITÉ DE L’ARBRE PRINCIPAL 0.8 0.8
OIL DIPSTICK
01 215 JAUGE À HUILE 0.3 0.3 0.3 0.3 0.3
PRESSURE CAP
01 216 BOUCHON À PRESSION 0.3 0.3 0.3 0.3 0.3
6 Can-Am - Volume 1
2016
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
ENGINE BRACKET AND/OR RUBBER MOUNT
01 217 ATTACHE MOTEUR ET/OU TAMPON D'ANCRAGE 0.3 0.3 0.3 0.3 0.3
MAIN DRIVE GEAR AND/OR PIN

01 220 ROUAGE D'ENTRAÎNEMENT PRINCIPALE ET/OU GOUPILLE 5.2 5.2 1.6 1.6 1.6
INTERMEDIATE GEAR AND/OR PIN AND/OR THRUST WASHER

01 221 ROUAGE INTERMEDIAIRE ET/OU GOUPILLE ET/OU RONDELLE D'APPUI 5.2 5.2 1.6 1.6 1.6
FRONT OUTPUT SHAFT SEAL

01 223 ANNEAU ÉTANCHÉITÉ ARBRE SORTIE AVANT 2.7 2.7 2.7
OUTPUT CRANKSHAFT SEAL (PTO SIDE)

01 245 ANNEAU ÉTANCHÉITÉ SORTIE VILBREQUIN (CÔTÉ PDM) 1.0 1.0 1.0 1.0 1.0
WATER PUMP GEAR AND/OR SEAL

01 246 5.5 5.5 5.5 5.5 5.8
ARBRE POMPE À EAU ET/OU JOINT ÉTANCHÉITÉ
REED VALVE AND/OR STOPPER
01 247 SOUPAPE À CLAPET ET/OU BUTOIR 1.6 1.6 1.6
BREATHER GEAR AND/OR V-RING

01 248 RENIFLARD ET/OU ANNEAU ÉTANCHÉITÉ EN «V» 1.6 1.6 1.6
CAMSHAFT POSITION SENSOR

01 249 CAPTEUR DE POSITION DE L’ARBRE À CAME 0.3 0.3 0.3
CRANKSHAFT POSITION SENSOR (CPS)

01 250 CAPTEUR DE POSITION DU VILEBREQUIN (CPV) 0.3 0.3 0.3 0.3 0.3
EXHAUST AND/OR INLET VALVES AND/OR SPRINGS AND/OR SEALS (4)

01 255 ÉCHAPPEMENT ET/OU VALVES ADMISSION ET/OU RESSORTS ET/OU ANNEAUX 3.3 3.3 3.3 3.3 3.3
D’ÉTANCHÉITÉ (4)
EXHAUST AND/OR INLET VALVES AND/OR SPRINGS AND/OR SEALS (8)
01 256 ÉCHAPPEMENT ET/OU VALVES ADMISSION ET/OU RESSORTS ET/OU ANNEAUX 6.4 6.4 6.1
D’ÉTANCHÉITÉ (8)
TIMING CHAIN (MAG SIDE)
01 261 CHAÎNE D’ENGRENAGE (CÔTÉ MAG) 2.8 2.8 2.8 2.8 2.8
LONG BLOCK
01 264 6.0 6.0 6.7 6.7 7.0
ENSEMBLE CARTER - CYLINDRE - CULASSE
CONNECTING ROD ASS’Y (1)
01 276 BIELLE COMPLET (1) 6.2 6.2
WATER PUMP DYNAMIC SEAL AND/OR OIL SEAL

01 301 ANNEAU D’ÉTANCHÉITÉ DYNAMIQUE DE LA POMPE À EAU 2.1 2.1 2.1 2.1 2.1
TIMING CHAINS (ALL)

01 303 CHAÎNES D’ENGRENAGE (TOUTES) 5.3 5.3 5.3
CHAINS TENSION GUIDE (ALL)

01 304 GUIDE DE TENSION DE CHAÎNES (TOUS) 5.3 5.3 5.3
CHAINS GUIDE (ALL)

01 305 GUIDE DE CHAÎNES (TOUS) 1.8 1.8 1.8
VALVE COVERS AND/OR GASKETS (2)

01 307 COUVERCLES SOUPAPE ET/OU JOINTS D’ÉTANCHÉITÉ (2) 0.6 0.6 0.6
Volume 1- Can-Am 7
2016
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
CYLINDER HEAD GASKET (1)
01 308 JOINT D’ÉTANCHÉITÉ DE LA CULASSE (1) 1.4 1.4 1.4 1.4 1.4
CYLINDER HEAD GASKETS (2)

01 309 JOINTS D’ÉTANCHÉITÉ DE LA CULASSE (2) 2.3 2.3 2.3
RADIATOR SUPPORT
01 318 SUPPORT DE RADIATEUR 0.4
FAN SUPPORT
01 324 SUPPORT DE VENTILATEUR 0.5
INJECTOR (1)
01 329 INJECTEUR(1) 1.8 1.8 1.8 1.8 1.8
INJECTOR (2)
01 330 1.9 1.9 1.9
INJECTEUR(2)
RADIATOR COVER
01 333 COUVERCLE DE RADIATEUR 0.3
FILLER NECK AND/OR HOSE

01 334 GOULOT REMPLISSAGE ET/OU BOYAU 1.1
COOLANT HOSE (ENGINE INLET)

01 336 BOYAU DE REFROIDISSEMENT (ENTRÉE DU MOTEUR) 0.4 0.4 0.4 0.4 0.4
PLUG SCREW
01 340 BOUCHON FILETÉ 0.5 0.5 0.5
8 Can-Am - Volume 1
2016
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01318
01333
01100
01216
01100
01334
0146
0108
0119
01324
0119
0137
01336
vtf2013-002-001_a
Volume 1- Can-Am 9
2016
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
01109
01113
01111
01179
01116
01255
01154
01191
01114
01113 01308
01134
01116
01255
0158 01117
0159
450 EFI 01192
vtf2015-001_a
10 Can-Am - Volume 1
2016
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01117
01101
450 EFI
01276
01140
01101
01276
01140
vtf2015-002_a
Volume 1- Can-Am 11
2016
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
01205 01153
450 EFI
01122
01172
vtf2015-003_a
2016
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
450 EFI
01264
01138
01139
01210
01209
vtf2015-004_a
Volume 1- Can-Am 13
2016
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
01215
0190 450 EFI
0103
01220
01137
01132
0196
vtf2015-005_a
2016
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01119
450 EFI
0138
01301
01246
0119
0118
01200
vtf2015-006_a
Volume 1- Can-Am 15
2016
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
FRONT/REAR
AVANT/ARRIÈRE
01109
01307
01113
0119
01111
01191 01192
01304
01116
01255
01154 01256
01261
01303 01134
01179
01305
01249
0158 01114
0159
01113
01116
01255
01256 01116
01255
01256
01308
01309
V07C2RY
2016
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
Volume 1- Can-Am 17
2016
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
01247 0156
0157
01139
01245
V07C2TS
2016
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01119
01301
0138
01246
01200
V07C2VV
Volume 1- Can-Am 19
2016
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
0103 01215
0190
01248
0196
01220
01137
V07C2WS 01132
2016
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01205
01152
01223
vtf2009-001-001_a
Volume 1- Can-Am 21
2016
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
01216
01100 0198
0179
0146
0108
0108
0137
vtf2012-002-001_a
2016
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01196
0183 0183
Outlander MAX 450 EFI
Engine/Moteur 500 EFI
01196
0186 0173
0184
Outlander STD 500 EFI
0170 0183
49
0173
Outlander STD 450 EFI

Outlander MAX
Outlander MAX 500 EFI
0185
0170 0186
Outlander STD
vtf2015-007_a
Volume 1- Can-Am 23
2016
02
SYSTEM/SYSTÈME
CARBURETOR AND FUEL SYSTEM
CARBURATEUR ET SYSTÈME D’ALIMENTATION D’ESSENCE
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
NO LABOR INVOLVED
AIR INTAKE SILENCER (ASS’Y)

02 01 1.8 1.8 1.8 1.8 1.8
SILENCIEUX D’ADMISSION D’AIR (COMPLET)
THROTTLE CABLE
02 06 0.6 0.6 0.6 0.6 0.6
CÂBLE D’ACCÉLÉRATEUR
INTAKE ADAPTOR
02 16 ADAPTATEUR D’ADMISSION
1.0 1.0 1.0 1.0 1.0
AIR INTAKE TUBE

02 19 TUYAU D’ADMISSION D’AIR
1.0 1.0 1.0 1.0 1.3
REAR AIR INTAKE TUBE AND/OR SLEEVE

02 23 TUYAU D’ADMISSION D’AIR ARRIÈRE ET/OU DOUILLE
1.8 1.8 1.8 1.8 2.2
AIR TEMPERATURE SENSOR

02 46 CAPTEUR DE TEMPÉRATURE D’AIR
0.3 0.3 0.3 0.3 0.3
FUEL FILTER
02 57 FILTRE À ESSENCE
1.0 1.0 1.0 1.0 1.0
FUEL TANK
02 58 RÉSERVOIR D’ESSENCE
1.6 1.6 1.6 1.6 1.6
INTAKE COVER AND/OR SEAL

02 59 COUVERCLE D’ADMISSION ET/OU JOINT D’ÉTANCHÉITÉ
0.3 0.3 0.3 0.3 0.3
FUEL CAP
02 60 BOUCHON DU RÉSERVOIR À ESSENCE 0.3 0.3 0.3 0.3 0.3
AIR FILTER
02 69 FILTRE À AIR 0.3 0.3 0.3 0.3 0.3
INTAKE MANIFOLD
02 72 1.9 1.9 1.9 1.9 1.9
CONNECTEUR D’ADMISSION
FUEL RAIL (1 OR 2)
02 79 1.9 1.9 1.9 1.9 1.9
RAMPE D’ESSENCE (1 OU 2)
THROTTLE BODY (ASS’Y)
02 81 1.7 1.7 1.7 1.7 2.0
CARTER ACCÉLÉRATEUR (COMPLET)
THROTTLE SENSOR
02 82 CAPTEUR POSITION D’ACCÉLÉRATEUR
1.5 1.5 1.5 1.5 1.5
IDLE BY-PASS VALVE

02 84 VALVE DU RALENTI
1.5 1.5 1.5 1.5 1.5
FUEL PUMP MODULE

02 89 MODULE POMPE À ESSENCE
1.0 1.0 1.0 1.0 1.0
FEMALE QUICK FITTING

02 94 CONNECTEUR RAPIDE FEMELLE
0.4 0.4 0.4 0.4 0.4
FUEL INJECTION HOSE (ASS’Y)

02 99 BOYAU À INJECTION D’ESSENCE (COMPLET)
0.4 0.4 0.4 0.4 0.4
2016
CARBURATEUR ET SYSTÈME D’ALIMENTATION D’ESSENCE 02
SYSTEM/SYSTÈME
0289
0294
0262
0258
vtf2012-002-004_a
Volume 1- Can-Am 25
2016
02
SYSTEM/SYSTÈME
CARBURATEUR ET SYSTÈME D’ALIMENTATION D’ESSENCE
0219
0201
0269
0223
vtf2012-002-005_a
2016
IGNITION SYSTEM
SYSTÈME D’ALLUMAGE 03
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
NO LABOR INVOLVED
MAGNETO (ASS’Y)
03 02 3.9 3.9 2.3 2.3 2.3
MAGNÉTO (COMPLET)
IGNITION COIL (EACH)
03 08 BOBINE D’ALLUMAGE (CHAQUE) 0.5 0.5 0.5 0.5 0.5
IGNITION CABLE
03 10 CÂBLE D’ALLUMAGE 0.5 0.5 0.5 0.5 0.5
STATOR (ASS’Y)
03 27 STATOR (COMPLET) 3.7 3.7 2.0 2.0 2.0
MAGNETO COVER
03 32 COUVERCLE DE MAGNÉTO 3.7 3.7 2.1 2.1 2.1
MAGNETO COVER GASKET

03 33 2.0 2.0 2.0
JOINT D’ÉTANCHÉITÉ COUVERCLE DE MAGNÉTO
Volume 1- Can-Am 27
2016
03
SYSTEM/SYSTÈME
IGNITION SYSTEM
SYSTÈME D’ALLUMAGE
450 EFI
0327
0302
0332
vtf2015-008_a
2016
IGNITION SYSTEM
SYSTÈME D’ALLUMAGE 03
SYSTEM/SYSTÈME
0332
0333 0327
0302
V07G29T
Volume 1- Can-Am 29
2016
04
SYSTEM/SYSTÈME
STARTER SYSTEM
SYSTÈME DE DÉMARREUR
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
NO LABOUR INVOLVED
04 00 AUCUNE MAIN-D’OEUVRE 0 0 0 0 0
ELECTRIC STARTER (ASS’Y)

04 02 0.3 0.3 2.0 2.0 2.0
DÉMARREUR (COMPLET)
STARTER RELAY
04 03 SOLÉNOÏDE DE DÉMARRAGE 0.3 0.3 0.3 0.3 0.3
STARTER DRIVE
04 19 LANCEUR DÉMARREUR 1.0 1.0 1.9 1.9 1.9
2016
TRANSMISSION AND LINKAGE SYSTEM
SYSTÈME DE TRANSMISSION ET DE TRINGLERIE
05
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
NO LABOR INVOLVED
05 00 AUCUNE MAIN-D’OEUVRE IMPLIQUÉE 0 0 0 0 0
05 12 DRIVEN PULLEY SLIDING HALF

DEMI-POULIE MENÉE COULISSANTE
0.5 0.6 0.5 0.6 0.5
BELT
05 19 COURROIE 0.4 0.5 0.4 0.5 0.4
LEVER BUTTON
05 55 BOUTON DE LEVIER 0.3 0.3 0.3 0.3 0.3
05 56 LEVER (ASS’Y) AND/OR LEVER SPRING

LEVIER (COMPLET) ET/OU RESSORT DE LEVIER
0.3 0.3 0.3 0.3 0.3
SPEED SENSOR
05 59 CAPTEUR DE VITESSE 0.6 0.6 0.6 0.6 0.6
LEVER
05 77 LEVIER 0.7 0.7 0.7 0.7 0.7
05 78 CVT COVER
COUVERCLE CVC
0.3 0.4 0.3 0.4 0.3
GASKET
05 79 JOINT D’ÉTANCHÉITÉ 0.3 0.4 0.3 0.4 0.3
GOVERNOR CUP
05 80 COUPOLE RÉGULATEUR 0.6 0.7 0.6 0.7 0.6
05 81 ONE WAY CLUTCH, FLANGE, RING, SPRING

EMBRAYAGE À ROUE LIBRE, FLASQUE, ANNEAU, RESSORT
0.6 0.7 0.6 0.7 0.6
DRIVE PULLEY (ASS’Y)

05 82 POULIE MOTRICE (COMPLET) 0.7 0.8 0.7 0.8 0.7
DRIVE PULLEY FIXED HALF

05 83 POULIE MOTRICE FIXE 0.7 0.8 0.7 0.8 0.7
05 84 DRIVEN PULLEY OUTER CAM AND/OR SPRING

CAME DE POULIE MENÉE EXTERNE ET/OU RESSORT
0.5 0.6 0.5 0.6 0.5
CENTRIFUGAL LEVER
05 85 LEVIER CENTRIFUGE 0.8 0.9 0.8 0.9 0.8
SLIDER SHOES
05 86 GLISSIÈRES 0.7 0.8 0.7 0.8 0.7
05 87 LEVER SPRING
LEVIER À RESSORT
0.3 0.3 0.3 0.3 0.3
REMOVE AND REPLACE TRANSMISSION (ASS’Y)

05 89 REMPLACEMENT DE LA TRANSMISSION (COMPLET) 5.1 5.1 5.4
MAIN SHAFT (ASS'Y)

05 91 ARBRE DE RENVOI (COMPLET) 6.7 6.7 7.0
AIR INTAKE (CVT)

05 95 0.3 0.3 0.3 0.3 0.4
ENTRÉE D'AIR (CVT)
AIR OUTLET (CVT)
05 96 SORTIE D'AIR (CVT) 0.3 0.3 0.3 0.3 0.4
Volume 1- Can-Am 31
2016
05
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
FLEXIBLE ADAPTOR
05 97 ADAPTATEUR FLEXIBLE 0.3 0.3 0.3 0.3 0.3
CAM, PLATE, DRIVEN SHAFT, SPRING

05 98 CAME, PLAQUE, ARBRE POULIE MENÉE, RESSORT 0.5 0.6 0.5 0.6 0.5
OUTPUT SHAFT
05 99 ARBRE DE SORTIE 5.9 5.9 6.2
REAR OUTPUT SHAFT SEALS

05 100 ANNEAUX ÉTANCHÉITÉ DE L’ARBRE DE SORTIE ARRIÈRE 2.2 2.2 2.2
GEARS KIT/MAIN SHAFT

05 101 ENSEMBLE D'ENGRENAGES/ARBRE PRINCIPAL 6.0 6.0 6.3
SHIFT SHAFT (ASS'Y )

05 102 6.0 6.0 6.3
ARBRE D'EMBRAYAGE (COMPLET)
SHIFT DRUM
05 103 TAMBOUR D'EMBRAYAGE 6.0 6.0 6.3
INDEX LEVER (ASS'Y)

05 104 LEVIER D'INDEXATION (COMPLET) 6.0 6.0 6.3
MAIN SHAFT SEAL

05 105 JOINT D'ÉTANCHÉITÉ DE L'ARBRE PRINCIPAL 0.9 0.9 0.9
LH HOUSING GEAR AND/OR BEARINGS AND/OR GEAR

05 106 LOGEMENT DE TRANSMISSION GAUCHE ET/OU ROULEMENT À BILLE ET/OU 6.0 6.0 6.3
ENGRENAGE
SPACER AND/OR O-RING
05 107 0.9 0.9 0.9
ENTRETOISE ET/OU JOINT TORIQUE
ACTUATOR AND/OR FORK AND/OR SEAL
05 108 ACTUATEUR ET/OU FOURCHETTE ET/OU JOINT D'ÉTANCHÉITÉ 0.5 0.5 0.5 0.5 0.5
FORK AND/OR PIN

05 109 FOURCHETTE ET/OU GOUPILLE 0.7 0.7 0.7 0.7 0.7
CENTER HOUSING GEAR AND/OR BEARING

05 110 LOGEMENT DE TRANSMISSION CENTRE ET/OU ROULEMENT 6.0 6.0 6.3
RH HOUSING GEAR AND/OR BEARING

05 111 LOGEMENT DE TRANSMISSION DROIT ET/OU ROULEMENT 5.9 5.9 6.2
SHIFTING SWITCH
05 113 0.3 0.3 0.3 0.3 0.3
INTERRUPTEUR D'EMBRAYAGE
SHIFT SHAFT SEAL
05 114 JOINT D'ÉTANCHÉITÉ D’ARBRE D’EMBRAYAGE 0.7 0.7 0.7
CVT AIR GUIDE AND/OR O-RINGS

05 115 GUIDE D'AÉRATION ET/OU JOINT D'ÉTANCHÉITÉ 0.8 0.8 0.8
GEARBOX POSITION SENSOR

05 120 CAPTEUR DE POSITION D’ENGRENAGE 0.4 0.4 0.4 0.4 0.4
SHIFT ARM BASE

05 166 BASE DU BRAS D’EMBRAYAGE 0.5 0.5 0.5 0.5 0.5
2016
05
SYSTEM/SYSTÈME
0598
0584
0512
0519
0583
0581
0580
0585
450 EFI
0586
0578
0579
vtf2015-009_a
Volume 1- Can-Am 33
2016
05
SYSTEM/SYSTÈME
05115
0598
0512
0584
0519
0583
0581 0579
0578
0582
0585
0580
0586
V07K15S
2016
05
SYSTEM/SYSTÈME
V500/650/800
05111 05100
05100
05114
05113
05112
05109
0599
05102
05110
05108 05101
05103
05104
0591
05106
05101
05105
05106
05107
V07K16S
Volume 1- Can-Am 35
2016
06
SYSTEM/SYSTÈME
BRAKE SYSTEM
SYSTÈME DE FREIN
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
NO LABOR INVOLVED
MASTER CYLINDRE
06 06 0.3 0.3 0.3 0.3 0.3
MAÎTRE-CYLINDRE
FRONT CALIPER (RH OR LH)
06 09 ÉTRIER AVANT (DROIT OU GAUCHE) 0.4 0.4 0.4 0.4 0.4
FRONT BRAKE PAD (RH OR LH)

06 10 PLAQUETTE DE FREIN AVANT (DROIT OU GAUCHE) 0.3 0.3 0.3 0.3 0.3
FRONT BRAKE DISC (RH OR LH)

06 11 DISQUE DE FREIN AVANT (DROIT OU GAUCHE) 0.5 0.5 0.5 0.5 0.5
FRONT FLEXIBLE BRAKE HOSE

06 12 BOYAU FLEXIBLE DE FREIN AVANT 0.6 0.6 0.6 0.6 0.6
FRONT BRAKE HANDLE HOSE

06 15 0.6 0.6 0.6 0.6 0.6
BOYAU DE FREIN DE LA MANETTE AVANT
FRONT MASTER CYLINDER
06 16 MAÎTRE-CYLINDRE AVANT 0.8 0.8 0.8 0.8 0.8
REAR BRAKE PEDAL

06 17 0.4 0.4 0.4 0.4 0.4
PÉDALE DE FREIN ARRIÈRE
REAR BRAKE PEDAL SPRING
06 18 RESSORT DE LA PÉDALE DE FREIN ARRIÈRE 0.3 0.3 0.3 0.3 0.3
BRAKE SWITCH
06 19 INTERRUPTEUR DE FREIN 0.5 0.6 0.5 0.6 0.5
REAR MASTER CYLINDER

06 22 MAÎTRE-CYLINDRE ARRIÈRE 0.7 0.7 0.7 0.7 0.7
REAR OIL HOUSING HOSE

06 23 BOYAU CARTER D’HUILE ARRIÈRE 0.6 0.6 0.6 0.6 0.6
REAR OIL HOUSING

06 24 0.3 0.3 0.3 0.3 0.3
CARTER D’HUILE ARRIÈRE
REAR BRAKE HOSE
06 25 BOYAU DE FREIN ARRIÈRE 0.6 0.6 0.6 0.6 0.6
REAR CALIPER
06 26 ÉTRIER ARRIÈRE 0.4 0.4 0.4 0.4 0.4
REAR BRAKE PAD

06 27 PLAQUETTE DE FREIN ARRIÈRE 0.3 0.3 0.3 0.3 0.3
REAR BRAKE DISC AND/OR HUB

06 28 DISQUE DE FREIN ARRIÈRE ET/OU MOYEU 0.5 0.5 0.5 0.5 0.5
BRAKE LINE
06 30 BOYAU DE FREIN 3.5 3.5 3.5 3.5 3.8
2016
0628
Europe
vtf2013-002-003_a
0627
Volume 1- Can-Am
0625
0622
0619
0610
Europe
0606
0615
0617 0618
0609 0611
0630
2016
0619
0624
0622
0625
0612
0616
0612
0610
BRAKE SYSTEM
SYSTÈME DE FREIN
0611
0609
06
37
SYSTEM/SYSTÈME
07
SYSTEM/SYSTÈME
STEERING - FRONT DRIVE SYSTEM AND SUSPENSION
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
NO LABOR INVOLVED
ARM PROTECTOR (RH OR LH)
07 04 PROTECTEUR DE BRAS (DROIT OU GAUCHE) 0.3 0.3 0.3 0.3 0.3
STEERING CLAMP AND/OR STEERING COVER SUPPORT
07 05 0.4 0.4 0.4 0.4 0.4
BRIDE DE DIRECTION ET/OU SUPPORT DU COUVRE-GUIDON
INTERNAL BALL JOINT (RH OR LH)
07 12 JOINT À ROTULE INTERNE (DROIT AU GAUCHE)
0.9 0.9 0.9 0.9 0.9
EXTERNAL BALL JOINT (RH OR LH)
07 13 JOINT À ROTULE EXTERNE (DROIT OU GAUCHE)
0.8 0.8 0.8 0.8 0.8
TIE ROD (RH OR LH)
07 19 0.9 0.9 0.9 0.9 0.9
BARRE D’ACCOUPLEMENT (DROIT OU GAUCHE)
MAIN TUBE
07 24 TUBE PRINCIPAL
2.6 2.6 2.6 2.6 3.0
HANDLEBAR
07 25 GUIDON
1.1 1.1 1.1 1.1 1.1
HANDLEBAR GRIP KIT (RH AND/OR LH)
07 26 0.3 0.3 0.3 0.3 0.3
ENSEMBLE DE GAINE DE GUIDON (DROIT ET/OU GAUCHE)
STEERING COVER
07 27 COUVRE-GUIDON
0.3 0.3 0.3 0.3 0.3
HALF HOUSING AND HOUSING BUSHING
07 28 DEMI-LOGEMENT ET DOUILLE DE LOGEMENT
2.1 2.1 2.1 2.1 2.4
LOWER STEERING MAIN TUBE BUSHING
07 29 1.0 1.0 1.0 1.0 1.0
DOUILLE INFÉRIEURE DE LA COLONNE DE DIRECTION
LOWER ARM AND/OR BALL JOINT (RH OR LH)
07 32 BRAS INFÉRIEUR ET/OU JOINT À ROTULE (DROIT OU GAUCHE)
0.7 0.7 0.7 0.7 0.7
UPPER ARM (RH OR LH)
07 33 BRAS DE SUSPENSION SUPÉRIEUR (DROIT OU GAUCHE)
0.8 0.8 0.8 0.8 0.8
HANDLE STEERING SUPPORT (ALL)
07 35 0.3 0.3 0.3 0.3 0.3
SUPPORT DE GUIDON (TOUS)
FRONT SHOCK AND/OR SPRING AND/OR STOPPER AND/OR PROTECTOR
AND/OR SEAT (RH OR LH)
07 37 AMORTISSEUR AVANT ET/OU RESSORT ET/OU BUTÉE ET/OU SIÈGE ET/OU
0.7 0.7 0.7 0.7 0.7
PROTECTEUR (DROIT OU GAUCHE)
FRONT DIFFERENTIAL (ASS’Y)
07 40 DIFFÉRENTIEL AVANT (COMPLET)
2.4 2.4 2.4 2.4 2.4
FRONT PROPELLER SHAFT (ASS’Y)
07 42 ARBRE DE PROPULSION AVANT (COMPLET)
1.3 1.3 1.3 1.3 1.3
CV JOINT (RH OR LH)
07 45 0.8 0.8 0.8 0.8 0.8
JOINT HOMOCINÉTIQUE (DROIT OU GAUCHE)
FRONT WHEEL HUB (SEAL AND/OR BEARING) (RH OR LH)
07 46 MOYEU DE ROUE AVANT (JOINT ET/OU ROULEMENT) (DROIT OU GAUCHE)
0.5 0.5 0.5 0.5 0.5
KNUCKLE (RH OR LH)
07 47 PORTE-FUSÉE (DROIT OU GAUCHE)
0.8 0.8 0.8 0.8 0.8
2016
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION 07
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
FRONT RIM AND/OR TIRE
07 50 JANTE AVANT ET/OU PNEU 0.4 0.4 0.4 0.4 0.4
THROTTLE HANDLE
07 56 0.3 0.3 0.3 0.3 0.3
MANETTE D’ACCÉLÉRATEUR
PITMAN ARM
07 65 LEVIER DE DIRECTION
2.6 2.6 2.6 2.6 2.6
INTERNAL BUSHING AND/OR CUSHION (LOWER AND/OR UPPER ARM) (RH OR
LH)
07 72 DOUILLE INTERNE ET/OU COUSSIN (BRAS INFÉRIEUR ET/OU SUPÉRIEUR)
0.4 0.4 0.4 0.4 0.4
(DROIT OU GAUCHE)
BALL JOINTS REPLACEMENT (2)
07 73 REMPLACEMENT DES JOINTS A ROTULE (2)
1.0 1.0 1.0 1.0 1.0
FRONT RIM
07 80 0.4 0.4 0.4 0.4 0.4
JANTE AVANT
RADIAL BALL BEARINGS
07 82 ROULEMENTS À BILLE RADIALES
0.8 0.8 0.8 0.8 0.8
RING GEAR AND/OR CARRIER AND/OR SHIM
07 85 COURONNE DE LANCEMENT ET/OU SUPPORT ET/OU CALE
3.0 3.0 3.0 3.0 3.0
RING GEAR DRIVE GEAR AND/OR BEARING AND/OR SHIM
07 88 PIGNON DE COMMANDE DE LA COURONNE ET/OU ROULEMENT À BILLE ET/OU 2.7 2.7 2.7 2.7 2.7
CALE
COVER AND/OR PINION COVER AND/OR SEAL AND/OR BEARING
07 89 COUVERCLE ET/OU COUVERCLE DE PIGNON ET/OU JOINT D’ÉTANCHÉITÉ ET/OU 3.0 3.0 3.0 3.0 3.0
ROULEMENT À BILLE
BOOT WHEEL KIT AND/OR CV JOINT (RH OR LH)
07 90 ENSEMBLE DE SOUFFLET DE ROUE ET/OU JOINT CV (DROIT OU GAUCHE)
0.8 0.8 0.8 0.8 0.8
BOOT DIFFERENTIAL KIT AND/OR PLUNGING JOINT (RH OR LH)
07 91 ENSEMBLE DE SOUFFLET DE DIFFÉRENTIEL ET/OU JOINT PLONGEANT (DROIT 0.8 0.8 0.8 0.8 0.8
OU GAUCHE)
SLEEVE AND/OR WEARRING
07 92 MANCHON ET/OU BAGUE D'USURE
1.3 1.3 1.3 1.3 1.3
UNIT PACK KIT
07 94 ENSEMBLE JOINT CARDAN
2.3 2.3 2.3 2.3 2.3
UPPER ARM BRACKET
07 96 ATTACHE BRAS SUPÉRIEUR
2.2 2.2 2.2 2.2 2.2
POWER STEERING
07 99 SERVODIRECTION
2.6 2.6 2.6 2.6 2.6
DEFLECTOR (LH OR RH)
07 101 DÉFLECTEUR (GA OU DR)
0.3 0.3 0.3 0.3 0.3
DIFFERENTIAL SEAL (1)
07 103 JOINT D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (1)
0.8 0.8 0.8 0.8 0.8
DIFFERENTIAL SEALS (2)
07 104 JOINTS D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (2)
1.5 1.5 1.5 1.5 1.5
DIFFERENTIAL BELLOWS
07 119 SOUFFLET DU DIFFÉRENTIEL
0.3 0.3 0.3 0.3 0.3
Volume 1- Can-Am 39
2016
07
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
DIFFERENTIAL OIL SEAL
07 120 ANNEAU D’ÉTANCHÉITÉ DU DIFFÉRENTIEL 1.3 1.3 1.3 1.3 1.3
2016
SYSTEM/SYSTÈME
0726
STD
0727 0724
0728
0725
0765
0735
DPS
0724
0726 0799
0713
0719
0765
0729
vtf2015-010_a
Volume 1- Can-Am 41
2016
07
SYSTEM/SYSTÈME
0737
0733
0733
0733
0796
0733
0732
0732
0732
0704
0732
vtf2012-002-009_a
2016
SYSTEM/SYSTÈME
07120
Volume 1- Can-Am 43
2016
08
SYSTEM/SYSTÈME
REAR DRIVE SYSTEM AND SUSPENSION
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
NO LABOR INVOLVED
REAR WHEEL HUB (RH)

08 05 0.5 0.5 0.5 0.5 0.5
MOYEU DE ROUE ARRIÈRE (DROIT)
REAR DIFFERENTIAL (ASS’Y)
08 07 DIFFÉRENTIEL ARRIÈRE (COMPLET) 1.8 1.8 1.8 1.8 1.8
REAR PROPELLER SHAFT (ASS’Y)

08 26 ARBRE DE PROPULSION ARRIÈRE (COMPLET) 1.5 1.5 1.5 1.5 1.5
SWING ARM
08 62 BRAS OSCILLANT 1.2 1.2 1.2 1.2 1.2
LH PROTECTOR
08 101 PROTECTEUR GAUCHE 0.3 0.3 0.3 0.3 0.3
RH PROTECTOR
08 102 0.3 0.3 0.3 0.3 0.3
PROTECTEUR DROIT
REAR WHEEL HUB (LH)
08 109 MOYEU DE ROUE ARRIÈRE (GAUCHE) 0.3 0.3 0.3 0.5 0.5
REAR SHOCK (RH OR LH)

08 111 0.4 0.4 0.4 0.4 0.4
AMORTISSEUR ARRIÈRE (DROIT OU GAUCHE)
REAR RIM AND/OR TIRE
08 114 JANTE ARRIÈRE ET/OU PNEU 0.4 0.4 0.4 0.4 0.4
CV JOINT (RH OR LH)

08 120 JOINT HOMOCINÉTIQUE (DROIT OU GAUCHE) 0.8 0.8 0.8 0.8 0.8
STABILIZER BAR
08 121 BARRE STABILISATRICE 2.3 2.3 2.3 2.3 2.3
RING GEAR AND/OR SHIM

08 122 COURONNE DE LANCEMENT ET/OU CALE 3.1 3.1 3.1 3.1 3.1
RING GEAR DRIVE GEAR AND/OR BEARING AND/OR SHIM

08 123 PIGNON DE COMMANDE DE LA COURONNE ET/OU ROULEMENT À BILLE ET/OU 3.1 3.1 3.1 3.1 3.1
CALE
COVER AND/OR PINION COVER AND/OR SEAL AND/OR BEARING
08 124 COUVERCLE ET/OU COUVERCLE DE PIGNON ET/OU JOINT D’ÉTANCHÉITÉ ET/OU 3.3 3.3 3.3 3.3 3.3
ROULEMENT À BILLE
BOOT WHEEL KIT AND/OR CV JOINT (RH OR LH)
08 125 ENSEMBLE DE SOUFFLET DE ROUE ET/OU JOINT CV (DROIT OU GAUCHE) 0.9 0.9 0.9 0.9 0.9
BOOT DIFFERENTIAL KIT AND/OR PLUNGING JOINT (RH OR LH)

08 126 ENSEMBLE DE SOUFFLET DE DIFFÉRENTIEL ET/OU JOINT PLONGENT 0.9 0.9 0.9 0.9 0.9
(DROIT OU GAUCHE)
RADIAL BALL BEARINGS
08 127 ROULEMENTS À BILLE RADIALES 1.0 1.0 1.0 1.0 1.0
UNIT PACK KIT

08 128 ENSEMBLE DE JOINT CARDAN 1.2 1.2 1.2 1.2 1.2
UNIT PACK KIT (2)

08 129 1.5 1.5 1.5 1.5 1.5
ENSEMBLE DE JOINT CARDAN (2)
2016
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION 08
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
DIFFERENTIAL SEAL (1)
08 134 JOINT D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (1) 0.9 0.9 0.9 0.9 0.9
DIFFERENTIAL OIL SEAL

08 148 ANNEAU D'ÉTANCHÉITÉ DU DIFFÉRENTIEL 1.0 1.0 1.0 1.0 1.0
DIFFERENTIAL SEALS (2)

08 135 JOINTS D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (2) 1.8 1.8 1.8 1.8 1.8
DFFERENTIAL OIL SEAL

08 148 ANNEAU D’ÉTANCHÉITÉ DU DIFFÉRENTIEL 1.0 1.0 1.0 1.0 1.0
AXIAL PIVOT
08 149 AXE DE PIVOT 0.5 0.5 0.5 0.5 0.5
Volume 1- Can-Am 45
2016
08
SYSTEM/SYSTÈME
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION
08124
08122
08124
08148
08134
08123 08135
08125
08126
08120
08120
08114
0826
0805
08109
08127
vtf2012-002-011_b
2016
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION 08
SYSTEM/SYSTÈME
08127 08121
08149 08121
0862
0862
0862
9
08127
08111 08101
08127
08102
vtf2015-011_a
Volume 1- Can-Am 47
2016
09
SYSTEM/SYSTÈME
BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
NO LABOR INVOLVED
09 00 AUCUNE MAIN D’OEUVRE IMPLIQUÉE 0 0 0 0 0
LUGGAGE RACK KIT (FRONT OR REAR)

09 13 0.5 0.5 0.5 0.5 0.5
ENSEMBLE DE PORTE-BAGAGES (AVANT OU ARRIÈRE)
CONSOLE
09 17 CONSOLE 0.3 0.3 0.3 0.3 0.3
SEAT
09 21 SIÈGE 0.3 0.3 0.3 0.3 0.3
FRONT BUMPER
09 26 PARE-CHOCS AVANT 0.5
FRONT FASCIA
09 28 FASCIA AVANT 0.9 0.9 0.9 0.9 0.9
REAR FASCIA
09 29 0.3 0.3 0.3 0.3 0.3
FASCIA ARRIÈRE
REAR BUMPER
09 34 PARE-CHOCS ARRIÈRE 0.3
REAR HANDLE (RH OR LH)

09 45 0.3 0.3
POIGNÉE ARRIÈRE (GAUCHE OU DROITE)
FOOTREST (RH OR LH)
09 48 MARCHEPIED (DROIT OU GAUCHE) 0.4 0.5 0.4 0.5 0.4
09 FRAME
49 12.5 13.0 13.0 13.5 13.5
* CHÂSSIS
REAR FENDER
09 56 AILE ARRIÈRE 0.9 0.9 0.9 0.9 0.9
FOOTREST SUPPORT (RH OR LH)

09 74 SUPPORT DE REPOSE PIED (DROIT OU GAUCHE) 0.4 0.5 0.4 0.5 0.4
FOOTWELL (RH OR LH)

09 91 REPOSE-PIED (DROIT OU GAUCHE) 0.3 0.4 0.3 0.4 0.3
FRONT SKID PLATE

09 93 PLAQUE DE PROTECTION AVANT 0.5
EACH DECAL (1)

09 95 0.3 0.3 0.3 0.3 0.3
CHAQUE AUTOCOLLANT (1)
REAR SEAT ASS'Y
09 108 SIÈGE ARRIÈRE ASS. 0.4 0.4
ENGINE SIDE PANELS (2)

09 149 PANNEAUX MOTEUR (2) 0.3 0.3 0.3 0.3 0.3
UPPER CONSOLE
09 157 CONSOLE SUPÉRIEURE 0.3 0.3 0.3 0.3 0.3
FRONT FENDER SUPPORT

09 158 SUPPORT D’AILE AVANT 1.3 1.3 1.3 1.3 1.3
BACKREST PARTS
09 198 PIÈCES DU DOSSIER 0.4 0.4
2016
CARROSSERIE ET ACCESSOIRES 09
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XMR 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
REAR SEAT BASE A/O ALL PARTS
09 199 BASE SIÈGE ARRIÈRE ET/OU TOUTES LES PIÈCES 1.0 1.0
REAR FENDER SUPPORT

09 200 SUPPORT D’AILE ARRIÈRE 1.9 1.9 1.9 1.9 1.9
CONSOLE SUPPORT
09 244 SUPPORT DE CONSOLE 0.5 0.5 0.5 0.5 0.5
REAR BOX
09 283 COFFRE ARRIÈRE 1.1 1.1 1.1 1.1 1.1
BOX DOOR
09 284 PORTE DE COFFRE 0.3 0.3 0.3 0.3 0.3
REAR SUPPORT
09 304 1.9 1.9 1.9 1.9 1.9
SUPPORT ARRIÈRE
INNER FENDER (RH OR LH)
09 305 FAUSSE AILE (DROIT OU GAUCHE) 0.3 0.3 0.3 0.3 0.3
HITCH
09 316 ATTACHE 0.3 0.3 0.3 0.3 0.3
CENTRAL SKID PLAT

09 336 PLAQUE DE PROTECTION CENTRALE 0.4 0.4 0.4 0.4 0.4
LOCK
09 367 VERROU 0.3 0.3 0.3 0.3 0.3
FRONT FENDER
09 438 1.0 1.0 1.0 1.0 1.0
AILE AVANT
GUN BOOT RACK
09 473 SUPPORT D'ÉTUI D'ARME 0.3
GUN BOOT
09 474 0.3
ÉTUI D'ARME
MOUNTED GEAR GRIPS
09 475 PINCES À CLIQUET 0.3
Volume 1- Can-Am 49
2016
09
SYSTEM/SYSTÈME
0913
0956
0913
09367
0991
0917
09284
9 0929
09152
0956
0991 09283
09244
0948
09149
09149
09158 0991
09305
09438 09305
09336 0991
0948
0928
vtf2015-012_a
2016
CARROSSERIE ET ACCESSOIRES 09
SYSTEM/SYSTÈME
09200
0949
0974
09304
09316
vtf2015-013_a
Volume 1- Can-Am 51
2016
09
SYSTEM/SYSTÈME
0921
09198
0945
0945
19
09108
09199
vtf2015-014_a
2016
ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE 10
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XRM 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
NO LABOR INVOLVED
IGNITION SWITCH
10 01 0.3 0.3 0.3 0.3 0.3
INTERRUPTEUR D’ALLUMAGE
HEADLAMP AND/OR HEADLAMP SUPPORT (ASS’Y) (RH OR LH)
10 09 PHARE AVANT ET/OU SUPPORT (COMPLET) (DROIT OU GAUCHE) 0.3 0.3 0.3 0.3 0.3
VOLTAGE REGULATOR
10 10 RÉGULATEUR DE TENSION 0.3 0.3 0.3 0.3 0.3
BATTERY
10 13 BATTERIE 0.3 0.3 0.3 0.3 0.3
MULTIFUNCTION SWITCH
10 21 INTERRUPTEUR MULTIFONCTION 0.8 0.8 0.8 0.8 1.1
SPEEDOMETER/TACHOMETER
10 28 0.3 0.3 0.3 0.3 0.3
INDICATEUR DE VITESSE/COMPTE-TOURS
TAIL LAMP HOUSING (ASS’Y)
10 29 BOÎTIER DE FEU ARRIÈRE (COMPLET) 0.3 0.3 0.3 0.3 0.3
DC OUTLET PLUG
10 31 0.3 0.3 0.3 0.3 0.3
PRISE D’ACCESSOIRE DC
ELECTRONIC MODULE
10 34 MODULE ÉLECTRONIQUE 0.4 0.4 0.4 0.4 0.4
ENGINE HARNESS
10 41 CÂBLAGE DU MOTEUR 1.4 1.4 1.4 1.4 1.4
WINCH (ASS'Y)
10 45 TREUIL (COMPLET) 0.4
WINCH SOLENOID
10 46 SOLÉNOÏDE DE TREUIL 0.5
WINCH SWITCH
10 47 0.4
INTERRUPTEUR DE TREUIL
MAIN WIRE HARNESS
10 51 CÂBLAGE PRINCIPAL 2.5 2.7 2.5 2.7 3.0
STARTING RELAY
10 52 RELAIS DE DÉMARRAGE 0.3 0.3 0.3 0.3 0.3
FRONT FLASHERS 1 OR 2 (CE ONLY)

10 61 CLIGNOTANTS AVANT 1 OU 2 (CE SEULEMENT) 0.3 0.3 0.3 0.3
REAR FLASHERS 1 OR 2 (CE ONLY)

10 62 CLIGNOTANTS ARRIÈRE 1 OU 2 (CE SEULEMENT) 0.3 0.3 0.3 0.3
12 VOLT RELAY (CE ONLY)

10 65 RELAIS 12 VOLT (CE SEULEMENT) 0.3 0.3 0.3 0.3
HORN
10 66 AVERTISSEUR 0.3 0.3 0.3 0.3
RELAY
10 67 0.3 0.3 0.3 0.3 0.3
RELAIS
Volume 1- Can-Am 53
2016
10
SYSTEM/SYSTÈME
ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
OUTLANDER
MAX 450
MAX 570
XRM 570
450
570
SYSTÈME
CODE
SYSTEM
DESCRIPTION
1 2 3 4 5
ANY BULBS
10 68 TOUTES LES AMPOULES 0.6 0.6 0.6 0.6 0.6
LICENSE LIGHT (ASS’Y) (CE ONLY)

10 71 LUMIÈRE D’IMMATRICULATION (COMPLET) (CE SEULEMENT) 0.3 0.3 0.3 0.3
MULTIFONCTION SWITCH (RH)

10 101 INTERRUPTEUR MULTIFONCTION (DR) 0.3 0.3 0.3 0.3 0.3
BATTERY SUPPORT
10 122 SUPPORT DE BATTERIE 0.5 0.5 0.5 0.5 0.5
SPOT LIGHT
10 144 PROJECTEUR 0.3
2016
ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE 10
SYSTEM/SYSTÈME
1061
1065 1021
1061
1009
1028
1062
1009
1021
Europe
1051
1001
1062
1010
1013
10122
1029
vtf2015-015_a
Volume 1- Can-Am 55
2016
Today we will go over the 2017 ATV technical presentation illustrating the line‐up
improvements and new features.
This year, the “L” is dropped from the name, but the G2L platform continues to
offer the same performance with an even better value for the 450 and 570
engines, while the class leading 650, 850 and 1000R engines remain on the G2
platform. So the 2017 Outlander 450 and Outlander 570 take over for last year’s
Outlander L
The rugged XT package is now added to this 2nd generation platform. Introducing
the new Outlander and Outlander MAX XT 570.
4
The new Can‐Am Renegade X mr 570 reinforces Can‐Am’s mud‐segment
leadership. Designed specifically for the mud, it offers an attractive and
affordable vehicle for sport 4x4 enthusiasts.
5
Introducing the ultimate hunting ATV: the Outlander Mossy Oak Hunting Edition
1000R.
The base for this model is the rugged XT package, plus fully equipped right out of
the factory with these much appreciated accessories and options.
6
Previously available only with the XT package, we are now adding the Outlander
6x6 DPS 650 to the family. It comes with a tri‐mode DPS, a 62 HP Rotax 650 v‐
twin engine and a 700 lb capacity cargo box with sidewalls and tailgate that can
be used for many purposes.
7
Completing the list of new packages is the DS 70 which returns to the line‐up
after a few years of absence. Designed for riders ages six and above, it features a
4‐stroke air‐colled engine with a CVT transmission, a built‐in throttle limiter and a
new Can‐Am red coloration.
8
New for 2017 on G2L platform models is the next generation DPS.
This DPS is a completely new design, software, and calibration.
New steering column and pitman arm along with a new support bracket were necessary
to adapt this new DPS.
Also new is a single connector for power and communication. Easily accessible for
diagnostic.
Now for all you curious techs let’s take a look inside.
Going right through is the single piece main shaft.
The torque sensor is located inside the top cover.
A new brushless motor means the armature is outside with the magnets in the center
rotating with the shaft which greatly help dissipate heat.
The worm and rotation gears match together at the perfect angle to minimize backlash.
The PC board is located in the cover with the connector.
Now that you know how it’s made inside……you don’t need to open one up….right?
Let’s take a look at the DPS assistance levels in regard to vehicle speed.
Zone A: At low vehicle speed all assistance levels are very similar, which means
that steering feel is the practically the same. The purpose is because we don't
want to penalize the driver who drives in DPS MIN (usually the one who loves
more ground feedback at higher speed) when maneuvering in parking lots or
tight trails. Nobody really needs ground feedback below 15km/h or 9mph. This
way, drivers who drives in MIN mode don’t have to switch modes constantly. We
give him the best of both worlds high assist in low speed and more ground
give him the best of both worlds, high assist in low speed and more ground
feedback at higher speed.
Zone B: Mid‐speed range, all 3 assistance level gets distinct assist reduction
slopes resulting in different steering attitudes.
Zone C: High‐speed range, all 3 assistance levels remain distinct but gets closer to
each other to make sure all drivers (mainly those who ride in MAX) get more
ground feedback and confidence in the steering system. In this speed range,
steering system naturally gets lighter, a low level of assistance is kept to reduce
long distance driver fatigue and counter‐act ground kick‐back.
Zone D: In reverse speed, assistance torque from the DPS is the same for all 3
assistance levels. Of course, it lowers quickly as reverse speed increases.
Let’s understand how this new generation DPS compares to the previous.
The red line is a handlebar movement from full left turning Right, the blue line is the DPS

assistance torque. Notice the blue line is following constantly adjusting to the steering
movement in distanced intervals.
The green line the handlebar turning Left, notice the blue line showing strong
adjustments when the direction is changed.
With the new generation DPS the assistance is more constant and adjusts quicker to the
steering movement. When the steering changes direction, the assistance is able to
quickly adjust and provide a fluid movement.
You will quickly notice the easy steering of the G2L models.
The introduction of the RF D.E.S.S. key into the Can‐Am line‐up is an
improvement offering more reliable key design in line with the current proven
technology in other BRP brands.
For international markets in 2017, Outlander PRO 450 and 570 are going to be
standard with the DESS key offering extra peace of mind.
Certain ATV’s in the line‐up upgrade from 12‐in to 14‐in wheels. Such is the case
for the Outlander DPS, Outlander XT, Outlander MAX DPS, Outlander MAX XT and
Outlander MAX LIMITED. Last but not least, new 14‐in beadlock wheels make
their way onto the Outlander and Outlander MAX XT‐P ATV’s.
Many Can‐Am ATV’s are now riding on new 26‐in, 6‐ply ITP Terracross tires that
feature a tread pattern aggressive enough to tackle tough terrain, yet provide a
smooth ride
smooth ride.
Becoming standard with the G2L platform rear suspension, the G2 platform will now
have the latest generation TTI swingarms.
Stiffer and lightweight design will benefit the G2 models handling.
New FOX QS3 shocks that allow simpler and quicker compression adjustments.
These high‐performance front and rear shocks feature a tool‐free adjuster
without the complication of counting detents. Through a 3‐position knob, the
suspension can be easily adjusted depending on the terrain or riding preference.
These new shocks can be found on the Outlander & Outlander MAX XT‐P, and
both the Outlander X mr 1000R and Renegade X mr 1000R.
Turn the knob to position 1 to get a smooth compression optimizing comfort and
performance for the long rides, select position 2 for a good all‐around leisure
ride, or go to position 3 to get that high‐performance race‐ready suspension.
Note that rebound stays constant within 3% in all positions.
2017 improvements in T3 kit logistics.
T3 parts will be shipped directly to Factory to be added in the crate. This means a 2nd
crate for the T3 kit is no longer used.
Electric harness & G2L rear facia will be installed at Factory.
The remaining T3 parts installed by dealer at PDI, this will help reduce PDI assembly
time for T3 models.
When customers choose between the Outlander and Outlander MAX XT‐P,
Outlander X mr 1000R and Renegade X xc 1000R, they can opt for this dramatic
triple black appearance of the units, which includes black paint, black plastics
and black rims.
The Outlander and Outlander MAX XT with the 650, 850 and 1000R engine
options are now available with a new White & Black painted color scheme.
Among the other coloration news, the premium Outlander MAX Limited 1000R,
add a new painted Midnight Blue coloration that is sure to grab the attention of
add a new painted Midnight Blue coloration that is sure to grab the attention of
those who looking for an extra touch of luxury.
28
The 570 versions add a new Pure Magnesium painted coloration.
And finally, after sporting the Can‐Am yellow for many years, the DS family
reveals a new Can‐Am red coloration.
29
The ATV line‐up introduces 5 new packages: the Outlander and Outlander MAX
XT 570, the Renegade X mr 570, the Outlander Mossy Oak Hunting Edition
1000R, the Outlander 6x6 DPS and the returning DS 70.
In terms of line‐up improvements and new features, new DPS on G2L platform,
RF key on select models, new wheels and tires, new rear suspension on G2
platform, and new FOX QS3 shocks are all proof that we’ve raised our game,
especially when you consider the fact that Can‐Am offers class‐leading power in
every engine category
every engine category.
Slide 61:
So there you have it, a 2017 Can‐Am ATV lineup that showcases a lot of new exciting
colors but most importantly, it provides industry leading performance to a wider
customer base thanks to the addition of many new user‐specific packages.
31
Slide 61:
So there you have it, a 2017 Can‐Am ATV lineup that showcases a lot of new exciting
colors but most importantly, it provides industry leading performance to a wider
customer base thanks to the addition of many new user‐specific packages.
32
THIS VEHICLE CAN BE HAZARDOUS TO OPERATE.
A collision or rollover can occur quickly, even during
routine maneuvers such as turning and driving on hills
or over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if

you do not follow these instructions:
• BEFORE YOU OPERATE THIS VEHICLE, READ THIS

OPERATOR’S GUIDE, ALL ON PRODUCT SAFETY
OUTLANDER Series / OUTLANDER MAX Series

LABELS AND WATCH THE SAFETY VIDEO.
2017
• NEVER OPERATE THIS VEHICLE WITHOUT
PROPER INSTRUCTIONS. Complete a certified
training course.
• DO NOT EXCEED VEHICLE SEATING CAPACITY
• FOR MAX MODELS, NEVER CARRY MORE THAN
ONE PASSENGER. You increase your risk of losing
control if you carry more than a passenger.
Operator’s
• FOR 1UP MODELS, NEVER CARRY A
PASSENGER. You increase your risk of losing control
Guide
if you carry a passenger.
• NEVER OPERATE THIS VEHICLE ON A PAVED
SURFACE. You increase your risk of losing control
if you operate this vehicle on pavement.
• NEVER OPERATE THIS VEHICLE ON PUBLIC
Includes
ROADS. You can collide with another vehicle if you Safety, Vehicle
operate this vehicle on a public road. and Maintenance Information
• OPERATOR AND PASSENGER (MAX models)
SHOULD ALWAYS WEAR AN APPROVED HELMET,
eye protection, and protective clothing.
• NEVER USE WITH DRUGS OR ALCOHOL.
They slow reaction time and impair judgment.
• NEVER OPERATE THIS VEHICLE AT EXCESSIVE
SPEEDS. You increase your risk of losing control if you
operate this vehicle at speeds too fast for the terrain,
visibility conditions, or your experience.
• NEVER ATTEMPT WHEELIES, JUMPS, OR OTHER
STUNTS.
OUTLANDER Series/ TM
OUTLANDER MAX Series

TM TM
2017
WARNING
219 001 733 Read this guide thoroughly. It contains important safety information.
OPERATOR’S GUIDE OUTLANDER / MAX Series (GL2) / ENGLISH
GUIDE DU COND. Séries OUTLANDER / MAX (GL2) / ANGLAIS
Minimum recommended age: Operator: 16 years old. Keep this Operator’s Guide in the vehicle.
FAIT AU / MADE IN CANADA U/M:P.C.

®™ AND THE BRP LOGO ARE TRADEMARKS OF BOMBARDIER RECREATIONAL PRODUCTS INC. OR ITS AFFILIATES.
©2016 BOMBARDIER RECREATIONAL PRODUCTS INC. ALL RIGHTS RESERVED. PRINTED IN CANADA. 2 1 9 0 0 1 7 3 3 Original Instructions
WARNING
YOUR VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rollover
can occur quickly, if you fail to take proper precautions, even during routine
maneuvers such as turning and driving on hills or over obstacles.
For your safety, understand and follow all the warnings contained in this
Operator's Guide and on the labels on your vehicle. Failure to follow these
warnings can result in SEVERE INJURY OR DEATH!
Keep this Operator's Guide with the vehicle at all times.
WARNING
Disregarding any of the safety precautions and instructions contained in
this Operator’s Guide, SAFETY VIDEO and on-product safety labels could
result in an injury including the possibility of death!
WARNING
This vehicle may exceed the performance of other vehicles you may have
ridden in the past. Take time to familiarize yourself with your new vehicle.
CALIFORNIA PROPOSITION 65 WARNING
WARNING
This vehicle contains or emits chemicals known to the state of California to
cause cancer and birth defects or other reproductive harm.
FOREWORD
Dieses Handbuch ist möglicherweise in Ihrer Landessprache

Deutsch verfügbar. Bitte wenden Sie sich an Ihren Händler oder besuchen Sie:
www.operatorsguides.brp.com
This guide may be available in your language. Check with your dealer or
English
go to: www.operatorsguides.brp.com
Es posible que este manual esté disponible en su idioma. Consulte a su
Español
distribuidor o visite: www.operatorsguides.brp.com
Ce guide peut être disponible dans votre langue. Vérifier avec votre
Français
concessionnaire ou aller à: www.operatorsguides.brp.com
このガイドは、言語によって翻訳版が用意されています。.
日本語ディーラーに問い合わせるか、次のアドレスでご確認ください：
www.operatorsguides.brp.com
Deze handleiding kan beschikbaar zijn in uw taal. Vraag het aan uw dealer
Nederlands
of ga naar: www.operatorsguides.brp.com
Denne boken kan finnes tilgjengelig på ditt eget språk. Kontakt din
Norsk
forhandler eller gå til: www.operatorsguides.brp.com
Este manual pode estar disponível em seu idioma. Fale com sua
Português
concessionária ou visite o site: www.operatorsguides.brp.com
Käyttöohjekirja voi olla saatavissa omalla kielelläsi. Tarkista jälleenmyyjältä
Suomi
tai käy osoitteessa: www.operatorsguides.brp.com
Denna bok kan finnas tillgänglig på ditt språk. Kontakta din återförsäljare
Svenska
eller gå till: www.operatorsguides.brp.com
Congratulations on your purchase of a Know Before you Go

new Can-Am® ATV. It is backed by the To learn how to reduce the risk for you
BRP warranty and a network of autho- or bystanders being injured or killed,
rized Can-Am dealers ready to provide read this Operator's Guide before you
the parts, service or accessories you operate the vehicle.
may require.
Also, read all safety labels on your ATV
Your dealer is committed to your sat- and watch attentively your SAFETY
isfaction. He has taken training to per- VIDEO.
form the initial setup and inspection of
your vehicle as well as completed the This vehicle is for off road use only. It is
final adjustment before you took pos- mainly for general recreational use but
session. If you need more complete it may also be used for utility purposes.
servicing information, please ask your Failure to follow the warnings con-
dealer. tained in this Operator's Guide can
At delivery, you were also informed of result in SERIOUS INJURY or DEATH.
the warranty coverage and signed the
PREDELIVERY CHECK LIST to ensure
your new vehicle was prepared to your
entire satisfaction.
_______________ 1
FOREWORD
Age Recommendation About this Operator's

This vehicle is a category G, always fol- Guide
low this age recommendation: This Operator's Guide has been pre-
– A person under 16 years old should pared to acquaint the owner/operator
never operate this vehicle. of a new vehicle with the various ve-
– Passenger on 2-UP models must be hicle controls, maintenance and safe
capable of keeping his feet on the operating instructions. It is indispens-
footrests and his hands on grab han- able for the proper use of the product.
dles at all times when seated on this
vehicle. WARNING
Throughout this Operator's Guide,
Training Course the term “1-UP” refers to vehi-
Never operate this vehicle without cles designed to carry the operator
proper instruction. Take a training only while the term “2-UP” refers
course. All operators should receive to vehicles designed to carry also
training from a certified instructor. a passenger.
For more information about ATV safety, Make sure to identify and follow
contact an authorized Can-Am dealer the warnings and instructions
to find out about available training that are applicable to your specific
courses nearest you. model.
In the United States, call the Specialty Note that this guide is available in sev-
Vehicle Institute of America (SVIA) eral languages. In the event of any dis-
at 1 800 887–2887 or in Canada, the crepancy, the English version shall pre-
Canada Safety Council (CSC) at 1 613 vail.
739–1535.
Keep this Operator's Guide in the vehi-
Safety Messages cle as you can refer to it for things such
as maintenance, troubleshooting and
The types of safety messages, what instructing others.
they look like and how they are used in
this guide are explained as follows: If you want to view and/or print an
extra copy of your Operator's Guide,
The safety alert symbol indicates simply visit the following website
a potential injury hazard. www.operatorsguides.brp.com.
The information contained in this doc-
ument are correct at the time of publi-
WARNING cation. However, BRP maintains a pol-
Indicates a potential hazard, if not icy of continuous improvement of its
avoided, could result in serious in- products without imposing upon itself
jury or death. any obligation to install them on prod-
ucts previously manufactured. Due
to late changes, some differences be-
CAUTION Indicates a hazard tween the manufactured product and
situation which, if not avoided, the descriptions and/or specifications
could result in minor or moderate in this guide may occur. BRP reserves
injury. the right at any time to discontinue or
NOTICE Indicates an instruction change specifications, designs, fea-
which, if not followed, could se- tures, models or equipment without
verely damage vehicle components incurring any obligation upon itself.
or other property.
2 _______________
FOREWORD
This Operator's Guide and the SAFETY

DVD should remain with the vehicle
when it is sold.
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious
injury or death.
_______________ 3
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Know Before you Go . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
About this Operator's Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY INFORMATION
GENERAL PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Avoid Carbon Monoxide Poisoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Avoid Gasoline Fires and Other Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Avoid Burns from Hot Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accessories and Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL SAFETY MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRE-RIDE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pre-Ride Inspection Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
RIDING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Riding Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Carrying a Passenger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Recreational Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Design Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Off-Road Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Riding Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
MOVING LOADS AND DOING WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Working with your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Carrying Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Loading the Cargo Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Hauling a Load (if Equipped with Hitch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Pulling a Trailer (if Equipped with Hitch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
IMPORTANT ON-PRODUCT LABELS(CANADA/UNITED STATES) . . . . . . . . . 62
Hang Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Vehicle Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Compliance Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Technical Information Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
IMPORTANT ON-PRODUCT LABELS (ALL COUNTRIES EXCEPT
CANADA/UNITED STATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Hang Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Vehicle Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Compliance Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Technical Information Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4 _______________
TABLE OF CONTENTS
VEHICLE INFORMATION
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1) Throttle Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2) LH Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3) Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4) Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5) Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6) Ignition Switch and Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7) Multifunction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8) 2WD/4WD Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
MULTIFUNCTION GAUGE (LCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Multifunction Gauge Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Multifunction Gauge Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Navigating in the LCD Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Gauge Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1) Operator's Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2) Passenger's Seat (2-UP Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3) Footpegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4) Grab Handles (2-UP Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5) 12-Volt Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6) Rear Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7) Cargo Racks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8) Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9) Tool Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10) Recovery Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
EQUIPMENT (IF AVAILABLE ON YOUR MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1) Full Underbody Aluminum Skid Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2) Portable Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3) Gun Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4) Gear Grips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5) Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6) Roller Fairlead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Vehicle Fueling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Operation During Break-In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
BASIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Shifting the Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Stopping the Engine and Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
What to Do if Water is in the CVT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
What to Do if Water is in the Air Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
_______________ 5
TABLE OF CONTENTS
SPECIAL PROCEDURES (cont’d)

What to Do if Vehicle is Turned Over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
What to Do if Vehicle is Immersed in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
TUNE YOUR RIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Suspension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Dynamic Power Steering (DPS) Assist Level Adjustment . . . . . . . . . . . . . . . . . 110
VEHICLE TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
MAINTENANCE
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

SEVERE DUSTY CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
MAINTENANCE SCHEDULE LEGEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Muffler Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Gearbox Oil (570 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Drive Shaft Boot and Protector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Wheel Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
VEHICLE CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Post-Operation Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Vehicle Cleaning and Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
STORAGE AND PRESEASON PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
TECHNICAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Engine Identification Number (EIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6 _______________
TABLE OF CONTENTS
NOISE EMISSION CONTROL SYSTEM REGULATION (CANADA/UNITED

STATES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
NOISE EMISSION AND VIBRATION VALUES (ALL COUNTRIES EXCEPT
CANADA/UNITED STATES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
EC-DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
TROUBLESHOOTING
TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

MULTIFUNCTION GAUGE MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
WARRANTY
BRP LIMITED WARRANTY USA AND CANADA: 2017 CAN-AM® ATV . . . . 166
US EPA EMISSION-RELATED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
BRP INTERNATIONAL LIMITED WARRANTY: 2017 CAN-AM® ATV. . . . . . . 172
BRP LIMITED WARRANTY FOR THE EUROPEAN ECONOMIC AREA, THE
COMMONWEALTH OF THE INDEPENDENT STATES AND TURKEY: 2017
CAN-AM® ATV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
CUSTOMER INFORMATION
PRIVACY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

CONTACT US. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Oceania . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
South America. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Asia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
CHANGE OF ADDRESS/OWNERSHIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
_______________ 7
TABLE OF CONTENTS
8 _______________
SAFETY
INFORMATION
________ SAFETY INFORMATION ________ 9

GENERAL PRECAUTIONS
Avoid Carbon Monoxide – For refueling, strictly adhere to in-
Poisoning structions in FUEL subsection.
All engine exhaust contains carbon – Never start or operate the engine if
monoxide, a deadly gas. Breathing car- the fuel cap is not properly installed.
bon monoxide can cause headaches, Gasoline is poisonous and can cause
dizziness, drowsiness, nausea, confu- injury or death.
sion and eventually death. – Never siphon gasoline by mouth.
Carbon monoxide is a colorless, odor- – If you swallow gasoline, get any in
less, tasteless gas that may be present your eye(s), or inhale gasoline vapor,
even if you do not see or smell any en- see your doctor immediately.
gine exhaust. Deadly levels of carbon If gasoline spills on you, wash with
monoxide can collect rapidly, and you soap and water and change your
can quickly be overcome and unable clothes.
to save yourself. Also, deadly levels of
carbon monoxide can linger for hours
or days in enclosed or poorly ventilated Avoid Burns from Hot Parts
areas. If you experience any symp- Certain components become hot dur-
toms of carbon monoxide poisoning, ing operation. Avoid contact with
leave the area immediately, get fresh those parts during and shortly after
air and seek medical treatment. operation to avoid burns.
To prevent serious injury or death from
carbon monoxide: Accessories and
– Never run the vehicle in poorly ven- Modifications
tilated or partially enclosed areas Do not make unauthorized modifica-
such as garages, carports or barns. tions, or use attachments or acces-
Even if you try to ventilate engine sories that are not approved by BRP.
exhaust with fans or open windows Since these changes have not been
and doors, carbon monoxide can tested by BRP, they may increase the
rapidly reach dangerous levels. risk of crashes or injury, and can render
– Never run the vehicle outdoors the vehicle illegal.
where engine exhaust can be drawn See your authorized Can-Am dealer for
into a building through openings available accessories for your vehicle.
such as windows and doors.
Avoid Gasoline Fires and

Other Hazards
Gasoline is extremely flammable and
highly explosive. Fuel vapors can
spread and be ignited by a spark or
flame many feet away from the en-
gine. To reduce the risk of fire or explo-
sion, follow these instructions:
– Use only an approved red gasoline
container to store fuel.
– - Never fill a gasoline container on
the vehicle. An electrical static dis-
charge may ignite the fuel.
10 _______ SAFETY INFORMATION ________

SPECIAL SAFETY MESSAGES
THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
– This vehicle handles differently from other vehicles including motorcycles
and cars. A collision or rollover can occur quickly, if you fail to take proper
precautions, even during routine maneuvers such as turning and driving on hills
or over obstacles.
SEVERE INJURY OR DEATH can result if you do not comply with the following in-
structions:
– Read this Operator's Guide and all on-product safety labels carefully and follow
the operating procedures described. Watch and pay attention to the SAFETY
VIDEO before operating the vehicle.
– Always follow this age recommendation: A person under 16 years old should
never operate this vehicle.
– Never take place on this vehicle without wearing an approved helmet of the
proper size and other required riding gears. Refer to RIDING GEAR in the
RIDING THE VEHICLE subsection for detailed information.
– Never carry a passenger on this vehicle unless you are operating a 2-UP model.
Passenger(s) affect balance and steering and increase risk of losing control.
– On 1-UP models, do not make any modifications to accommodate a passenger
or use racks to carry a passenger.
– This vehicle is not designed to ride on paved surfaces; if you must shortly use
the vehicle on such surfaces, avoid abrupt inputs to steering, accelerator and
brakes. Reduce your speed.
– This vehicle is not designed for riding on roads or highways (in most places it is
an illegal practice). Riding your vehicle on roads or highways could cause a col-
lision with another vehicle.
– Never use this vehicle if you are tired, ill or with drugs or alcohol. Your reaction
time and judgement is greatly affected under these conditions.
– Never attempt wheelies, jumps, or other stunts.
– Never operate at excessive speeds. Always go at a speed that is proper for the
terrain, visibility, and operating conditions, and your experience.
– Always go slowly and be extra careful when operating on unfamiliar terrain. Al-
ways be alert to changing terrain conditions when operating this vehicle.
– Never operate on excessively rough, slippery or loose terrain until you have
learned and practiced the skills necessary to control this vehicle on such terrain.
Always be especially cautious on these kinds of terrain.
– Always follow proper procedures for turning as described in RIDING TECH-
NIQUES in this Operator's Guide.
– Never operate this vehicle on hills too steep for the vehicle or for your abilities.
– Always follow proper procedures for climbing hills as described in RIDING
TECHNIQUES in this Operator's Guide. Check the terrain carefully before you
start up any hill. Never climb hills with excessively slippery or loose surfaces.
– Always follow proper procedures for going down hills and for braking on hills as
described in RIDING TECHNIQUES in this Operator's Guide. Check the terrain
carefully before you start down any hill.
– Always follow proper procedures for crossing the side of a hill as described in
RIDING TECHNIQUES in this Operator's Guide. Avoid hills with excessively
slippery or loose surfaces.

– Always use proper procedures if you stall or roll backwards when climbing a
hill. To avoid stalling, use low gear and maintain a steady speed when climbing
a hill. If you stall or roll backwards, follow the driving technique procedures as
described in RIDING TECHNIQUES in this Operator's Guide.
– Always check for obstacles before operating in a new area. Never attempt to
operate over large obstacles, such as large rocks or fallen trees. Always follow
proper procedures when operating over obstacles as described in RIDING
TECHNIQUES in this Operator's Guide.
– Always be careful when skidding or sliding. Learn to safely control skidding or
sliding by practicing at low speeds and on level smooth terrain. On extremely
slippery surfaces, such as ice, go slowly and be very cautious in order to reduce
the chance of skidding out of control. If you are operating a 2-UP model and
have a passenger on-board, never attempt skidding or sliding; overturn or
passenger ejection may occur.
– Never operate this vehicle through deep or fast flowing water. Water should
never exceed footrests. Remember that wet brakes may have reduced stop-
ping ability. Test your brakes after leaving water, mud or snow. If necessary,
apply them several times to let friction dry out the pads.
– Always keep in mind that braking distance is readily affected by but not limited
to; weather and terrain conditions, braking system and tire conditions, vehicle
speed and attitude, and vehicle load including towing. Remember to adjust
your driving accordingly.
– Always be sure there are no obstacles or people behind the vehicle when you
operate in reverse. When it is safe to proceed in reverse, go slowly. Take into
account that on a 2-UP model the passenger can obstruct your view.
– BRP recommends sitting on your ATV when operating in reverse. Avoid stand-
ing up. Your weight could shift forward against throttle lever, causing an unex-
pected acceleration and may lead to a loss of control.
– Never exceed the stated load limits for this vehicle including operator, passen-
ger (2-UP models), all other loads and added accessories. Cargo should be prop-
erly distributed and securely attached. Reduce speed and follow instructions in
this guide for carrying cargo or pulling a trailer. Allow greater distance for brak-
ing.
– Always inspect and confirm the safe operating condition of your vehicle prior to
ride. Refer to PRE-RIDE INSPECTION subsection in this Operator's Guide. Al-
ways follow the maintenance schedules as described in this Operator's Guide.
Refer to MAINTENANCE section.
– Never operate the vehicle if the controls do not function normally.
– Always maintain proper tire pressure. When replacing tires, use only the rec-
ommended tire size and type. For tire information, refer to SPECIFICATIONS
in this guide.
– Riding your vehicle too fast for your skills or the conditions may result in injury.
Apply only enough throttle to proceed safely. Statistics show that mishaps and
injury usually result from high speed turns. Always remember that this vehicle
is heavy! Its pure weight alone may entrap you should it fall, resulting in injury.

– This vehicle is not designed for jumping, nor can it fully absorb the high impact
energy generated during manoeuvres such as jumping which, can be passed on
to you, the operator. Performing wheelies can cause the vehicle to flip over onto
you. Both practices have a high risk for you and your passenger (2-UP models)
and should be avoided at all times.
– The tires of this vehicle are not suited for paved road use.
2-UP Models
Driver must:
– Not forget he is responsible for the safety of the passenger.
– Inform the passenger concerning the basic rules for a safe ride.
– Instruct the passenger to read the vehicle’s safety labels and to watch the
SAFETY VIDEO.
– Always practice the maneuvers described in this Operator's Guide without and
with a passenger. Greater skills are required with a passenger.
– Always remember that the vehicle handling and stability may be affected when
riding with a passenger. Safely reduce speed. Use proper judgement. If in
doubt, do not attempt and disembark the passenger before executing any
maneuver.
– Always remember that the vehicle braking distance may be longer when riding
with a passenger. Allow greater distance for braking.
– Never carry passenger on a 2-UP model if the passenger seat is not properly in-
stalled.
– Never carry more than one (1) passenger. Do not allow passenger to sit any-
where else than the designated passenger seat.
– Never carry a passenger if you judge his ability or judgement insufficient to con-
centrate on the terrain conditions and adapt accordingly.
– Never carry a passenger who has used drugs or alcohol, or is tired or ill. These
slow reaction time and impair judgment.
Passenger must:
– Be capable of resting his feet on the footrests and his hands on grab handles
when seated on this vehicle.
– Never take place on this vehicle without wearing an approved helmet (including
a chin guard) that fits properly. The passenger should also wear eye protection
(goggles or face shield), gloves, boots, long sleeved shirt or jacket, and long
pants.
– Be seated on the designated passenger's seat.
– Always keep hands on grab handles and feet on the footrests during operation.
Never hold on to the operator.
– Never get up during vehicle operation. An excessive movement could cause
loss of control.
– Pay attention to vehicle and operator movements.
– Not wait and tell the driver to slow down or stop if you feel uncomfortable or in-
secure for any reason.

OPERATION WARNINGS
The following warning and their format have been requested by the United States
Consumer Product Safety Commission and are required to be in the Operator's
Guide for all ATVs.
NOTE: The following illustrations are general representations only. Your model
may differ.
WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does not know
how to operate this vehicle properly in different situations and on different
types of terrain.
HOW TO AVOID THE HAZARD
Beginners and inexperienced operators should complete a training course.
They should then regularly practice the skills learned during the course as
well as the operating techniques described in this Operator's Guide.
For more information about a training course, contact an authorized
Can-Am dealer.

OPERATION WARNINGS
WARNING
V00A1AQ
POTENTIAL HAZARD
Failure to follow the age recommendations for this vehicle.
WHAT CAN HAPPEN
A lack of respect for this age recommendation can lead to severe injury or
death of the child.
Even though a child may be within the age group for which this vehicle is
recommended, he may not have the skills, abilities, or judgment needed to
operate this vehicle safely and may be involved in a serious accident.
No one under 16 should operate this vehicle.

OPERATION WARNINGS
2-UP Models Only
WARNING
vmo2014-005-100
POTENTIAL HAZARD
Failure to respect the physical limitations of the passenger on 2-UP models.
WHAT CAN HAPPEN
A passenger that cannot completely lean his feet on footrests can be ejected
when riding on uneven terrain.
The passenger must be capable of keeping his feet on the footrests and his
hands on grab handles at all times when he is seated on the vehicle.

OPERATION WARNINGS
1-UP Models Only
WARNING
V00A02Q
POTENTIAL HAZARD
Carrying a passenger on this vehicle.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and control this vehicle.
Could cause an accident, resulting in harm to you and/or your passenger.
Never carry passenger. Even with a long seat that provides unrestricted op-
erator movement, it is not designed nor intended to carry passenger(s).

OPERATION WARNINGS
2-UP Models Only
WARNING
V00A1CQ
POTENTIAL HAZARD
Carrying more than one (1) passenger on this vehicle.
WHAT CAN HAPPEN
Carrying more than one (1) passenger reduces your ability to balance and
control this vehicle.
Could cause an accident, resulting in harm to you and/or your passengers.
Never carry more than one (1) passenger. Even with a long seat that pro-
vides unrestricted operator movement, the vehicle is not designed nor
intended to carry more than one (1) operator and one (1) passenger. The
passenger must use the designated passenger's seat when he is seated on
the vehicle with feet firmly planted on footrests and always hold on to the
grab handles.

OPERATION WARNINGS
WARNING
V00A2DQ
POTENTIAL HAZARD
Allowing passenger(s) to sit on front or rear racks on this vehicle.
WHAT CAN HAPPEN
Allowing a passenger could:
– Impair vehicle stability which could lead to a loss of control.
– Result in injury to passenger(s) from impact on hard surfaces.
– Cause an accident, resulting in harm to you and/or your passenger(s).
Never allow any passenger to sit on front or rear racks on this vehicle.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
Never operate this vehicle on any public street, road or highway, even a dirt
or gravel one. In many states it is illegal to operate this vehicle on public
streets, roads and highways.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Riding this vehicle without wearing an approved helmet, eye protection and
protective gear. On 2-UP models, passenger should also have an approved
helmet with a rigid chin guard.
WHAT CAN HAPPEN
– Riding without an approved helmet increases the chances of a severe
head injury or death in the event of an accident.
– Riding without eye protection can result in an accident and increases the
chances of a severe injury in the event of an accident.
– Riding without protective gear increases the chances of severe injury in
the event of an accident.
Always wear an approved helmet that fits properly. You should also wear:
– Eye protection (goggles or face shield)
– Rigid chin guard
– Gloves and boots
– Long sleeved shirt or jacket
– Long pants.

OPERATION WARNINGS
WARNING
V00A07Q
POTENTIAL HAZARD
Using this vehicle with drugs or alcohol.
WHAT CAN HAPPEN
Could cause the passenger to fall off (2-UP models).
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident or death.
The operator and the passenger (2-UP models) should never use this vehi-
cle with drugs or alcohol.

OPERATION WARNINGS
WARNING
V00A08Q
POTENTIAL HAZARD
Operating this vehicle at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of the vehicle, which can result in
an accident.
Always travel at a speed which is appropriate for the terrain, visibility and
operating conditions, and your experience.
On 2-UP models, the vehicle handling, stability and braking distance may
be affected when riding with a passenger. Safely reduce speed when riding
with a passenger. Allow greater distance for braking.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps and other stunts.
WHAT CAN HAPPEN
Increases the chance of an accident, for the operator and the passenger
(2-UP models), including an overturn.
Never attempt stunts, such as wheelies or jumps. Do not try to show off.
WARNING
POTENTIAL HAZARD
Failure to inspect the vehicle before operating.
Failure to properly maintain the vehicle.
WHAT CAN HAPPEN
Increases the possibility of an accident or equipment damage.
Always inspect your vehicle prior to ride to make sure the vehicle is in safe
operating condition.
Always follow the maintenance schedule described in this Operator's
Guide.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Riding on frozen waterways.
WHAT CAN HAPPEN
Breaking through the ice can lead to severe injury or death.
Never ride this vehicle on a frozen surface before you are sure the ice is thick
enough and sound enough to support the vehicle and its load, as well as the
force that is created by a moving vehicle.
WARNING
POTENTIAL HAZARD
Removing hands from handlebars for the operator and from grab handles
for the passenger (2-UP models), or feet from the footrests during opera-
tion.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce your ability to control the vehi-
cle or could cause you to lose your balance and fall off the vehicle. If you re-
move a foot from the footrests, your foot or leg may come into contact with
the rear wheels, which could injure you or cause an accident.
Operator must always keep both hands on the handlebars and passenger
(2-UP models) on grab handles..Both feet (operator and passenger on 2-UP
models) must rest on the footrests during vehicle operation.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating this vehicle on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps, or holes, without enough time to
react.
Could result in the vehicle overturning, passenger ejection (2-UP models) or
loss of control.
Go slowly and be extra careful when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating the vehicle.
Do not forget, on 2-UP models, the operator is responsible for the safety of
his passenger. Safely reduce speed when riding with a passenger.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating on excessively rough, slippery or
loose terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle control, which could result in an acci-
dent, including an overturn or passenger ejection (2-UP models).
Do not operate on excessively rough, slippery or loose terrain until you
have learned and practiced the skills necessary to control this vehicle on
such terrain.
Always be especially cautious on these kinds of terrain.
the passenger. In doubt, disembark him before operating on these terrains.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
Vehicle could go out of control, causing a collision or an overturn or a pas-
senger ejection (2-UP models).
Always follow proper procedures for turning as described in this Operator's
Guide. Practice turning at low speeds before attempting to turn at faster
speeds.
the passenger. Never perform this maneuver with a passenger. Always re-
member that the vehicle handling, stability and braking distance may be af-
fected when riding with a passenger.
Do not turn at excessive speed.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on extremely steep hills than on level
surfaces or small hills.
Never operate this vehicle on hills too steep for the vehicle or for your abili-
ties.
Practice, without and with passenger (2-UP models), on smaller hills before
attempting larger hills.
Always remember that, on 2-UP models, even if this vehicle can climb some
steep hills, it is not recommended to climb such hills with a passenger; al-
ways disembark him before attempting this maneuver. Show good judge-
ment.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Could cause loss of control, passenger ejection (2-UP models) or cause ve-
hicle to overturn.
Always follow proper procedures for climbing hills as described in this Op-
erator's Guide.
Always check the terrain carefully before you start up any hill. Do not
forget, on 2-UP models, the operator is responsible for the safety of the
passenger. In doubt, disembark him before climbing hill. Always remem-
ber that the vehicle handling, stability and braking distance may be affected
when riding with a passenger.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward (operator and passenger on 2-UP models).
Never open the throttle suddenly or make sudden gear changes. The vehi-
cle could flip over backwards.
Never go over the top of any hill at high speed. An obstacle, a sharp drop, or
another vehicle or person could be on the other side of the hill.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
hicle to overturn.
Always follow proper procedures for going down hills as described in this
Operator's Guide.
NOTE: A special technique is required when braking as you go down a hill.
Always check the terrain carefully before you start down any hill. Do not
forget, on 2-UP models, the operator is responsible for the safety of the
passenger. In doubt, disembark him before going down hill. Always re-
member that the vehicle handling, stability and braking distance may be
affected when riding with a passenger.
Shift your weight backward (operator and passenger on 2-UP models).
Never go down a hill at high speed.
Avoid going down a hill at an angle which would cause the vehicle to lean
sharply to one side. Go straight down the hill where possible.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
WHAT CAN HAPPEN
hicle to overturn.
Never attempt this maneuver on 2-UP models when the passenger is on
board. Always disembark him before executing.
Never attempt to turn the vehicle around on any hill until you have mastered
the turning technique as described in this Operator's Guide on level ground.
Be very careful when turning on any hill.
Avoid crossing the side of a steep hill if possible.
When crossing the side of a hill:
Always follow proper procedures as described further in this Operator's
Guide.
Avoid hills with excessively slippery or loose surfaces.
Operator and passenger (2-UP models) must shift weight to the uphill side
of the vehicle.

OPERATION WARNINGS
WARNING
V00A1PQ
POTENTIAL HAZARD
Stalling, rolling backwards or improperly dismounting while climbing a hill.
WHAT CAN HAPPEN
Could result in vehicle overturning.
Use low gear and maintain steady speed when climbing a hill.
If you lose all forward speed:
Operator and passenger (2-UP models) must keep their weight uphill.
Never open the throttle suddenly or make sudden gear changes. The
vehicle could flip over backwards.
Apply the brakes.
Lock parking brake after you have stopped.
Disembark on uphill side, or to a side if pointed straight uphill (passenger
first on 2-UP models).
If you begin rolling backwards:
Operator and passenger (2-UP models) must keep their weight uphill.
Never open the throttle suddenly or make sudden gear changes. The
vehicle could flip over backwards.
Never apply the rear brake while rolling backwards.
Apply the front brake gradually.
When fully stopped, apply rear brake as well and lock parking brake.
Disembark on uphill side, or to a side if pointed straight uphill (passenger
first on 2-UP models).
Turn the vehicle around and remount, following the procedure described
further in this Operator's Guide.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control (passenger ejection on 2-UP models), or a colli-
sion.
Could cause the vehicle to overturn.
Before operating in a new area, check for obstacles.
Never attempt to ride over large obstacles, such as large rocks or fallen
trees.
On 2-UP models, the operator is responsible for the safety of his passenger.
In doubt, disembark him before riding over obstacles. Always remember
that the vehicle handling and stability may be affected when riding with a
passenger.
When you go over obstacles, always follow proper procedures as described
in this Operator's Guide.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Skidding or sliding improperly.
WHAT CAN HAPPEN
You may lose control of this vehicle.
You may also regain traction unexpectedly, which may cause the vehicle to
overturn or passenger ejection (2-UP models).
Learn to safely control skidding or sliding by practicing at low speeds and
on level smooth terrain.
On 2-UP models, never slide or skid with passenger. Always remember that
the vehicle handling and stability may be affected when riding with a pas-
senger.
On extremely slippery surfaces, such as ice, go slowly and be very cautious
in order to reduce the chance of skidding or sliding out of control.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle through deep or fast flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control, which could lead
to an accident.
Never operate this vehicle in fast flowing water or in deep water.
Check water depth and current before you attempt to cross any water. Wa-
ter should not go above footrests.
Remember that wet brakes may have reduced stopping ability. Test your
brakes after leaving water. If necessary, apply them several times to let
friction dry out the pads.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind the vehicle, resulting in serious
injury.
When you select reverse gear, make sure there are no obstacles or people
behind the vehicle. When it is safe to proceed, go slowly. On 2-UP models,
take account that the passenger can obstruct your view.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper tires, or with improper or uneven tire
pressure.
WHAT CAN HAPPEN
Use of improper tires on this vehicle, or operation of this vehicle with
improper or uneven tire pressure, may cause loss of control, tire blow outs,
tire to move around on its rim, and increases the risk of an accident.
Always use the size and type of tires specified in this Operator's Guide for
this vehicle.
Always maintain proper tire pressure as described in this Operator's Guide.
Always replace wheels or tires that are damaged.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of this vehicle may
cause changes in handling which in some situations could lead to an acci-
dent.
Never modify this vehicle through improper installation or use of acces-
sories. All parts and accessories added to this vehicle should be approved
by BRP and should be installed and used according to instructions. If you
have questions, consult an authorized Can-Am dealer.
NEVER install a passenger seat (1-UP models) or use the racks to carry a
passenger.
Modification of the vehicle to increase speed and performance may violate
the terms and conditions of your vehicle limited warranty. In addition, cer-
tain modifications including the removal of engine or exhaust components
are illegal under most laws.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Overloading this vehicle, carrying or towing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling which could lead to an accident.
Never exceed the stated load capacity for this vehicle including operator
and passenger (2-UP models) as well as other loads and added accessories.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow greater dis-
tance for braking.
Always follow the instructions in this Operator's Guide for carrying cargo or
pulling a trailer.

OPERATION WARNINGS
WARNING
V03M01Q
POTENTIAL HAZARD
Transporting flammable or dangerous material can lead to explosions.
WHAT CAN HAPPEN
This can cause serious injury or death.
Never transport flammable or dangerous material.

PRE-RIDE INSPECTION
WARNING
Perform a pre-ride inspection before each ride to detect any potential prob-
lem that could occur during operation. The pre-ride inspection can help you
monitor component wear and deterioration before they become a problem.
Correct any problem that you discover to reduce the risk of a breakdown or
crash.
Before using this vehicle, the operator should always perform the following
pre-ride inspection check list.
Pre-Ride Inspection Check List

What to Do Before Starting the Engine (Key OFF)
ITEMS TO BE
INSPECTION TO PERFORM ✔
INSPECTED
Engine oil Check engine oil level.
Coolant Check coolant level.
Brake fluid Check brake fluid level
Leaks Check for any leaks under vehicle
Activate throttle lever several times to ensure it operates
Throttle lever
freely. It must return to idle position when released
Parking brake Apply parking brake and check if it operates properly
Check tire pressure and condition.
Tires – Front: 48.3 kPa (7 PSI)
– Rear: 48.3 kPa (7 PSI)
Check wheels for damage and for abnormal play, and
Wheels
check lug nuts are tightened
Radiator Check cleanliness of the radiator
Drive shaft boots Check drive shaft boots and protectors condition
Check if operator seat is in place and properly latched
Check if passenger seat is in place and properly latched
Seat(s) (2-UP Models)
Check the passenger backrest and grab handles condition
(2-UP Models)

PRE-RIDE INSPECTION
ITEMS TO BE
INSPECTED
If you transport a cargo, respect the load capacity
Ensure cargo is properly secured to the racks
If you are pulling a trailer or another equipment:
Cargo
– Check hitch and trailer ball condition
– Respect the tongue capacity and towing capacity
– Ensure trailer is properly secured to hitch
Storage
Check if rear storage compartment is properly latched
compartment
Chassis and Check underneath vehicle for any debris on chassis or
suspension suspension and clean them properly
What to Do Before Starting the Engine (Key ON)

ITEMS TO BE
INSPECTED
Check operation of indicator lamps in multifunction gauge
Multifunction gauge (during first few seconds of key ON)
Check for messages on multifunction gauge
Check operation and cleanliness of headlights and taillight
Lights Check operation of low and high beams
Check operation of brake light
Fuel level Check the fuel level.
What to Do After the Engine is Started

ITEMS TO BE
INSPECTED
Check if steering operates freely by completely turning it
Steering
from side to side
Shift lever Check operation of shift lever (P, R, N, H and L)
2WD/4WD selector Check operation of 2WD/4WD selector
Drive forward slowly a few feet and apply brake lever
Brakes and brake pedal individually. The brakes must fully apply.
Lever and pedal must fully return when released
Emergency engine Check that the emergency engine stop switch is working
stop switch properly
Check if ignition switch is working properly by restarting
Ignition switch
and stopping the engine

RIDING THE VEHICLE
To fully appreciate the pleasures and excitement of riding this vehicle, there are
some basic rules and tips that you MUST follow. Some may be new to you while
others may be common sense or obvious.
Please take the time to study this Operator's Guide and all on-product safety labels
as well as the SAFETY VIDEO that came with this vehicle. They more completely
describe what you should know about this vehicle before riding it.
Whether you are a new user or an experienced rider, it is important for your
personal safety that you know the controls and features of this vehicle. Equally
important is knowing how to properly ride.
This is a high performance ATV for off-road use only. Inexperienced riders may
overlook risks and be surprised by the specific behavior of this ATV in any terrain
condition.
We recommend following the age recommendation indicated on the safety label
affixed on the unit. Even though a person may be within the age group for which
this vehicle is recommended, he may not have the skills, abilities, or judgment
needed to operate this vehicle safely and may be involved in a serious accident.
Individuals with cognitive or physical impairments or who are high risk takers have
an increased exposure to overturns or collisions which may result in injury includ-
ing death.
Not all vehicles are the same. Each has its own unique performance characteris-
tics, controls and features. Each will ride and handle differently.
Become completely familiar with the operational controls and the general opera-
tion of the vehicle before venturing into off road conditions. Practice driving in a
suitable area free of hazards and feel the response of each control. Drive at low
speeds. Higher speeds require greater experience, knowledge and suitable riding
conditions.
Riding conditions vary from place to place. Each is subject to weather conditions
which may radically change from time to time and from season to season.
Riding on sand is different than riding on snow or through forests or marshes.
Each location may require a greater degree of awareness and skill. Show good
judgement. Always proceed with caution. Please do not take any unnecessary
risks that could leave you stranded or possibly injured.
Never assume that the vehicle will go everywhere safely. Sudden changes in ter-
rain caused by holes, depressions, banks, softer or harder “ground” or other irreg-
ularities may cause the vehicle to topple or become unstable. To avoid this, slow
down and always observe the terrain ahead. If the vehicle does begin to topple or
tip over, the best advice is to immediately get off AWAY from the direction of the tip
over!
We encourage you to have an Annual Safety Inspection of your vehicle. Please
contact an authorized BRP dealer for further details. Though not required, it is
recommended that an authorized BRP dealer performs the preseason preparation
of your vehicle. Each visit to your authorized BRP dealer is a great opportunity for
your dealer to verify if your vehicle is included in any safety campaign. We also
urge you to visit your authorized BRP dealer in a timely manner if you become
aware of any safety related campaigns.
See an authorized BRP dealer for available accessories you may require.

RIDING THE VEHICLE
Riding Gear
Actual weather conditions should help you decide how to dress. Dress for the
coldest weather expected. Thermal underwear next to the skin also provides a
good insulation. It is important that the operator always wears the appropriate
protective riding gear and apparel, including an approved helmet, eye protection,
boots, gloves, a long sleeved shirt and pants. This type of clothing will provide
you protection from some of the minor hazards you may encounter en route. The
operator must never wear loose clothing such as a scarf that may get entangled in
the vehicle or on tree branches and shrubs. Depending on conditions, anti-fogging
goggles or sunglasses may be required. Different colored lenses available for
goggles or sunglasses help you distinguish terrain variations. Sunglasses should
only be worn during the daytime.
Approved
helmet
Eye protection
Rigid chin
guard
Chest
protector
Long
sleeves
Gloves
Long, sturdy
pants
Boots
V00A0RN
Carrying a Passenger
1-UP Models
This vehicle is designed to carry ONE (1) operator only. Do not install passenger
seat or use the racks to carry a passenger.

RIDING THE VEHICLE
2-UP Models
This vehicle is designed specifically to carry an operator and ONE (1) passenger
only. The passenger must be seated on the designated passenger's seat and
hold on to the grab handles at all times. NEVER install other passenger's seat
other than the one recommended by BRP. Do not use the racks or their location to
carry passenger(s). Carrying more than one (1) passenger may affect the stability
and your control of the vehicle. When the passenger seat is not installed,, the
vehicle becomes a ONE-RIDER vehicle (1-UP model) and NO PASSENGER must
be allowed on it.
Recreational Riding
Respect the rights and limitations of others. Stay away from areas designated
for other types of off road use. This includes snowmobile trails, equestrian trails,
cross country ski trails, mountain bike trails, etc. Never assume there are no other
users on the trail. Always stay to the complete right of the trail and do not zigzag
to one side of the trail then the other. Be prepared to stop or pull off to the side if
another trail user appears in front of you.
Join a local ATV club. It will provide you with a map and advice or inform you where
you can ride. If a club does not exist in your area, help to start one. Group riding and
club activities provide a pleasurable, social experience.
Always keep a safe distance from other riders. Your judgment of speed, ter-
rain conditions, weather, mechanical condition of your vehicle and the “trust in
judgment” you have in others around you will help you make a better choice of
appropriate safe distance. This vehicle, like any other motorized vehicle, cannot
stop “on a dime”. Allow greater distance for braking. On 2-UP models, the
vehicle handling, stability and braking distance may be affected when riding with
a passenger. Safely reduce speed when riding with a passenger.
Before you ride, tell someone where you are planning to travel and your expected
time of return.
Depending on the length of your ride, carry additional tools , drinking water, food
and emergency equipment. Find out where you can get additional gasoline and oil.
Be prepared for the possible conditions you may encounter.
First aid kit Adjustable wrench
Mobile phone Knife
Friction tape Flashlight
A rope Colored lens goggles
Spare light bulbs Trail map
Provided tool kit Snack
Environment
One of the benefits of this vehicle is that it can take you off the beaten path away
from most communities. However, you should always respect nature and the
rights of others to enjoy it. Do not ride in environmentally sensitive areas. Do not
drive over forest crops or shrubs nor cut down trees or take down fencing nor spin
your wheels and destroy the terrain. “Tread Lightly”.

RIDING THE VEHICLE
This vehicle can cause OHV wildfires if debris builds up near the exhaust or other
engine hot spots and ignites then falls off into dry grass. Avoid riding in wet areas,
through muskeg or tall grass, where debris can build up. Should you ride in those
areas, inspect and remove all debris from your engine and hot spots.
Chasing wildlife is in many areas illegal. Wildlife can die of exhaustion after being
chased by a motorized vehicle. If you encounter animals on the trail, stop and ob-
serve quietly and with caution. It will be one of the better memories of your life.
Observe the rule “what you take in, carry out”. Do not litter. Do not start camp-
fires unless you have permission to do so and then only away from dry areas. The
hazards you may create on the trail may cause injury to others or yourself, even at
a later date.
Respect farm lands. Always obtain the permission of the landowner before riding
on private land. Respect crops, farm animals and property lines. If you come to a
closed gate, close it again behind you.
Finally, do not pollute streams, lakes or rivers and do not modify the engine or ex-
haust system, or remove any of its components.
Design Limitation
Although the vehicle is exceptionally rugged for its class, it is still a light vehicle by
definition and its operation must be restricted to its proper purpose.
The addition of weight to any part of the vehicle changes its gravitational stability
and modifies its performance.
Off-Road Operation
The very nature of off-road operation is dangerous. Any terrain, which has not
been specially prepared to carry vehicles, presents an inherent danger where
angularity, terrain substance and exact steepness are unpredictable. The terrain
itself presents a continual element of danger, which must be knowingly accepted
by anyone venturing over it.
An operator who takes a vehicle off-road should always exercise the utmost care in
selecting the safest path and keeping close watch on the terrain ahead of him. On
no account should the vehicle be operated by anyone who is not completely famil-
iar with the driving instructions applicable to the vehicle, nor should it be operated
on steep or treacherous terrain.
Riding Techniques
Information in this guide is limited. Increase your knowledge and improve your
skills by following a certified training course.
Care, caution, experience and driving skill are the best precautions against the haz-
ards of vehicle operation.
Respect and follow all posted trail signs. They are there to help you and others.
In off-road operation, power and traction, not speed, are important. Never drive
faster than visibility and your own ability to select a safe route permits.
Constantly watch the terrain ahead for sudden changes in slopes or obstacles,
such as rocks or stumps, that may cause loss of stability, resulting in tip over or
rollover.

RIDING THE VEHICLE
It is also wise to know the terrain condition on the other side of a hill or bank. All too
often there exists a sharp drop-off that is impossible to negotiate or descend.
Whenever there is the slightest doubt that the vehicle can safely negotiate an ob-
stacle or a particular piece of terrain, always choose an alternate route.
Always use proper riding techniques to avoid vehicle overturns on hills and rough
terrain and in turns.
Body Position
To maintain proper control, it is strongly advised that you keep your hands on the
handlebar and within easy reach of all controls. The same holds true for your feet
on the footpegs. To minimize the possibility of a leg or foot injury, keep your feet on
the footpegs at all times. Do not direct your toes outwards nor extend your feet out
to assist in turning as they can be hit or be snagged on passing obstacles, or may
come into contact with the wheels.
Even though there is a suspension on this vehicle, there are “washboard” or rough
terrain conditions that will make you feel uncomfortable and can even cause a back
injury. “Posting” or riding in a crouched position will often be required. Slow down
and allow your flexed legs to absorb part of the impact energy.
vmo2012-012-520
2-UP Models
The passenger must keep his hands on the grab handles and his feet on footrests
at all times.
The passenger must synchronize his movements with the operator.
Crossing Roads
If you have to cross a road, the lead driver should get off his vehicle, then observe
and give directions to the other riders. The last person after crossing then assists
the lead driver to cross. Do not travel on sidewalks. They are designated for
pedestrian use.

RIDING THE VEHICLE
Turning
Practice turning at low speeds before attempting to turn at faster speeds.
Keep both hands on handlebars and feet on footpegs.
Maintain a constant speed or a slight acceleration during turn.
To reduce the risk of rollovers:
– Use care when turning.
• Do not turn the handlebar too far or too fast for your speed and environment.
Adjust steering inputs accordingly.
• Slow down before entering a turn. Avoid hard braking during a turn.
• Avoid sudden or hard acceleration when turning, even from a stop or low
speed.
– Never attempt donuts, skids, slides, fishtails, jumps, or other stunts. If vehicle
starts to skid or slide, steer in the direction of the skid or slide. Never slam the
brakes and lock the wheels.
– Avoid paved surfaces. This vehicle is not designed to operate on paved surfaces
and is more likely to roll over. If you must drive on pavement, turn gradually, go
slowly, and avoid abrupt acceleration and braking.
Avoid sudden inputs to steering, throttle or brakes while turning.
WARNING
Do not attempt turns at excessive speed.
vmo2012-012-525
If you do get into a slide or skid, it may help to turn the handlebar in the direction of
the skid until you regain control. Never jam the brakes and lock the wheels.

RIDING THE VEHICLE
WARNING
The tires of this vehicle are not suited for paved road use. Also this vehicle
is not equipped with a rear differential (rear wheels are always turning at
the same speed). For these reasons, pavement may seriously affect the
handling and control of the vehicle.
Braking
Always keep both hands on handlebars and feet on footpegs when braking.
Practice braking to get familiar with the brake response.
– Do it at low speed first, then increase the speed.
– Practice braking in straight line at different speeds and different braking force.
– Practice emergency braking; optimal braking is obtained in straight line, with
high force applied, without locking the wheels.
Remember, braking distance depends on vehicle speed, load and the type of sur-
face. Also, the tires and brakes conditions play a major role.
NOTE: If going forward the vehicle weight is transferred to the front wheels when
braking. To obtain greater stopping efficiency, the brake system distributes more
braking force to the front wheels. This will affect vehicle handling and steering
control when braking vigorously. Take it into account when braking.
Reverse Operation
When operating in reverse, check that the path behind the vehicle is free of people
or obstacles. Proceed slowly and avoid sharp turns.
When riding on a 2-UP model, take into account that the passenger can obstruct
your view. Disembark the passenger if necessary.
We recommend sitting on your ATV when operating in reverse. Avoid standing
up. Your weight could shift forward against throttle lever, causing an unexpected
acceleration.
Obstacles
Obstacles in the “trail” should be traversed with caution. This includes loose
rocks, fallen trees, slippery surfaces, fences, posts, and embankments and
depressions. You should avoid them whenever possible. Remember that some
obstacles are too large or dangerous to cross and should be avoided. Small
rocks or fallen trees may be safely crossed approach at a 90° angle. Stand on
the footrests while keeping your knees flexed. Adjust speed without losing mo-
mentum and do not “gun” the throttle. Hold handlebar (operator) or grab handles
(passenger on 2-UP models) firmly. Place body weight rearwards (operator and
passenger 2-UP models) and proceed. Do not try to lift the vehicle front wheels
off the ground. Be aware that the object may be slippery or may move while
crossing.
When riding on 2-UP models, the operator is responsible for the safety of the pas-
senger; in doubt, disembark the passenger before proceeding.

RIDING THE VEHICLE
Uphill Driving
1-UP Models
Before trying to climb a hill, keep these things in mind. Hill Climbing should only
be attempted by experienced operators. Start on shallow slopes. Always drive
straight uphill and keep your body weight forward towards the top of the hill.
Keep your feet on the footrests, shift your ATV into a lower gear and accelerate
before you start to climb. Try to keep a steady speed and go easy on the throttle
to avoid acceleration. Abrupt slope or terrain variation or rolling one wheel over
an obstacle could have a big impact on the stability as it will lift the front of the
vehicle increasing the risk of tipping over. Some hills are too steep to safely stop or
recover from after an unsuccessful climbing attempt. Try to avoid steep inclines.
If you're not careful, you could tip over when going up hills. If the hill is too steep
and you cannot proceed or the vehicle begins to roll backwards, apply the brake,
being careful not to slide. Dismount then use the “K” turn (while walking back,
next to the vehicle on the up hill side and with a hand on the brake lever, slowly
back the rear of the vehicle toward the top of the hill then drive downhill). Always
walk or dismount on the upside of the slope while keeping clear of the vehicle and
its rotating wheels. Do not try to hold on to the vehicle if it begins to topple. Stay
clear. Do not ride over the crest of the hill at high speed. Obstacles, including
sharp drop-offs, may exist.
vmo2012-012-526
2-UP Models
The passenger must synchronize his movements with the operator. The passen-
ger must remain seated at all times.
Do not forget, the operator is responsible for the safety of the passenger. In doubt,
disembark the passenger before climbing a hill.
Before trying to climb a hill, keep these things in mind. Hill Climbing should only
be attempted by experienced operators. Start on shallow slopes. Always drive
straight uphill. Operator and passenger must keep their body weight forward,
towards the top of the hill. Keep feet on the footrests, shift the ATV into a lower
gear and accelerate before you start to climb. Try to keep a steady speed and
go easy on the throttle to avoid acceleration. Abrupt slope or terrain variation or
rolling one wheel over an obstacle could have a big impact on the stability as it
will lift the front of the vehicle increasing the risk of tipping over. Some hills are

RIDING THE VEHICLE
too steep to safely stop or recover from after an unsuccessful climbing attempt.
Try to avoid steep inclines. If you're not careful, you could tip over when going up
hills. If the hill is too steep and you cannot proceed or the vehicle begins to roll
backwards, apply the brake, being careful not to slide. Dismount, passenger first,
then use the “K” turn (while walking back, next to the vehicle on the up hill side
and with a hand on the brake lever, slowly back the rear of the vehicle toward the
top of the hill then drive downhill). Always walk or dismount on the upside of the
slope while keeping clear of the vehicle and its rotating wheels. Do not try to hold
on to the vehicle if it begins to topple. Stay clear. Do not ride over the crest of the
hill at high speed. Obstacles, including sharp drop-offs, may exist. The passenger
should get on the vehicle only when the vehicle has returned to a safe location.
V00A1XL
Vehicle Behaviors
Due to configuration, this vehicle has excellent climbing ability, so much so that
it is possible to tip over before traction is lost. For example, it is common to
encounter terrain situations where the top of the hill has eroded to a point that
the hill peak rises very sharply. The vehicle can readily negotiate such a condition,
however, in doing so, when the front of the vehicle is driven to a point that the
vehicle's balance moves rearward, a tip over can occur.
The same situation may apply if an embedded object causes the front of the vehi-
cle to climb more than desired. If such a situation occurs take an alternate route.
Be aware of side hilling dangers when doing so. Refer to SIDE HILLING.

RIDING THE VEHICLE
vmo2012-012-526
Downhill Driving
1-UP Models
Keep your body weight rearwards. Stay seated. Apply the brake gradually to pre-
vent skidding. Do not “coast” down the slope using solely engine compression or
in neutral gear.
Decelerating while negotiating a slippery downhill slope could “toboggan” the
vehicle. Maintain steady speed and/or accelerate slightly to regain control. Try
to avoid steep inclines. If you're not careful, you could tip over when going down
hills.
vmo2012-012-523
2-UP Models
The operator is responsible for the safety of the passenger; in doubt, disembark
the passenger before proceeding.
Always remember that the vehicle handling, stability and braking distance may be
affected when riding with a passenger.

RIDING THE VEHICLE
Operator and passenger must keep their body weight rearwards. Apply the brake
gradually to prevent skidding. Do not “coast” down the slope using solely engine
compression or in neutral gear. Try to avoid steep inclines. If you're not careful,
you could tip over when going down hills.
V00A1YL
Vehicle Behaviors
This vehicle can climb slopes that are steeper than it can safely descend. There-
fore, it is essential to ensure that a safe route exists to descend a slope before you
climb it.
Side Hilling
This is one of the most risky types of riding since it may drastically change the bal-
ance of the vehicle. It should be avoided whenever possible. However, if it is nec-
essary to do so , it is important that you ALWAYS keep your body weight on the up-
side of the slope and be prepared to dismount on that side should the vehicle begin
to topple.
Avoid all objects or depressions that will intensify the raising of one side of the ve-
hicle higher than the other, thus causing rollover.
WARNING
Do not try to stop or save the vehicle from damage.
WARNING
Be careful when loading and transporting liquid reservoirs. They can affect
vehicle stability when side hilling by pulling downhill and increasing the risk
of a roll over.

RIDING THE VEHICLE
vmo2012-012-527
2-UP Models
The operator is responsible for the safety of the passenger; in doubt, disembark
the passenger before proceeding.
Drop-Offs
This vehicle will “bottom-out” and usually stop if either the front or rear wheels are
driven over a drop-off. If the drop is sharp or deep, the vehicle will nose dive and tip
over.
When riding on a 2-UP model, the operator is responsible for the safety of the pas-
senger; in doubt, disembark the passenger before proceeding.
WARNING
Avoid negotiating drop-offs. Reverse and select an alternate route.
Crossing Water
Water can be a unique hazard. If it is too deep the vehicle may “float” and topple.
Check the water depth and current before you attempt to cross any water. Water
should not go above the footrest. Be wary of slippery surfaces such as rocks,
grass, logs, etc., both in the water and on its banks. A loss of traction may occur.
Do not attempt to enter the water at high speed. The water will act as a brake and
could throw you off the vehicle, on the ground.

RIDING THE VEHICLE
vmo2012-012-524
Wet brakes will affect the braking ability of your vehicle. Make sure you dry the
brakes by applying them several times after the vehicle leaves the water, mud or
snow. Allow greater distance for braking.
Mud or marsh lands may be encountered near water. Be prepared for sudden
“holes” or changes in depth. Similarly so, be watchful of hazards such as rocks,
logs, etc., partially covered by vegetation.
Riding on Ice
If your route crosses frozen waterways, make sure the ice is thick enough and
sound enough to support the total weight of yourself, your passenger (2-UP mod-
els), the vehicle and its load. Be ever watchful of open water it is a sure indication
that the ice thickness will vary.
On 2-UP models, the operator is responsible for the safety of the passenger; in
doubt, do not attempt to cross.
Ice will also affect the control of the vehicle. Slow down and do not “gun” the
throttle. This will only result in spinning of the tires and possible tip over of the
vehicle or passenger ejection (2-UP models). Avoid rapid braking. This again will
possibly result in an uncontrolled slide and tip over of the vehicle or passenger
ejection (2-UP models). Slush should be avoided at all times since it could block
the operation or controls of the vehicle.
Riding on Snow Covered Surfaces

When performing the pre-ride inspection, pay special attention to locations on the
vehicle where snow and/or ice accumulations may obstruct visibility of the taillight
and reflectors, clog ventilation openings, block the radiator and fan, and interfere
with the movement of control levers, switches and brake pedal. Before starting
with your ATV check the steering, throttle and brake lever and pedal controls for
interference free operation.
Whenever an ATV is ridden on a snow covered drive path the tire grip is generally
reduced causing the vehicle to react differently to control inputs from the operator.
On low grip surfaces, the steering responses are not as crisp and precise, stopping
distances are lengthened and acceleration becomes sluggish. Slow down and do
not "gun" the throttle. This will only result in spinning of the tires and possibly in an

RIDING THE VEHICLE
over steering slide of the vehicle. Avoid hard braking. This will possibly result in a
straight line slide of the vehicle. Again, the best advice is to safely reduce speed in
anticipation of a maneuver so to give yourself time and distance to regain total ve-
hicle control before it spins out of your control.
As you drive your ATV over a loose snow covered surface, snow dust will be
picked up in the wake turbulence of the moving vehicle and transported to contact
and accumulate or melt on some exposed components including rotating parts
like brake discs. Water, snow or ice may affect the response time of the brake
system of your ATV. Even when not required to reduce vehicle speed apply brakes
frequently to prevent ice or snow accumulation and to dry brake pads and discs.
While doing so in low risk driving situations you will test for grip level and keep
yourself alerted to how the vehicle reacts to your control inputs. Always keep
brake pedal, footrests, floor boards, brake and throttle levers free of snow and ice.
Frequently wipe snow off seat, hand grips, headlights, taillights and reflectors.
The depth of the snow cover may hide rocks, tree stumps or other objects and if it
is wet may totally impede the driveability as the vehicle becomes bogged down or
completely looses traction in slushy snow. Look far ahead and always be watchful
of any visible clues that might indicate the presence of such obstacles. In doubt
steer clear. Avoid driving on any frozen body of water before checking that the
ice will safely support the ATV, its riders and its load of cargo. Remember that a
given thickness of ice may be sufficient to support a snowmobile but not an ATV
of an identical weight because of the smaller load bearing surface of the four tire
contact patches as compared to that of a snowmobile track and skis.
To maximize comfort and avoid frostbite, always wear clothing and ATV protective
equipment appropriate for the weather conditions you will be exposed to during
your ride.
At the end of each ride it is a good practice to clean the vehicle body and all moving
components (brakes, steering components, drivelines, controls, radiator fan etc.)
from any snow or ice accumulations. Wet snow will turn to ice during the shut
down period and become more difficult to remove at the next pre-ride inspection.
Riding in snow may reduce the brakes stopping capability. Safely reduce speed
and allow greater distance for braking. Snow projection may cause ice build up or
snow accumulation on brake components and controls. Apply brakes frequently
to prevent ice or snow accumulation.
Riding on Sand
Riding on sand, sand dunes or on snow is another unique experience, but there are
some basic precautions that should be observed. Wet, deep or fine sand/snow
may create a loss of traction and cause the vehicle to slide, drop off or become
“bogged” down. If this occurs look for a firmer base. Again, the best advice is to
slow down and be watchful of the conditions. When you ride with a passenger
(2-UP models), slow down even more.
When riding in sand dunes it is advisable to equip the vehicle with an antenna type
safety flag. This will help make your location more visible to others over the next
sand dune. Proceed carefully should you see another safety flag ahead. Since the
antenna type safety flag can snag and rebound on your body if caught, do not use
it in areas where there are low hanging branches or obstacles. Always remember
when riding on a 2-UP model that the vehicle handling and stability may be affected
when riding with a passenger.

RIDING THE VEHICLE
Riding on Loose Stones

Riding on loose stones or gravel is very similar to riding on ice. They will affect the
steering of vehicle possibly causing it to slide or tip over especially at high speeds
(resulting in operator and passenger ejection (2-UP models).
Again, the best advice is to slow down and be watchful of the conditions. When
you ride with a passenger (2-UP models), slow down even more.
In addition, braking distance may be affected. Remember that “gunning” the
throttle or sliding may cause loose stones to be ejected rearwards into the path of
another rider. Never do it deliberately.

MOVING LOADS AND DOING WORK
Working with your Vehicle WARNING
Your vehicle can help you perform a The vehicle handling, stability and
number of different LIGHT tasks rang- braking distance are affected when
ing from snow removal to pulling wood loading racks and using the vehi-
or carrying cargo. A variety of acces- cle. Correct loading and weight
sories are available from your autho- distribution are therefore impor-
rized Can-Am dealer. To prevent pos- tant. Never overload, tow or carry
sible injury, follow the instructions and cargo improperly. Always en-
warnings that accompany the acces- sure the cargo is safely secured
sory. Always respect the load limits and properly distributed on the
of the vehicle. Overloading the vehi- rack(s) before operating the vehi-
cle can overstress the components cle. Safely reduce speed accord-
and cause failure. Avoid overexerting ing to terrain conditions when car-
yourself if you lift or pull heavy loads or rying cargo or pulling a trailer, and
manually push the vehicle. avoid hills and rough terrain. Al-
low greater distance for braking,
Carrying Loads especially on inclined surfaces and
when a passenger (2-UP models)
WARNING is on board. Be careful not to skid
or slide. Always secure cargo as
– On 1-UP models, NEVER exceed low as possible on the rack(s) to
90 km/h (55 MPH) if total load is reduce the effect of a higher center
more than 164 kg (360 lb). of gravity. Failure to follow the rec-
– On 2-UP models, NEVER exceed ommendations here could cause
90 km/h (55 MPH) if total load is changes in vehicle handling which
more than 132 kg (290 lb). could lead to an accident.
– On 2-UP models, NEVER exceed
90 km/h with a passenger.
Any load carried on the vehicle includ-

ing a passenger (2-UP models) and/or
the carrying rack(s) will affect the han-
dling, stability and braking distance
of the vehicle. Do not exceed the
load limits of the vehicle, including
the weight of operator and passenger
cargo, accessories and trailer tongue
weight. Always make sure the load is
secured, properly distributed (1/3 of
cargo weight in front and 2/3 of cargo
weight in back) and cannot interfere
with your proper control. Always be vmo2015-005-001_a
aware that the “load” may slide or fall 1. 1/3 of cargo weight
off and create an accident. Avoid loads 2. 2/3 of cargo weight
that may protrude sideways and get
snagged or caught in brush or other ob-
stacles. Avoid covering and obstruct-
ing the headlights or taillight with the
cargo.

MAXIMUM LOAD TABLE

1-UP 235 kg
TOTAL MODELS (518 lb) Includes weight of operator, passenger,
LOAD cargo, accessories and trailer tongue
ALLOWED 2-UP 272 kg weight.
MODELS (600 lb)
54 kg
FRONT LOAD Evenly distributed.
(120 lb)
Evenly distributed.
109 kg
REAR LOAD Includes rear rack, rear glove box
(240 lb)
and tongue load.
Loading the Cargo Racks Hauling a Load

NOTICE When loading or unload-
(if Equipped with Hitch)
ing, do not exceed the weight limit Never pull a load by attaching it to the
of 109 kg (240 lb) for rear load and bumper or luggage racks; this can
54 kg (120 lb) for front load. cause the vehicle to tip over. Use only
the trailer hitch (if installed) to pull a
Load cargo as low as possible – a load.
higher load can raise the vehicle’s In an emergency situation, use the
center of gravity, which can reduce recovery hook to recover a stuck ve-
stability. Position cargo on the rack as hicle. Refer to RECOVERY HOOKS in
evenly as possible. EQUIPMENT subsection.
Secure the load on the cargo rack. Do When pulling loads with a chain or ca-
not secure cargo to other parts of the ble, ensure that there is no slack before
vehicle. If it is not properly secured, a starting and maintain tension while
load may slide or fall off, possibly strik- pulling.
ing occupants or bystanders; or it may
shift during riding, affecting the han- When pulling loads with a chain or ca-
dling of the vehicle. ble, be sure to brake progressively.
The inertia of the load could lead to an
Objects that are high may affect visibil- impact.
ity for the driver and may act as projec-
tiles in case of an accident. Loads that When hauling a load, respect the maxi-
protrude sideways can get snagged or mum hauling capacity. See PULLING
caught in bush, branches or other ob- A TRAILER subsection.
stacles. Avoid covering and obstruct-
ing the brake lights with the cargo. WARNING
Ensure no cargo protrudes outside the Slack can cause the chain or cable
cargo rack and that cargo will not inter- to break and snap back.
fere with your visibility or control of the
vehicle.
When pulling another vehicle, be sure
Do not overload cargo rack. that someone is controlling the pulled
Never carry gasoline container(s) or vehicle. They must brake and steer to
any dangerous liquids on the cargo prevent the vehicle from going out of
rack. control.

Reduce your speed when hauling a When stopped or parked, block the ve-
load and turn gradually. Avoid hills and hicle and trailer wheels from possible
rough terrain. Never attempt steep movement.
hills. Allow more distance for brak- Use caution when disconnecting a
ing, especially on inclined surfaces and loaded trailer; it or its load may topple
when a passenger (2-up models) is on on you or others.
board. Be careful not to skid or slide.
When hauling a trailer, respect the ma-
Pulling a Trailer ximum hauling capacity indicated on
the label on the hitch.
(if Equipped with Hitch)
MAXIMUM HAULING CAPACITY
NOTICE A BRP approved rear
hitch must be properly installed on TONGUE
TRAILER LOAD
the vehicle for hauling trailers. WEIGHT
ALLOWED
ALLOWED
Riding this vehicle with a trailer sub-
stantially increases the risk of toppling, 590 kg (1,300 lb) 23 kg (50 lb)
especially on inclined slopes. If a trailer
NOTE: Includes trailer and trailer load.
is used behind the vehicle make sure
Ensure to properly load the trailer so
that its hitch is compatible with the
that tongue is always pushing on hitch
one on the vehicle. Make sure the
support and not pulling on hitch ball.
trailer is horizontal with the vehicle. (In
some instances a special extension
may have to be installed on the vehicle
hitch). Use security chains or cables to
secure the trailer with the vehicle.
Reduce your speed when pulling a
trailer and turn gradually. Avoid hills
and rough terrain. Never attempt
steep hills. Allow more distance for
braking, especially on inclined surfaces
and when a passenger (2-up models)
is on board. Be careful not to skid or
slide.
Improperly loading a trailer may cause
loss of control. Respect the recom-
mended maximum hauling capacity
and maximum tongue load (Refer to
MAXIMUM HAULING CAPACITY ta-
ble). Make sure there is at least some
weight on the tongue.
Always make sure load is evenly dis-
tributed and safely secured on the
trailer; an evenly balanced trailer is
easier to control.
Always put the shift lever to L (low
range) for hauling a trailer – in addition
to providing more torque, operating
in low range helps account for the in-
creased load on the rear tires.

IMPORTANT ON-PRODUCT LABELS
(CANADA/UNITED STATES)
Canada/United States
Hang Tag
This vehicle comes with a hang tag and labels containing important safety informa-
tion.
Any person who rides this vehicle should read and understand this information be-
fore riding.
704903310
TYPICAL - 1-UP MODELS

IMPORTANT ON-PRODUCT LABELS(CANADA/UNITED STATES)
NEVER USE WITH

DRUGS OR
ALCOHOL.
704903314
704903314
704901107
vmo2006-005-009_en
TYPICAL

Vehicle Safety Labels

Read and understand all the safety la-
bels on your vehicle.
These labels are affixed to the vehicle
for the safety of the operator, passen-
ger (2-UP) or bystanders.
The safety labels on your vehicle
should be considered permanent parts
of the vehicle. If missing or damaged,
they can be replaced free of charge.
See an authorized Can-Am dealer. vmo2015-005-059_a
NOTE: In the event of any discrep-

ancy between this guide and the ve-
hicle, the safety labels on the vehicle
have precedence over the labels in this
guide.
vmo2015-005-058_a
vmo2015-005-061_a
vmo2015-005-057_a
vmo2015-005-062_a

vmo2015-005-054_b
MAX MODELS ONLY
704903153C
LABEL 1 - 2-UP MODELS
704902787 704902775A
LABEL 1 - 1-UP MODELS LABEL 2 - 1-UP MODELS
704903087A

704902793
704902785
LABEL 3
704903093B
• NEVER carry a passenger on this carrier.

• MAXIMUM FRONT LOAD: 54 kg (120 lb) evenly distributed.
• MAXIMUM REAR LOAD: 109 kg (240 lb) evenly distributed.
(Includes trailer tongue weight if applicable).
704904404
704904440
Improper loading of a trailer may 704904404
cause loss of vehicle control, LABEL 6
resulting in severe injury or death.

• Maximum towing weight
590 kg (1300 lb)
• Maximum tongue weight
23 kg (50 lb) 704904438
704904438
LABEL 5
704902777A
LABEL 7

Improper tire pressure or overloading can cause loss of control, resulting in

SEVERE INJURY or DEATH.
ALWAYS maintain proper tire pressure according to the load on the vehicle. Refer to table.
NEVER underinflate tire as it could cause the tire to disloge from the rim.
exceed the vehicle load capacity of 235 kg (517 lb), including weight of operator,
cargo, accessories and trailer tongue weight.
exceed 90 km/h if total load is more than 164 kg (360 lb)
COLD TIRE PRESSURE

ATV LOADING and TRAILER TOWING FRONT 48.3 kPa (7 psi)
• Cargo loading or trailer towing can affect stability and
handling. Load must be proprely distributed on racks. REAR 48.3 kPa (7 psi)
• When loaded with cargo or towing a trailer:
- reduce speed.
- allow more distance to stop. 704906306
- avoid hills and rough terrain.
704906306
Improper tire pressure or overloading can cause loss of control, resulting in

SEVERE INJURY or DEATH.
ALWAYS maintain proper tire pressure according to the load on the vehicle. Refer to table.
NEVER underinflate tire as it could cause the tire to disloge from the rim.
exceed the vehicle load capacity of 272 kg (600 lb), including weight of operator,
cargo, accessories and trailer tongue weight.
exceed 90 km/h if total load is more than 132 kg (290 lb)
exceed 90 km/h with a passenger
COLD TIRE PRESSURE
ATV LOADING and TRAILER TOWING
FRONT 48.3 kPa (7 psi)
• Cargo loading or trailer towing can affect stability and
handling. Load must be proprely distributed on racks. REAR 48.3 kPa (7 psi)
• When loaded with cargo or towing a trailer:
- reduce speed.
- allow more distance to stop. 704906307
- avoid hills and rough terrain.
704906307

Compliance Labels
This vehicle is an all terrain vehicle and is not These labels indicate vehicle's compli-
intended for use on public roads. 704905139 ance.
Ce véhicule est un véhicule tout

terrain qui n’est pas destiné a CAN ICES-2 / NMB-2
être utilisé sur les POWER
704904556
kW
voies publiques. PUISSANCE
WET WEIGHT
POIDS EN ETAT kg
DE MARCHE
704905139
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.
LABEL 9 CE VEHICULE EST UN VEHICULE TOUT TERRAIN QUI N'EST PAS DESTINÉ À ÊTRE UTILISÉ SUR
LES VOIES PUBLIQUES.
704904556
LOCATION: UNDER SEAT, ON THE UPPER

FRAME MEMBER
EMISSION CONTROL INFORMATION

THIS VEHICLE IS CERTIFIED TO OPERATE ON UNLEADED
GASOLINE AND CONFORMS TO U.S. EPA AND
CALIFORNIA EMISSION / EVAP REGULATIONS FOR ATV.
704902941 ENGINE FAMILY FAMILLE DE MOTEUR
PERMEATION FAMILY FAMILLE DE PERMEATION
LABEL 10 CERTIFICATION LIMITE DES ÉMISSIONS
STANDARD (FEL) DE LA FAMILLE
ENGINE DISPLACEMENT CYLINDRÉE
EXHAUST EMISSION SYSTÈME DE CONTRÔLE

CONTROL SYSTEM DES ÉMISSIONS
RENSEIGNEMENTS SUR LE DISPOSITIF ANTIPOLLUTION
CE VÉHICULE EST CERTIFIÉ POUR FONCTIONNER À L'ESSENCE SANS PLOMB ET IL
EST CONFORME AUX NORMES DE L'EPA ET DE LA CALIFORNIE AU NIVEAU
DES RÉGLEMENTATIONS DE L’ÉCHAPPEMENT ET DE L’ÉVAPORATION POUR LES VTT.
SEE OPERATOR’S GUIDE FOR MAINTENANCE SCHEDULE
VOIR LE PROGRAMME D’ENTRETIEN DANS LE GUIDE DU CONDUCTEUR
BOMBARDIER RECREATIONAL PRODUCTS INC. 704904648
vmo2010-010-100_a 704904648
LABEL 11 TYPICAL - LOCATION: UNDER SEAT, ON THE

UPPER FRAME MEMBER
Always make sure to properly install passenger seat or

glove box in place before riding.
TO INSTALL PASSENGER SEAT
. Ensure that the latch lever is in the open position by pulling it
towards the front of seat.
. Using a forward motion, insert both front tabs of the seat into
the vehicle anchor housings.
. Rotate downwards to engage the rear latch. 704903327
. Close the latch lever by pushing it rearwards to secure the seat
in position. LOCATION: REAR FENDER
. Check if the seat is firmly secured in position before using it.
TO INSTALL GLOVE BOX
• Open glove box cover and turn handle to the unlock position.
• Align and insert glove box latching system into
Technical Information
this vehicle's “LINQ” opening.
• Turn handle to the lock position.
Labels
• Close cover and verify if glove box is locked
in position.
FOR MORE DETAILS REFER TO OPERATOR’S GUIDE
704904358
704904358
707800373

FRAME MEMBER

IMPORTANT ON-PRODUCT LABELS (ALL
COUNTRIES EXCEPT CANADA/UNITED STATES
All Countries Except Canada/United States
Hang Tag
This vehicle comes with a hang tag and labels containing important safety informa-
tion.
Any person who rides this vehicle should read and understand this information be-
fore riding.
WARNING
– Locate and read operator's guide. Improper ATV use can result in SE-
VERE INJURY or DEATH. Follow all instructions and warnings.
– Always wear ear protection.
– Always use an approved helmet and protective gear.
– Never use on public roads.
– Never carry passengers on 1-up models and NEVER carry more than one
passenger on 2-up models.
– Never use with drugs or alcohol.
G
GENERAL USE MODEL
THIS ATV IS FOR

RECREATIONAL USE OR UTILITY USE
704903930
704903930A

IMPORTANT ON-PRODUCT LABELS (ALL COUNTRIES EXCEPT CANADA/UNITED STATES
G
GENERAL USE MODEL
704903946
704903946
704901107
vmo2006-005-009_en
TYPICAL: APPLICABLE WHEN EQUIVALENT

TO A MODEL CERTIFIED TO US EPA
STANDARDS

Vehicle Safety Labels

Read and understand all the safety labels on your vehicle.
These labels are affixed to the vehicle for the safety of the operator, passenger
(2-UP) or bystanders.
The safety labels on your vehicle should be considered permanent parts of the ve-
hicle. If missing or damaged, they can be replaced free of charge. See an autho-
rized Can-Am dealer.
NOTE: In the event of any discrepancy between this guide and the vehicle, the
safety labels on the vehicle have precedence over the labels in this guide.
vmo2015-006-401_b
vmo2015-005-062_a
vmo2015-005-061_b

704903962
704903962A
vmo2015-005-059_d LABEL 1 - 1-UP MODELS
704903734
vmo2015-005-054_e 704903734A
MAX MODELS ONLY LABEL 1 - 2-UP MODELS
Label 1 Label 2
WARNING WARNING
– Locate and read operator's Operating this ATV if you are under
guide. Improper ATV use can the age of 16 increases the chance
result in SEVERE INJURY or of SEVERE INJURY or DEATH to
DEATH. Follow all instructions the operator, and to both the oper-
and warnings. ator and passenger on 2-up mod-
– Always wear ear protection. els. NEVER operate this ATV if you
are under age 16.
– Always use an approved helmet
and protective gear.
– Never use on public roads.
– Never carry a passenger on 1-up
models and NEVER carry more
than one passenger on 2-up
models.
– Never use with drugs or alcohol.
704903964
704903964
LABEL 2

Label 3
•ATV MUST be stopped before shifting lever.

•ALWAYS apply foot brake to shift from
Park (P) and Neutral (N).
704903970
704903737
704903970
LABEL 3 LABEL 4 - 2-UP MODELS
Label 4 Label 5
WARNING WARNING
– Locate and read operator's – NEVER carry a passenger on
guide. this carrier.
– NEVER carry a passenger on – MAXIMUM FRONT LOAD: 54 kg
1-up models and NEVER carry (120 lb) evenly distributed.
more than 1 passenger on 2-up – MAXIMUM REAR LOAD: 109 kg
models. (240 lb) evenly distributed (in-
– Passenger on 2-up models must cluding trailer tongue weight if
always use an approved helmet applicable).
and protective gear.
– Passenger on 2-up models must
NEVER ride after using drugs or
< 109 kg (240 lb)
alcohol.
< 54 kg
(120 lb)
704904405
704904405
LABEL 5
704903968
704903968

Label 6
WARNING
NEVER attach here or on the lug-
gage rack to pull a load This can
cause the vehicle to tip over. AL-
WAYS use the trailer hitch or the
recovery hook to pull a load.
704903955
704903955A
LABEL 6
Label 7
WARNING
– Locate and read operator's guide. Improper tire pressure or overloading
can cause loss of control, resulting in SEVERE INJURY or DEATH.
– ALWAYS maintain proper tire pressure as shown.
– On 1-up models, NEVER exceed the load capacity of 235 kg (517 lb)
including weight of operator, cargo, accessories, and trailer tongue
weight.
– On 2-up models, NEVER exceed the load capacity of 272 kg (600 lb)
including weight of operator, cargo, accessories, and trailer tongue
weight.
– ALWAYS pull a load using the trailer hitch or recovery hook.
– NEVER exceed the maximum towing weight of 590 kg (1,300 lb).
– NEVER exceed the maximum tongue weight of 23 kg (50 lb).
– On 1-up models, NEVER exceed 90 km/h (55 MPH) if total load is more
than 164 kg (360 lb).
– On 2-up models, NEVER exceed 90 km/h (55 MPH) if total load is more
than 132 kg (290 lb).
– On 2-up models, NEVER exceed 90 km/h with a passenger.

=
< 235 kg (517 lb) 48.3 kpa 48.3 kpa
kPa (7 psi) (7 psi)
90 km/h
55 mph
590 kg
(1300 lb)
23 kg
> 164 kg (360 lb) (50 lb)
704906308
704906308
=
< 272 kg (600 lb)
48.3 kpa 48.3 kpa
kPa (7 psi) (7 psi)
90 km/h
55 mph
590 kg
(1300 lb)
90 km/h
55 mph
23 kg
(50 lb)
> 132 kg (290 lb) 704906309
704906309

Label 8
WARNING; GET FAMILIAR WITH THIS ATV. WARNUNG: MACHEN SIE SICH MIT DIESEM
INEXPERIENCED RIDERS MAY OVERLOOK ATV VERTRAUT. UNERFAHRENE FAHRER
RISKS. KÖNNEN RISIKEN ÜBERSEHEN.
ADVARSEL: LÆR ATV’EN GRUNDIGT AT KENDE.
UERFARNE FØRERE KAN LET OVERSE FARERNE. ΠΡΟΕΙΔΟΠΟΙΗΣΗ: ΕΞΟΙΚΕΙΩΘΕΙΤΕ ΜΕ ΑΥΤΟ
ΤΟ ΟΧΗΜΑ ΠΑΝΤΟΣ ΕΔΑΦΟΥΣ (ATV). ΟΙ
WAARSCHUWING: MAAK UZELF VERTROUWD ΧΡΗΣΤΕΣ ΧΩΡΙΣ ΕΜΠΕΙΡΙΑ ΜΠΟΡΕΙ ΝΑ
MET DEZE ATV. ONERVAREN BESTUURDERS ΠΑΡΑΒΛΕΨΟΥΝ ΤΥΧΟΝ ΚΙΝΔΥΝΟΥΣ.
KUNNEN DE RISICO'S OVER HET HOOFD ZIEN.
AVERTISSEMENT : FAMILIARISEZ-VOUS AVEC AVVERTENZA: ACQUISIRE FAMILIARITÀ CON
CE VTT. LES UTILISATEURS INEXPÉRIMENTÉS QUESTO ATV. I PILOTI INESPERTI POTREBBERO
POURRAIENT SOUS ESTIMER LES RISQUES. SOTTOVALUTARE I RISCHI.
VAROITUS : TUTUSTU HUOLELLISESTI TÄMÄN ADVERTÊNCIA: FAMILIARIZE-SE COM ESTE
ATV: N KÄYTTÖÖN. KOKEMATTOMAT ATV. PILOTOS INEXPERIENTES PODEM
KULJETTAJAT SAATTAVAT ALIARVIOIDA SUBESTIMAR OS RISCOS.
VAARATILANTEET.
ADVERTENCIA: TÓMESE EL TIEMPO VARNING: BEKANTA DIG VÄL MED DENNA
NECESARIO PARA FAMILIARIZARSE CON EL ATV. OERFARNA FÖRARE KAN FÖRBISE
ATV. LA FALTA DE EXPERIENCIA PUEDE DAR RISKERNA.
LUGAR A LA OMISIÓN DE RIESGOS
IMPORTANTES.
IMPORTANTES 704903895
704903895
LABEL 8
Label 9
vmo2010-010-100_a
LABEL 9

Label 10 Compliance Labels

These labels indicate vehicle's compli-
WARNING ance.
Do not open when hot.
POWER
kW
704904557
PUISSANCE
WET WEIGHT
POIDS EN ETAT kg
EN 15997 DE MARCHE
Representative: BRP Europe N.V., Skaldenstraat 125, Ghent, Belgium, 9042.
704904557

FRAME MEMBER
EMISSION CONTROL INFORMATION

704903688 THIS VEHICLE IS CERTIFIED TO OPERATE ON UNLEADED
GASOLINE AND CONFORMS TO U.S. EPA AND
CALIFORNIA EMISSION / EVAP REGULATIONS FOR ATV.
704903688 ENGINE FAMILY FAMILLE DE MOTEUR
FAMILLE DE PERMEATION
LABEL 10 PERMEATION FAMILY
CERTIFICATION LIMITE DES ÉMISSIONS
STANDARD (FEL) DE LA FAMILLE
Label 11 ENGINE DISPLACEMENT CYLINDRÉE
EXHAUST EMISSION SYSTÈME DE CONTRÔLE

CONTROL SYSTEM DES ÉMISSIONS
RENSEIGNEMENTS SUR LE DISPOSITIF ANTIPOLLUTION
CE VÉHICULE EST CERTIFIÉ POUR FONCTIONNER À L'ESSENCE SANS PLOMB ET IL
EST CONFORME AUX NORMES DE L'EPA ET DE LA CALIFORNIE AU NIVEAU
DES RÉGLEMENTATIONS DE L’ÉCHAPPEMENT ET DE L’ÉVAPORATION POUR LES VTT.
SEE OPERATOR’S GUIDE FOR MAINTENANCE SCHEDULE
Always make sure to properly install passenger seat or VOIR LE PROGRAMME D’ENTRETIEN DANS LE GUIDE DU CONDUCTEUR
glove box in place before riding. BOMBARDIER RECREATIONAL PRODUCTS INC. 704904648
TO INSTALL PASSENGER SEAT
.Ensure that the latch lever is in the open position by pulling it 704904648
towards the front of seat.
.Using a forward motion, insert both front tabs of the seat into the TYPICAL : APPLICABLE WHEN EQUIVALENT
vehicle anchor housings. TO A MODEL CERTIFIED TO US EPA
.Rotate downwards to engage the rear latch.
.Close the latch lever by pushing it rearwards to secure the seat STANDARDS - LOCATION: UNDER SEAT, ON
in position. THE UPPER FRAME MEMBER
.Check if the seat is firmly secured in position before using it.
TO INSTALL GLOVE BOX
• Open glove box cover and turn handle to the unlock position.
• Align and insert glove box latching system into
this vehicle's “LINQ” opening.
Technical Information
• Turn handle to the lock position.
• Close cover and verify if glove box is locked
Labels
in position.
FOR MORE DETAILS REFER TO OPERATOR’S GUIDE
704904442
704904442
707800373

FRAME MEMBER

This page is
intentionally blank

VEHICLE
INFORMATION
_______________ 79
CONTROLS
NOTE: Some vehicle safety labels are not shown on illustrations. For information
on vehicle safety labels, refer to VEHICLE SAFETY LABELS subsection.
6 5
vmo2015-005-052_b
1) Throttle Lever
The throttle lever is located on the RH
side of the handlebar.
The throttle lever controls the engine
speed.
To increase or maintain vehicle speed,
press the throttle lever with your right
thumb.
To decrease vehicle speed, release the
throttle lever. vmo2015-005-020_a
TYPICAL
1. Throttle lever
2. To accelerate
3. To decelerate
80 ______________
CONTROLS
2) LH Brake Lever 2 1
The LH brake lever is located on the LH
side of the handlebar.
V07K02Y
V07K01Y
TYPICAL
1. Brake lever lock
TYPICAL 2. Press to apply parking brakes
1. Brake lever
2. To apply brakes NOTE: Locking lever can be adjusted
in several positions.
The brake lever function is to slow
down or stop the vehicle. WARNING
When the brake lever is compressed, Ensure when the parking brake is
the front and rear brakes are applied. applied that the vehicle stays se-
Braking effect is proportional to the curely in place.
force applied on the lever.
To release parking brake: Squeeze
3) Parking Brake brake lever. Lever lock should auto-
The parking brake is located on the LH matically return to its original position.
side of the handlebar. Brake lever should return to rest posi-
tion.
The parking brake function is to apply
brake to all wheels to prevent vehicle
from moving when parked. WARNING
Make sure parking brake is re-
WARNING leased before operating the ve-
hicle. If parking brake is left ON
Always use the parking brake and while riding, it may cause damage
engage the PARK position on the to the brake system and cause loss
shift lever when the vehicle is not of braking capacity and/or fire.
in operation.
To engage parking brake: Squeeze

4) Brake Pedal
brake lever and maintain while moving The brake pedal is located on the RH
lever lock. Brake lever is now com- side of the vehicle near engine.
pressed and applying all brakes.
_______________ 81
CONTROLS
SHIFT LEVER POSITIONS

N Neutral
H High range (forward)
L Low range (forward)
vmo2015-005-003_a
1. Brake pedal
The brake pedal function is to slow

down or stop the vehicle.
When the brake pedal is pressed
down, only the rear brake is applied.
vmo2012-012-036
Braking effect is proportional to the
force applied on the pedal. TYPICAL - SHIFT PATTERN
NOTE: The brake will have also an ef- The vehicle must be stopped and
fect on front wheels through the drive brakes applied prior to selecting any
train when 4WD is engaged. gear.
5) Shift Lever NOTICE This gearbox is not de-

signed to shift while vehicle is mov-
The shift lever is located on the RH side ing.
of the vehicle near steering column.
P: Park
The park position locks the gearbox to
help prevent vehicle movement.
WARNING
Always use the PARK (P) position
when the vehicle is not in oper-
ation. The vehicle can roll if the
shift lever is not set to P (PARK).
vmo2015-005-005_a R: Reverse
SHIFT LEVER LOCATION
The reverse position allows the vehicle
The shift lever is used to change the to go backwards.
gearbox position. NOTE: In reverse operation, the en-
The shift lever has 5 positions: gine's RPM is limited, thus limiting the
vehicle reverse speed.
SHIFT LEVER POSITIONS
POSITION GEAR WARNING
When driving downhill in reverse,
P Park gravity can increase the vehicle
R Reverse speed above the set limited re-
verse speed.
82 ______________
CONTROLS
Neutral OFF
The neutral position disengages the The key can be inserted or removed in
gearbox. this position only.
In OFF position, the electrical system
WARNING of the vehicle is disabled.
Always use the PARK (P) position The engine is shut down by turning the
when the vehicle is not in oper- ignition switch to OFF position.
ation. The vehicle can roll if the
shift lever is set to N (NEUTRAL). NOTE: While the engine can be
stopped by turning the ignition key to
OFF position, we recommend the en-
High Range (Forward) gine be stopped by setting the emer-
This position selects the high speed gency engine stop switch to the STOP
range of the gearbox. It is the normal position.
driving speed range. It allows the vehi- NOTE: When turning the key to OFF
cle to reach its maximum speed. position, the vehicle electrical system
will take a few seconds to shut down.
Low Range (Forward)
This position selects the low speed ON with Lights
range of the gearbox. It allows the ve- When the key is turned in this position,
hicle to move slowly with maximum the electrical system of the vehicle is
torque at the wheels. activated.
NOTICE Use the low speed range The gauge should wake-up.
to pull a trailer, carry heavy cargo, The vehicle lights are turned on.
go over obstacles or drive uphill and
downhill. The engine can be started.
Keys
6) Ignition Switch and
Keys Basic Key (All Models Except Pro
The ignition switch is located on the LH Models)
side of the central panel below the han- The vehicle is delivered with a basic ig-
dlebar. nition key.
Digitally Encoded Security System
(D.E.S.S.) (Pro Models)
The ignition keys contain an electronic
circuit that gives it a unique electronic
serial number.
The D.E.S.S. system reads the key
code and allows engine starting for
keys it recognizes.
Types of Keys
219001735-001_a
This vehicle can be operated using 2
IGNITION SWITCH POSITIONS different types of keys:
1. OFF
2. ON “with light” – Normal key (grey)
– Performance key (black)
_______________ 83
CONTROLS
The key type is differentiated by its The controls located on this multifunc-
color. tion switch are:
WARNING
Rollovers, tipovers, collisions and
loss of control resulting in serious
injury or death are possible with
the performance or normal. Using
the normal key is not a substitute
for the operator being prepared,
qualified, and operating with care.
Normal Key 219001733-001_a

The vehicle is delivered with a normal TYPICAL — MULTIFUNCTION SWITCH
key. 1. Headlight switch
2. Emergency engine stop switch
The normal key limits the vehicle 3. Engine start button
speed to 70 km/h (44 MPH). 4. Override/DPS button (if applicable)
WARNING Low/High/OFF Headlight Switch

On steep downhills, the engine This switch is used to select either the
speed limiter may not prevent the headlights low or high beams or to turn
vehicle from accelerating beyond them OFF.
this speed.
This key may be useful for riders who

prefer more gradual acceleration, or
for riding in environments where full
speed and high acceleration are not
desirable. For example, in narrow,
winding trails, operators may prefer
the normal key.
Performance Key
The vehicle is delivered with a perfor-
mance key, which allows the user to 219001733-003_a
access the full torque of the engine as HEADLIGHT SWITCH FUNCTIONS

well as the top speed of the vehicle. 1. Lights OFF
2. Low beam and taillight
This may be useful for riders who pre- 3. High beam and taillight
fer crisper throttle response, and for
environments where higher speeds
and greater acceleration are appro-
priate. For example, in wide-open
straight trails, operators may prefer
the performance key.
7) Multifunction Switch
The multifunction switch is located on
the LH side of the handlebar.
84 ______________
CONTROLS
Emergency Engine Stop Switch When engine start button is pressed

and held, it starts the engine.
NOTE: To allow engine starting, the
ignition switch must be in the ON po-
sition and the emergency engine stop
button set to RUN.
Override/DPS Button
Depending on the vehicle model, this
button has up to 2 functions.
219001733-001_b
TYPICAL
This switch can be used to stop the en-

gine and as an emergency control.
To stop engine, set the emergency en-
gine stop switch to the STOP position.
NOTE: While the engine can be
stopped by turning the ignition key to 219001733-001_e
OFF position, we recommend the en- TYPICAL
gine be stopped by setting the emer- 1. Override/DPS button
gency engine stop switch to the STOP 2. Engine start button
position.
Override Function
Engine Start Button The override switch main function is to
bypass the engine speed limiter in re-
verse operation by allowing maximum
engine torque.
WARNING
Only use the override to help get
the vehicle unstuck from mud or
other soft terrain. Do not use the
override for normal operation in
reverse. This would allow driving
in reverse at excessive speeds and
219001733-00_g
can increase the risk of losing con-
TYPICAL trol.
1. Engine start button
WARNING
injury or death.
_______________ 85
CONTROLS
To engage the override function, pro- NOTICE The vehicle must be

ceed as follows: stopped to engage or disengage
While the shift lever is set to REVERSE 2WD/4WD switch. Mechanical dam-
position. age may occur if switch is engaged
or disengaged while driving.
1. Ensure that the vehicle is stopped.
2. Press and hold the override switch The 4WD mode is engaged when the
then press the throttle lever gradu- switch is pushed downwards.
ally.
NOTE: When using the override func-
tion, the gauge will scroll an OVER-
RIDE message to confirm that the
function is activated.
3. To disengage the override function,
simply release the override switch.
DPS Function (Models with DPS)
This button is also used to change the
Dynamic Power Steering (DPS) mode.
To change DPS mode, refer to TUNE
YOUR RIDE subsection.
8) 2WD/4WD Selector
The 2WD/4WD selector is located on
the RH side of the handlebar.
V07I0DY
4WD MODE - TYPICAL
The 2WD mode is engaged when the

switch is pushed upwards. The vehicle
is then rear wheel drive only.
vmo2012-012-007_a
TYPICAL
1. Selector
2. 2WD position
3. 4WD position
This switch selects 2 wheel drive or 4

wheel drive mode when the vehicle is
stopped and the engine is running.
86 ______________
CONTROLS
V07I0EY
2WD MODE - TYPICAL
WARNING
injury or death.
_______________ 87
MULTIFUNCTION GAUGE (LCD)
The multifunction gauge is located in
the gauge support.
WARNING
Reading the multifunction gauge
display can distract from the op-
eration of the vehicle, particularly
from constantly scanning the envi- vmr2007-050-002_d
ronment. 1. Transmission position
DISPLAY FUNCTION
Multifunction Gauge
Description P Park
R Reverse
N Neutral
H High range
L Low range
3) Main Screen
The main screen is used to display nu-
merous functions of the multifunction
vmo2013-010-001_a
gauge.
1. Selector button
2. Transmission position display Refer to MULTIFUNCTION GAUGE
3. Main screen MODES for the different available
4. Fuel level display modes:
5. 4WD indicator lamp
6. Low fuel level indicator lamp
7. Check engine indicator lamp 4) Fuel Level Display
8. High beam indicator lamp Bar gauge continuously indicates the
9. MPH, Km/h indicator lamp
level of fuel in the fuel tank while riding.
1) Selector Button
The selector button is used to navigate
or change settings in the multifunction
gauge.
2) Transmission Position Display

This display will show transmission po-
sition.
vmo2013-010-001_b
88 ______________
5) 4WD Indicator Lamp Multifunction Gauge

Modes
Speed Mode
When this indicator is ON, it indicates In this mode, the main screen shows
the 4WD system is activated. the speed of the vehicle either in km/h
or in mph.
6) Low Fuel Level Indicator Lamp
When this indicator is ON, it indi-

cates that there is approximately 5 L
(1.3 U.S. gal.) of fuel left in fuel tank.
vdd2008-001-084
7) Check Engine Indicator Lamp
RPM Mode
In this mode, the main screen shows
the engine RPM.
When this indicator is ON, it indicates
an engine fault code, look for a mes-
sage at the LCD display.
When this indicator blinks, it indicates
that the LIMP HOME mode is acti-
vated.
Refer to TROUBLESHOOTING section
for more details.
vdd2008-001-089
8) High Beam Indicator Lamp

Combined Mode
In this mode, the main screen shows
the speed of the vehicle and the engine
When this indicator is ON, it indicates RPM.
that high beam is selected on the
headlights and that ignition key is in
ON with lights position.
9) KM/H or MPH Indicator Lamp
vdd2008-001-085_a
The proper lamp turns on to indicate
1. Vehicle speed
the unit the speedometer uses. 2. Engine RPM
Odometer (OD)
Odometer records the total distance
travelled either in miles or kilometers.
_______________ 89
vsi2009-018-030
vsi2009-018-032
Clock Press and HOLD the selector button

Shows current time. for 2 seconds to reset the hour meter.
Engine Hour Meter (EH)

The engine hour meter records engine
running time.
vmo2011-008-001
Refer to GAUGE SETUP to set current

time. vsi2009-018-033
Trip Meter (TP) Message Display Mode

The trip meter records the travelled If an abnormal engine condition oc-
distance since it has been reset. Dis- curs, a message may scroll across the
tance travelled is displayed either in main screen in conjunction with a pilot
kilometers or miles. lamp. Refer to TROUBLESHOOTING
section for details.
Fault Code Mode

Switch to HI beam and select engine
hour meter display. Press and hold se-
lector button while switching high and
low beam (three cycles) to access di-
agnostic fault codes.
vsi2009-018-031
Navigating in the LCD
Press and HOLD the selector button Gauge
for 2 seconds to reset the trip meter.
Default Display Mode
Trip Hour Meter (TH)
After vehicle startup, the default dis-
The trip hour meter records vehicle play mode is either:
running time when the electrical sys-
tem is activated. It can be used to – Vehicle speed
establish traveling time between 2
places.
90 ______________
– Engine revolutions per minute

(RPM)
– Both parameters simultaneously
(combined mode).
To change from one display to the
other, proceed as follows.
1. Turn ignition key to ON to power-up vmr2007-050-002_c
the system.
1. Selector button
2. Wait until the “greeting message”
has been displayed. The gauge will display the selected
3. Press and release selector button mode for 10 seconds then will return
once to display OD (odometer). to the normal display mode.
4. Press and HOLD selector button for While in a resettable mode, push and
2 seconds. HOLD selector button for 2 seconds to
reset it.
This will change the Mode to either
Speed, RPM or Combined. Gauge Setup
Clock Setting Using Gauge Selector
Button
To set current time, proceed as fol-
lows:
1. Select the clock display.
vdd2008-001-083
5. To select another mode, repeat

steps 3 and 4 until the desired mode
is displayed.
Temporary Display Mode

In the temporary display mode, the fol-
lowing functions are available:
– Odometer vmo2011-008-001_a
– Clock 1. Selector button

2. Time
– Trip meter (resettable)
– Trip Hour meter (resettable) 2. Press and HOLD selector button.
– Engine hour meter. NOTE: The display will flash.
Press and release selector button to 3. Choose the 12-hour (12H) or
change the default display mode to the 24-hour (24H) format by pressing
temporary mode. button.
4. If the 12-hour format was selected,
choose Am (A) or Pm (P) by pressing
button.
5. Choose hour first digit by pressing
button.
_______________ 91
6. Choose hour second digit by press-

ing button.
7. Choose minutes first digit by press-
ing button.
8. Choose minutes second digit by
pressing button.
NOTE: The gauge will display the cur-
rent time for 10 seconds then will re-
turn to the normal display mode.
Unit Selection (km/h vs mph)

The speedometer, odometer and trip
meter are factory preset in miles but
it is possible to change them to kilo-
meter reading. Contact an authorized
Can-Am dealer.
Language Selection
The gauge display language can be
changed. Refer to an authorized
Can-Am dealer for language availability
and setup the gauge to your prefer-
ence.
WARNING
injury or death.
92 ______________
EQUIPMENT
NOTE: Some vehicle safety labels are not shown on illustrations. For information
on vehicle safety labels, refer to VEHICLE SAFETY LABELS subsection.
7
6
9
8,10
5
3
7
10
vmo2015-005-035_a
TYPICAL - 1-UP MODEL
_______________ 93
EQUIPMENT
4
2 6
1
7
4
8,10
9
3
5
10
vmo2015-005-036_a
TYPICAL - 2-UP MODEL
94 ______________
EQUIPMENT
1) Operator's Seat WARNING

The seat is designed for an operator Confirm that the operator's seat
only. is properly locked in position by
pulling back and up several times.
WARNING
Never allow anyone to seat as a 2) Passenger's Seat (2-UP
passenger on this vehicle. Models)
Seat Removal WARNING
To remove the operator's seat, push its Never operate the vehicle without
latch upward. This latch is located un- passenger's seat or glove box in-
derneath the rear of seat. stalled.
The passenger's seat is designed for a

passenger only. The integrated back-
rest supports his back during the ride.
vmo2015-005-007_a
1. Seat latch
Pull seat rearward. Continue lifting

movement until you can release the vmo2015-005-054_a
front retaining device then completely 1. Passenger's seat

remove seat. 2. Integrated backrest
Seat Installation WARNING

Insert front tabs of seat on U-rod Without its passenger's seat, the
welded to frame. When seat rests vehicle becomes a ONE RIDER ve-
in its position, firmly push seat down hicle (1-UP model) and NO PAS-
to latch. SENGER must be allowed on vehi-
NOTE: A distinctive snap will be felt. cle.
Double check that the seat is secure by
giving it a tug to confirm proper latch-
ing.
WARNING
injury or death.
_______________ 95
EQUIPMENT
Passenger's Seat Removal 3) Footpegs

1. To unlock latch, pull the passenger's The operator footpegs are located on
seat latch lever toward the front of the RH and LH side of the vehicle.
the seat.
vmo2015-005-029_a
TYPICAL - 1-UP SHOWN

1. Operator's LH footpeg
vmo2015-005-054_c
1. Seat handle WARNING

Operator must have both feet on
2. While maintaining latch lever pulled footpegs at all time during vehicle
towards the front, apply downward operation.
pressure on the back of latch lever
to clear rear latch from pin and tog-
gle seat towards front using back- 2-UP Models
rest. The passenger footpegs are located on
3. Pull seat rearward and up out of lo- the RH and LH side of the vehicle be-
cation to clear the front tabs. hind the operator footpegs.
Passenger's Seat Installation

1. Ensure the latch lever is in the open
position by pulling it towards the
front of seat.
2. Using a forward motion, insert both
front tabs of the seat into the vehicle
anchor housings.
3. Rotate downwards to engage the
rear latch.
4. Close the latch lever by pushing it vmo2015-005-008_a
rearwards to secure seat in posi- TYPICAL
tion. 1. Operator's LH footpeg
5. Check if the seat is firmly secured in 2. Passenger's LH footpeg
position before using it.
WARNING
WARNING Passenger must have both feet on
It is of the upmost importance for footpegs at all time during vehicle
the passenger's safety that you operation.
confirm that the passenger's seat
is properly locked in position by
pulling back and up several times.
96 ______________
EQUIPMENT
4) Grab Handles (2-UP Remove protective cap to use. Always

Models) reinstall it after use to protect against
weather.
The grab handles are located on the RH
and LH side of the passenger's seat. Do not exceed the rating capacity. Re-
fer to FUSES in the MAINTENANCE
The grab handles must be used by the subsection.
passenger to hold on firmly during vehi-
cle operation.
6) Rear Storage
WARNING Compartment
The passenger must always hold Convenient location to carry personal
on to the passenger grab han- articles.
dles, not the operator. He must
also have both feet resting firmly
against the footrests.
vmo2015-005-009_a
1. Rear storage compartment cover
WARNING
Always engage the PARK position
vmo2015-005-054_d
on the shift lever before opening
TYPICAL cover. Never leave any heavy or
1. Grab handles
2. Passenger's seat loose breakable objects in the stor-
age area. Always latch cover be-
fore riding.
5) 12-Volt Power Outlet
Convenient for handheld spotlight or To Open Rear Storage
other portable equipment. Compartment
Unlatch cover and gently lift cover.
vmo2012-012-018_a vmo2015-005-009_a
1. 12 V power outlet 1. Rear storage compartment latch
_______________ 97
EQUIPMENT
To Close Rear Storage to SPECIFICATIONS subsection for

Compartment carrying loads and towing recommen-
Gently lower and latch cover. dations.
7) Cargo Racks
Cargo racks are convenient for carry-
ing equipment and various other cargo.
They must never be used to carry a
passenger.
vmo2015-005-038_a
TYPICAL
1. Trailer hitch
WARNING
Ensure to install the proper ball
size that matches the equipment
you will tow.
NOTE: Follow manufacturer's instruc-

vmo2015-005-002_a
tions for proper attachment.
TYPICAL
1. Front cargo rack
2. Rear cargo rack 9) Tool Kit
The tool kit is located under seat. It
WARNING contains tools for basic maintenance.
– Never carry a passenger on a
cargo rack.
– Cargo must never interfere with
the drivers line of sight or affect
his ability to properly steer the
vehicle.
– Do not overload the vehicle.
– Always ensure all cargo is prop-
erly secured and does not ex-
tend out pass the racks. vmo2015-005-026_a
1. Tool kit
Refer to SPECIFICATIONS subsection
for cargo weight recommendations. 10) Recovery Hooks
Convenient hook that can be use to re-
8) Trailer Hitch cover a stuck ATV.
Convenient hitch to install a ball to tow
a trailer or other equipment. Install
the proper ball size as per trailer man-
ufacturer recommendations. Refer
98 ______________
EQUIPMENT
vmo2015-005-012_a
1. Front recovery hook
vmo2015-005-010_a
1. Recovery hook
_______________ 99
EQUIPMENT (IF AVAILABLE ON YOUR MODEL)
vmo2016-029-006_b
1) Full Underbody WARNING

Aluminum Skid Plate Never drive vehicle with portable
Aluminum plates provide essential pro- light on.
tection.
NOTE: In some regions, restrictions
may apply to the usage of portable
light when gun boot is installed on ve-
hicle. Refer to local laws before using
spotlight.
vmo2016-029-004_a
1. Full underbody skid plate
2) Portable Light
A convenient 12 V powered spotlight
that can easily be moved around to pro- vmo2016-029-002_a
vided additional lighting on the spot. 1. Portable light
2. 12V power outlet
100 ______________
NOTICE Remove portable light Installing Gun Boot Into Gun Boot
and store when transporting vehi- Mount
cle. Install gun boot into gun boot mount.
WARNING Insert pin into gun boot support and
gun boot.
Do not operate the vehicle with
the spotlight or coil cable obstruct-
ing or interfering with the driver
and/or the operation of the vehicle
control devices. Do not use this
light while the vehicle is in mo-
tion, as it may blind other vehicles
drivers.
3) Gun Boot
vsi2012-105-040_a
This easy access gun boot is designed 1. Bent plate of gun boot support
to accommodate a variety of rifle and
shotguns along with their mods. Install lock onto pin.
NOTE: In some regions, gun boot
should be removed from vehicle out-
side of hunting season. Refer to local
laws.
vsi2012-105-039_a
1. Locked pin
Secure rear section of gun boot using

vmo2016-029-005_a locking pin.
GUN BOOT IN POSSIBLE INSTALLATION Insert pin into rear section of gun boot.
LOCATIONS
Install lock onto pin.
NOTICE Remove gun booth when
transporting vehicle.
WARNING
Reduce your speed while firearm
case is installed on vehicle.
NOTICE Avoid areas with a lot of

branches. If avoiding such areas is
impossible, make sure branches do
not hit the firearm case.
______________ 101
tsi2012-076-004_a
1. Rear section of Gun Boot

2. Pin
3. Lock
4) Gear Grips
These durable and flexible grips allow
for easy transportation of tools, bows,
and other implements.
vmo2016-029-001_a
TYPICAL
1. Close grips to hold item.
2. Press button to release grips.
Rotating the Gear Grips

NOTE: Gear grip can be rotated to
360°. To do so, simply remove the
U-clip by pushing on the plastic tabs
toward exterior side and pulling on
the U-clip. Rotate the gear grip into its
vmo2016-029-003_a mounting base.
1. Gear grips
NOTICE Failure to apply small
Using the Gear Grips pressure toward exterior side to the
plastic tabs may result in damage to
Close grip to hold item and press but- the U-clip.
ton to release grip.
102 ______________
The following tips will help to reduce

the risk of discharging the battery:
Always unreel manually: Unlock the
cable using the handle then pull on the
hook strap to unreel.
It is recommended to let the vehicle
run while winching. Do not stop vehi-
cle immediately after winching to let
battery recharge.
Also, when winching for more than
tsi2012-078-006_a 30 seconds, it is recommended to in-
TYPICAL crease engine RPM in the range of
1. Plastic tabs 3000 RPM to increase charging power
to the battery.
WARNING NOTE: Make sure vehicle is in NEU-
Use gear grips in pair. Gear grips TRAL (N) before increasing engine
should always be installed so the RPM.
dual arms are facing toward driver. Refer to BASIC GUIDE TO WINCHING
Do not use gear grip to support or TECHNIQUES for more information
hold heavy objects. Objects can about the winch.
dislodge from the grip when riding
fast or in a bumpy trail. Reduce 6) Roller Fairlead
your speed and often verify if gear
remains in place. Ensure objects The roller fairlead is used to prevent
loaded do not extend wider than damages to the vehicle and guide the
the vehicle width. wire rope into the winch.
5) Winch
The winch can be actuated using the
winch control switch or with the re-
mote control (sold separately).
219001733-002_a
1. Winch
2. Roller fairlead
3. Winch hook
4. Hook strap
219001733-002_a
1. Winch
2. Roller fairlead
3. Winch hook
4. Hook strap
NOTE: Using the winch intensively

over a long period of time may dis-
charge the battery.
______________ 103
FUEL
Fuel Requirements Use of fuel labeled E15 is prohibited by
U.S. EPA Regulations.
NOTICE Always use fresh gaso-
line. Gasoline will oxidize; the re- Vehicle Fueling Procedure
sult is loss of octane, volatile com-
pounds, and the production of gum
and varnish deposits which can WARNING
damage the fuel system. – Fuel is flammable and explosive
Alcohol fuel blending varies by coun- under certain conditions.
try and region. Your vehicle has been – Never use an open flame to
designed to operate using the recom- check fuel level.
mended fuels, however, be aware of – Never smoke or allow flame or
the following: spark in vicinity.
– Use of fuel containing alcohol above – Always work in a well-ventilated
the percentage specified by gov- area.
ernment regulations is not recom-
mended and can result in the fol- 1. Stop engine.
lowing problems in the fuel system
components: WARNING
• Starting and operating difficul-
ties. Always stop engine before refuel-
ing.
• Deterioration of rubber or plastic
parts.
• Corrosion of metal parts. 2. Have operator get off vehicle.
• Damage to internal engine parts.
– Inspect frequently for the presence WARNING
of fuel leaks or other fuel system Do not allow anyone to remain on
abnormalities if you suspect the the vehicle while fueling. If there is
presence of alcohol in gasoline ex- a fire or explosion during fueling, a
ceeds the current government reg- vehicle occupant could be unable
ulations. to quickly leave the area.
– Alcohol blended fuels attract and
hold moisture which may lead to 3. Unscrew slowly the fuel reservoir
fuel phase separation and can result cap counterclockwise to remove it.
in engine performance problems or
engine damage.
Recommended Fuel
Use common unleaded gasoline with
an AKI (R+M)/2 octane rating of 87, or
an RON octane rating of 92.
NOTICE Never experiment with
other fuels. Engine or fuel system
damages may occur with the use of
an inadequate fuel.
NOTICE Do NOT use fuel from fuel vmo2015-005-027_a
pumps labeled E85. 1. Fuel reservoir cap
104 ______________
FUEL
WARNING
If a differential pressure condition
is noticed (whistling sound heard
when loosening fuel reservoir cap)
have vehicle inspected and/or re-
paired before further operation.
4. Insert the spout into the filler neck.

5. Pour fuel slowly so that air can es-
cape from the tank and prevent fuel
flow back. Be careful not to spill
fuel.
6. Stop filling when the fuel reaches
the bottom of filler neck. Do not
overfill.
WARNING
Never top up the fuel tank before
placing the vehicle in a warm area.
As temperature increases, fuel ex-
pands and may overflow.
7. Fully tighten fuel reservoir cap clock-

wise.
WARNING
Always wipe off any fuel spillage
from the vehicle.
______________ 105
BREAK-IN PERIOD
Operation During Break-In
A break-in period of 10 operating hours
or 300 km (200 mi) is required for the
vehicle.
Engine
During the break-in period:
– Avoid full throttle operation
– Maximum throttle should not ex-
ceed 3/4
– Avoid sustained accelerations
– Avoid prolonged cruising speeds
– Avoid engine overheating.
However, brief accelerations and
speed variations contribute to a good
break-in.
NOTE: It is normal that the engine will
not operate at its maximum efficiency
until the break-in period is completed.
Brakes
WARNING
New brakes will not operate at
their maximum efficiency until
their break-in is completed. Use
extra caution.
Belt
A new belt requires a break in period of
50 km (30 mi).
During the break-in period:
– Avoid strong acceleration and decel-
eration
– Avoid pulling a load
– Avoid high speed cruising.
106 ______________
BASIC PROCEDURES
Starting the Engine Stopping the Engine and
The shift lever must be set to PARK or Parking the Vehicle
NEUTRAL.
NOTE: For your convenience, an over- WARNING
ride mode allows the engine to be Avoid parking on steep slope as
started with the shift lever in any po- the vehicle may roll away.
sition. Press and hold the brake lever
or the brake pedal while pressing the
engine start button. WARNING
Insert key in ignition switch and turn to Always put the vehicle in PARK
ON position. when stopped or parked to pre-
vent rolling.
Set the emergency engine stop switch
to RUN.
Press the engine start button and hold WARNING
until the engine starts. Avoid parking in places where hot
Release the engine start button imme- parts can start a fire.
diately when the engine has started.
When stopped or parked always bring
NOTICE If engine does not start shift lever to park position. This is es-
after a few seconds, do not hold the pecially important when parking on
engine start button more than 10 a slope. On very steep inclines or
seconds. Refer to TROUBLESHOOT- if the vehicle is carrying a cargo, the
ING section. wheels should be blocked using rocks
or bricks.
Shifting the Transmission Select the flattest terrain available for
Apply brakes and immobilize vehicle, parking.
then select the desired shift lever posi-
Release accelerator pedal and use
tion.
brakes to completely stop the vehi-
Release brakes. cle.
NOTICE When changing gear se- Set shift lever in PARK position.
lection, always completely stop the Turn key in ignition switch to OFF posi-
vehicle and apply the brakes prior tion.
to moving the shift lever. Otherwise
Remove key from ignition switch.
damage to the transmission may oc-
cur. If you must park on a steep incline or if
the vehicle is carrying cargo, block the
Gradually press the throttle lever to wheels using rocks or bricks.
increase engine speed and thus en-
gaging the continuously variable trans-
mission (CVT).
At the opposite, when the throttle
lever is released, the engine speed
decreases.
______________ 107
SPECIAL PROCEDURES
What to Do if Water is in the 450 Models
CVT Reinstall slotted hexagonal 15 mm
The CVT drain plug is located on the (19/32 in) drain plug.
CVT cover. It is accessible from the
rear LH fender.
570 Models
Reinstall the drain plug and secure it
450 Models using the spring clamp.
Remove the CVT drain plug to validate NOTE: Make sure hose is properly in-
if water is present. serted on CVT cover nipple.
NOTICE See an authorized
Can-Am dealer to have the CVT in-
spected and cleaned.
What to Do if Water is in the

Air Filter Housing
Remove the LH side panel.
Inspect the drain reservoir underneath
the air filter housing to validate if water
is present.
vmo2015-005-301_a
450 MODELS
1. CVT drain plug
570 Models
Inspect the CVT drain plug to validate if
water is present.
If water is present, remove CVT drain
plug to expel water.
vmo2012-012-054_a
TYPICAL
1. Air filter housing drain reservoir
If water is present, press clamp and re-

move reservoir to drain water from air
filter housing.
If one of the following conditions is
met, bring the vehicle to your nearest
authorized Can-Am dealer to have the
vmo2015-005-303_a
vehicle serviced:
570 MODELS
– If more than 50 ml (2 U.S. oz) of
1. CVT drain plug water (approximately 5 drain reser-
voirs) is found in the air filter hous-
All Models ing.
– If any deposits are present in the
NOTICE If water is present in the drain reservoir.
CVT, it could result in belt slippage.
The engine will accelerate but the
vehicle will remain still.
108 ______________
SPECIAL PROCEDURES
In such a case, the vehicle must be ser- Whenever the vehicle is turned over, it
viced for: should be inspected by an authorized
– Vents Can-Am dealer.
– CVT cleaning
– Fuel tank breather replacement What to Do if Vehicle is
– Lubricant inspection and replace- Immersed in Water
ment as required (engine, gearbox Should the vehicle become immersed,
and rear final drive). immediately stop the engine. Do not
use:
NOTICE Failure to have vehicle
– Any electrical equipments
serviced may lead to permanent
damage to the following compo- – Winch (if equipped)
nents but not limited to: It will be necessary to take the vehi-
– Engine and gearbox cle to an authorized Can-Am dealer as
– Fuel pump soon as possible. NEVER ATTEMPT
TO START THE ENGINE!
– CVT
– Front differential NOTICE Immersion of the vehi-
– Rear final drive. cle can cause serious damage if the
correct restart procedure is not fol-
What to Do if Vehicle is lowed.
Turned Over As soon as vehicle is pulled out of wa-
When vehicle is turned over or stays ter, carry out the following:
tilted on the side, put the vehicle back – Drain CVT. See procedure in this
on its wheel. Inspect vehicle for dam- subsection.
ages.
NOTICE The vehicle should be ser-
viced as soon as possible by an au-
WARNING thorized Can-Am dealer.
Never operate the vehicle if dam-
aged. Refer to an authorized
Can-Am dealer.
If vehice has no damage, refer to

MAINTENANCE section and inspect
the following.
– Inspect air filter housing for oil accu-
mulation, if any oil is found, clean air
filter and air filter housing.
– Check engine oil level and refill if
necessary.
– Check engine coolant level and refill
if necessary.
– Check gearbox oil level and refill if
necessary. (570 Models)
– Check rear final drive oil level and re-
fill if necessary.
– Start engine. If the oil pressure light
stays on, stop engine immediately.
See an authorized Can-Am dealer.
______________ 109
TUNE YOUR RIDE
WARNING
Suspension adjustment could af-
fect vehicle handling. Always take
time to familiarize yourself with
the vehicle's behavior after any
suspension adjustment have been
made.
Suspension Adjustment
Suspension adjustment and loading vmo2015-005-040_a
can have an effect on your vehicle han- 1. Adjustment cam
dling and comfort. 2. Softer adjustment
3. Firmer adjustment
Choice of suspension adjustments
vary with driver's weight, personal
preference, riding speed and field con- Dynamic Power Steering
dition. (DPS) Assist Level
Adjustment
Spring Preload Adjustment
All Models Except Base Models
WARNING The Tri-Mode Dynamic Power Steering
(DPS) offers easy steering assistance
The left and right shock adjust- to the rider. The level of assistance
ment on front or rear suspension will automatically adapt according to
must always be set to the same the vehicle's speed and rider’s de-
position. Never adjust one only. mand, in order to provide maximum
Uneven adjustment can cause steering power at lower speed where
poor handling and loss of stability, the demand is normally higher. As
which could lead to an accident. speed increases, the assistance is pro-
gressively reduced to keep maximum
Shorten the springs for a firmer ride steering feel and precision to the rider.
and rough conditions.
It is possible to choose between three
Lengthen the springs for a softer ride modes of assistance: Minimum,
and smooth conditions. Medium and Maximum. Each mode
Adjust spring preload by turning adjust- will continue to automatically adapt
ment cam. Use tool from vehicle tool to the vehicle’s speed and rider’s de-
kit. mand, so it does not require to be
changed when riding. These modes
are used to set the level of assistance
to match each rider's preferences.
The following DPS modes are preset in
the vehicle.
110 ______________
TUNE YOUR RIDE
DPS MODE NOTE: The DPS adjustment will not

be possible if the vehicle transmission
DPS is set to REVERSE.
Maximum steering assist
MAX.
DPS
Medium steering assist
MED.
DPS
Minimum steering assist
MIN.
To show the active DPS mode, pro-

ceed as follows:
1. Press and release DPS button.
vmo2010-004-003_a
1. DPS button
2. Check the multifunction gauge to

confirm the active DPS mode.
1. DPS mode display
To change the DPS mode, proceed as

follows:
1. Press and hold DPS button for 2 sec-
onds to go to the next setting.
2. Release DPS button.
3. Repeat until desired setting is se-
lected.
______________ 111
VEHICLE TRANSPORTATION
When transporting this vehicle, secure
it to a trailer or in pickup box with suit-
able tie-downs. Use of ordinary ropes
is not recommended.
WARNING
Do not tow this vehicle behind a
car or other vehicle. Use a trailer.
Never tip this vehicle on end for
transporting. The vehicle must be
in its normal operating position
vmo2015-005-013_a
(on all four wheels).
1. Rear tie-down point location
NOTICE Securing vehicle at other

locations may damage the vehicle.
V00A17Y
Remember to:
– Unload vehicle racks before trans-
portation.
– Set shift lever to PARK position.
– Set the parking brake.
– Secure the vehicle by the front and
rear tie-down points.
vmo2015-005-012_a
1. Front tie-down point location
112 ______________
MAINTENANCE
______________ 113
Maintenance is very important for keeping your vehicle in safe operating condition.
The vehicle should be serviced as per the maintenance schedule.
The maintenance schedule does not exempt the pre-ride inspection.
A repair shop or person of the owner's choosing may maintain, replace, or repair
emission control devices and systems. These instructions do not require compo-
nents or service by BRP or authorized Can-Am dealers. Although an authorized
Can-Am dealer has an in-depth technical knowledge and tools to service the
Can-Am ATV, the emission-related warranty is not conditioned on the use of
an authorized Can-Am dealer or any other establishment with which BRP has a
commercial relationship. For emission-related warranty claims, BRP is limiting
the diagnosis and repair of emission-related parts to the authorized Can-Am
dealers. For more information, please refer to the US EPA EMISSION-RELATED
WARRANTY contained herein. Proper maintenance is the owner’s responsibility.
A warranty claim may be denied if, among other things, the owner or operator
caused the problem through improper maintenance or use.
You must follow the instructions for fuel requirements in the fueling section of
this manual. Even if gasoline containing greater than ten volume percent ethanol
is readily available, the US EPA issued a prohibition against the use of gasoline
containing greater than 10 vol% ethanol that applies to this vehicle. The use of
gasoline containing greater than 10 vol% ethanol with this engine may harm the
emission control system.
WARNING
Failure to properly maintain the vehicle according to the maintenance
schedule and procedures can make it unsafe to operate.
SEVERE DUSTY CONDITIONS

Engine Air Filter Maintenance Guideline
Air filter maintenance should be adjusted according to riding conditions.
Air filter maintenance must be increased in frequency in the following dusty condi-
tions:
– Riding on dry dirt covered surfaces
– Riding on dry gravel roads or similar conditions.
NOTE: Riding in a group in these conditions would increase even more the air filter
maintenance.
MAINTENANCE SCHEDULE LEGEND

Operation in trail riding conditions
Operation in severe riding conditions (dusty or muddy) or carrying heavy loads condition
114 ______________
Make sure to perform proper maintenance at recommended intervals as indicated
in the tables. Some items of the maintenance schedule must be performed in
function of the calendar, regardless of the distance or time of operation.
EVERY 750 KM (500 MI) OR 25 HOURS (whichever comes first)
Verify and clean engine air filter. Replace as needed
Verify battery connections
Lubricate rear propeller shaft joint
Inspect tie rod ends and ball joints for play and boots condition
Lubricate front suspension arm bushings
Lubricate rear stabilizer bar bushings
Inspect the drive shaft boots and protectors
Inspect brake pads. Replace as needed
Inspect wheel bearings for abnormal play

Adjust valve clearance
Clean muffler spark arrester
Verify and clean throttle body
Replace fuel vent breather filter
Verify CVT drive belt and clean CVT pulleys
Lubricate the one way bearing of the drive pulley
The following must be performed at least once a year:
Change engine oil and filter
Lubricate throttle cable
Inspect and clean brake system
Inspect battery condition
Verify steering system for abnormal play
Verify front differential and rear final drive oil level and look for contamination
Verify gearbox oil level and look for contamination (570)
______________ 115
PERFORM AT THE FIRST 3 000 KM (2,000 MI)AND AT 6 000 KM (4,000 MI)

THEN FOLLOW THE REGULAR SCHEDULE
PERFORM AT THE FIRST 1 500 KM (1,000 MI) AND AT 3 000 KM (2,000 MI)
THEN FOLLOW THE REGULAR SCHEDULE
Replace gearbox oil (570)
Clean the vehicle speed sensor (VSS) (570)

Verify the cooling system
Test engine coolant strength
Verify fuel system for leaks
Verify fuel pump pressure
Replace spark plugs
Replace front differential oil
Replace rear final drive oil
Replace gearbox oil (570 only)
Inspect input and output shaft seals (gearbox, differential and final drive)
Clean vehicle speed sensor
Clean and lubricate lower and upper steering column half bushings
The following must be performed every 2 years:
Replace the brake fluid

Replace engine coolant
116 ______________
MAINTENANCE PROCEDURES
This section includes instructions for Air Filter Removal
basic maintenance procedures. I
NOTICE Never remove or mod-
ify any component in the air filter
WARNING housing. Otherwise, engine perfor-
Unless otherwise indicated, al- mance degradation or damage can
ways turn ignition switch to OFF occur. The engine is calibrated to
position and remove key before operate specifically with these com-
performing any maintenance. ponents.
Remove seat.
WARNING Lift rear portion of console upwards
Should removal of a locking de- until the studs are released from the
vice be required (e.g. lock tab, grommets.
self-locking fastener, etc.), always
replace it with a new one.
Air Filter
Air Filter Maintenance Guideline
As with any ATV, air filter maintenance
is critical to ensure proper engine per-
formance and life span.
Air filter maintenance should be ad-
justed according to riding conditions. vmo2015-005-021_a
Air filter maintenance must be in- TYPICAL

creased in frequency and oil must be 1. Console
added to the foam filter for the follow- 2. Studs and grommets
ing dusty conditions: Pull console rearwards.
– Riding on dry sand.
Rotate air filter cover counterclock-
– Riding on dry dirt covered surfaces. wise to remove.
– Riding on dry gravel trails or similar
conditions. NOTE: A socket wrench may be used
to ease removal.
NOTE: Riding in a group in these con-
ditions would increase even more the
air filter maintenance. Refer to AIR
FILTER CLEANING AND OILING in this
subsection for maintenance proce-
dure.
NOTE: An accessory pre-filter for
"dusty conditions" may be used. Con-
tact an authorized Can-Am dealer for
details.
vmo2015-005-014_a
1. Air filter cover
Remove air filter.
______________ 117
vmo2015-005-015_a vmr2012-010-017_b
AIR FILTER REMOVAL TYPICAL - SOME PARTS REMOVED FOR

CLARITY
Engine Air Filter Housing Inspection 1. Air filter drain tube
and Draining
Air Filter Cleaning and Oiling
1. Remove LH side panel.
2. Drain air filter housing inlet drain
tube. CAUTION Always wear ap-
propriate skin and eye protection.
Chemicals can cause a skin rash and
eye injury.
Paper Filter Cleaning
1. Ensure that the foam filter is re-
moved from paper filter.
2. Tap out heavy dust from the paper
filter.
This will allow dirt and dust to get out of
the paper filter.
vmr2012-010-017_a
NOTE: Paper filter have a limited
life span; replace filter if too dirty or
TYPICAL - SOME PARTS REMOVED FOR
CLARITY clogged.
1. Air filter housing inlet drain tube
NOTICE It is not recommended to
3. Check air filter dirty chamber for blow compressed air on the paper
cleanliness. filter; this could damage the paper
– If any debris or water are found, fibers and reduce its filtration ability
clean air filter chamber using a when used in dusty environments.
vacuum cleaner. NOTICE Do not wash the paper fil-
NOTICE Do not blow compressed ter with any cleaning solution.
air into air filter chamber. Foam Filter Cleaning
4. Check air filter drain tube (clean 1. Spray the foam filter inside and out
chamber). with a good air filter cleaner and fol-
– If any debris or water are found, low manufacturer's instructions.
refer to SPECIAL PROCEDURES
subsection.
– Investigate for contamination
source.
118 ______________
vbs2009-012-015_a
219700340
TYPICAL - SPRAY THE FOAM FILTER
AIR FILTER OIL (P/N 219 700 340)
2. Dry the foam filter completely.
vbs2009-012-014
vbs2009-012-005
TYPICAL - DRY TYPICAL - OIL THE FOAM FILTER
NOTE: A second application may be 3. Let stand for 3 to 5 minutes.

necessary for heavily soiled elements. 4. Remove any excess of oil that
could transfer to the paper filter by
Foam Filter Oiling wrapping the foam filter into an ab-
1. Make sure filter is clean. Refer to sorbent cloth and squeezing gently.
FOAM FILTER CLEANING. This will also ensure a full oil cover-
age on foam filter.
2. Spray AIR FILTER OIL (P/N 219 700
340) or equivalent on the foam filter 5. Reinstall the foam filter over the pa-
previously dried. per filter.
vbs2009-012-001
TYPICAL
______________ 119
Air Filter Installation Engine Oil

Slightly grease O-ring seal and plastic
body of air filter. Engine Oil Level
Install air filter as the reverse of re- NOTICE Check level frequently
moval. and refill if necessary. Do not over-
Ensure air filter cover is properly locked fill. Operating the engine/gearbox
onto the air filter housing. See indica- with an improper level may severely
tions on filter cover and housing. damage engine/gearbox. Wipe off
any spillage.
NOTE: While checking the oil level, vi-
sually inspect engine area for leaks.
vmo2015-005-014_b
1. Cover position arrow

2. Locked
3. Unlocked
Install console as the reverse of re- vmr2015-008-100_a

moval. However, pay attention to the 450 MODEL - RH SIDE OF ENGINE
following. 1. Dipstick
Align console front tabs with slots,
then push console forward.
Then align and insert studs with grom-
mets on rear portion of console until
studs engage with grommets.
vmr2015-063-100_a
570 MODEL - RH SIDE OF ENGINE

1. Dipstick
NOTE: Do not lose the O-ring placed

vmo2015-005-021_a
on the dipstick.
TYPICAL With vehicle on a level surface and en-
1. Console gine cold, not running, check the oil
2. Studs and grommets level as follows:
1. Unscrew dipstick then remove it
and wipe clean.
120 ______________
2. Reinstall dipstick, screw in it com- RECOMMENDED SERVICE PRODUCT

pletely.
3. Remove and check oil level. It Outside of
the U.S.
(P/N 619 590 114)
should be near or equal to the up-
per mark. XPS 4-STROKE
Within the
U.S.
SYNTHETIC OIL
(P/N 293 600 112)
NOTE: The XPS oil is specially formu-

lated and tested for the severe require-
ments of this engine. BRP recom-
mends the use of its XPS 4-stroke oil.
If XPS engine oil is not available, use
a 4-stroke SAE 5W40 engine oil that
1 meets or exceeds the requirements
3 for API service classification SJ, SL,
2 SM or SN. Always check the API ser-
vice label certification on the oil con-
tainer it must contain at least one of
the above standards.
V07C02Y NOTICE Damages caused by the
TYPICAL
use of oil not suitable for this engine
1. Full may not be covered by the BRP lim-
2. Add ited warranty.
3. Operating range
Engine Oil Change
To add oil, remove dipstick. Place a
funnel into the dipstick tube to avoid Start and warm-up engine. Stop en-
spillage. gine.
Add a small amount of recommended Ensure vehicle is on a level surface.
oil and recheck oil level. Remove dipstick.
Repeat the above procedures until Clean the oil drain plug area.
oil level reaches the dipstick's upper
mark. Do not overfill. Place a drain pan under the oil drain
plug area.
Properly tighten dipstick.
Unscrew oil drain plug.
Recommended Engine Oil
For the summer season, use: CAUTION The engine oil can
be very hot. In order to avoid poten-
RECOMMENDED SERVICE PRODUCT tial burns, do not remove the engine
drain plug if the engine is hot. Wait
Outside of until engine oil is warm.
the U.S.
(P/N 619 590 109)
Within the
XPS 4-STROKE SYNTH.
U.S.
BLEND OIL (P/N 293
600 121)
For all season, use:
______________ 121

1. Clean oil filter area.
2. Remove oil filter cover.
3. Remove oil filter.
vmr2015-063-101_a
TYPICAL - SOME PARTS REMOVED FOR

CLARITY
1. Drain plug
2. Access through frame
Allow enough time for oil to flow out of

oil filter.
Replace the oil filter. Refer to OIL FIL-
TER in this subsection. 1. Oil filter screw
2. Oil filter cover
Change gasket on oil drain plug. 3. O-ring
Clean gasket area on engine and oil 4. Oil filter
drain plug then reinstall plug.
Oil Filter Installation
Refill engine at the proper level with
the recommended oil. 1. Check and clean the oil filter inlet
and outlet area of dirt and other con-
Refer to SPECIFICATIONS subsection taminations.
for oil capacity.
Start engine and let idle for a few min-
utes.
Ensure oil filter area and oil drain plug
areas are not leaking.
Stop engine.
Wait a while to allow oil to flow down to
crankcase then check oil level.
Refill as necessary.
Dispose of oil as per your local environ-
mental regulations. vmr2015-063-003_a
1. Inlet bore from the oil pump to the oil filter

Oil Filter 2. Outlet bore to the engine oil providing
system
Oil Filter Removal
2. Install a NEW O-ring on oil filter
To reach oil filter, remove the following cover.
parts:
3. Install the filter into the cover.
– Seat
– Console 4. Apply engine oil on O-ring and on
end of filter.
122 ______________
Inspect radiating fins. They must be

clean, free of mud, dirt, leaves and any
other deposit that would prevent the
radiator to cool properly.
Remove as much deposits as you can
with your hands. If water is available in
proximity, try rinsing the radiating fins.
If available, use a garden hose to rinse
the radiating fins.
vmr2006-008-001_a
1. Slightly oil CAUTION Never clean radiator

2. Slightly oil with your hands when it is hot. Let
the radiator cool down before clean-
5. Install the cover on the engine. ing.
6. Tighten oil filter cover screws to rec- NOTICE Be careful not to damage
ommended torque. the radiating fins when cleaning. Do
TIGHTENING TORQUE not use any object/tool that could
damage the fins. The fins are pur-
Oil filter cover 10 N•m ± 1 N•m posely thin parts to allow efficient
screws (89 lbf•in ± 9 lbf•in) cooling. WHEN HOSING, USE LOW
PRESSURE ONLY, NEVER USE A
7. Reinstall remaining parts if applica- HIGH PRESSURE WASHER.
ble.
See an authorized Can-Am dealer, re-
Radiator pair shop or person of your own choos-
ing to check the performance of the
Radiator Inspection cooling system.
Periodically check the radiator area for Engine Coolant
cleanliness.
Engine Coolant Level Verification
WARNING
Check coolant level with engine
cold. Never add coolant in cooling
system when engine is hot.
Place vehicle on a level surface.

Remove the gauge support.
Remove engine coolant reservoir cap.
vmo2012-012-041
With vehicle on a level surface, liquid
TYPICAL - PARTS REMOVED FOR CLARITY
should be between MIN. and MAX.
level marks of coolant reservoir.
Inspect radiator and hoses for leaks or
any damage.
______________ 123
BRP
RECOMMENDED COOLANT
PRODUCT
Finland, Norway
LONG LIFE
and Sweden
ANTIFREEZE
(P/N 219 702 685)
All other
LONG LIFE
countries
ANTIFREEZE(F)
(P/N 619 590 204)
vmo2015-005-017_a Distilled water
1. Engine coolant reservoir and antifreeze
Alternative, or if
solution (50%
not available
NOTE: When checking level at tem- distilled water,
perature lower than 20°C (68°F), it may 50% antifreeze)
be slightly lower than MIN. mark.
Add coolant if required. Engine Coolant Replacement
WARNING Cooling System Draining

Warning: Do not remove the Remove the gauge support.
coolant reservoir cap if engine is Remove the coolant reservoir cap.
hot.
WARNING
Use a funnel to avoid spillage. Do not
Warning: To avoid potential burns,
overfill.
do not remove the pressure cap if
Properly reinstall and tighten reservoir the engine is hot.
cap.
Reinstall gauge support.
WARNING
In order to avoid potential burns,
do not remove the radiator cap if
the engine is hot.
NOTE: A cooling system that fre-

quently requires coolant is the indica-
tion of leaks or engine problems. See
an authorized Can-Am dealer.
Recommended Engine Coolant vmo2015-005-017_a
1. Engine coolant reservoir cap

NOTICE Always use ethylene-gly-
col antifreeze containing corrosion Unscrew the coolant drain plug and
inhibitors specifically for internal drain the coolant into a suitable con-
combustion aluminum engines. tainer.
124 ______________
vmr2015-016-105_a
vmr2015-008-103_a
TYPICAL - SOME PARTS REMOVED FOR TYPICAL
CLARITY 1. Front cylinder bleed screw
NOTE: Do not unscrew the coolant

drain plug completely.
Disconnect the lower radiator hose
and drain the remaining coolant into a
suitable container.
NOTE: Take note of the position of the
hose clamp on the lower radiator hose
at the radiator.
Reinstall radiator hose as noted prior to
removal.
Reinstall cooling system drain plug tmo2011-001-502_a
with a new gasket ring. TYPICAL - 570 MODELS ONLY
Tighten the coolant drain plug. 1. Rear cylinder bleed screw
COOLING SYSTEM DRAIN 2. Fill the cooling system until coolant

PLUG TORQUE comes out of the bleed screw.
9 N•m to 11 N•m
3. Squeeze the top of the coolant hose
(80 lbf•in to 97 lbf•in)
between the radiator and coolant
pump several times until all air is
bled from the highest point of the
Bleed cooling system, refer to COOL- hose.
ING SYSTEM BLEEDING.
4. Install the bleed screw( using NEW
Cooling System Filling and Bleeding gasket ring and torque as per follow-
1. Unscrew bleed screws above both ing chart.
front and rear cylinders. TIGHTENING TORQUE
5.0 N•m ± 0.6 N•m
Bleed screws
5. Continue adding coolant until sys-

tem is full up to the pressure cap.
6. Refill coolant tank up to MAX level
mark.
______________ 125
7. Run engine at idle with the radiator

cap off. Slowly add coolant if neces-
sary.
8. At this point, wait until engine
reaches normal operating tempera-
ture.
9. Depress the throttle lever two or
three times; then add coolant if re- vmo2015-005-037_a
quired.
TYPICAL
10. Stop the engine and let it cool 1. Muffler
down. 2. Clean out plug
11. Install coolant reservoir cap. Block the end of the muffler with a
12. Inspect all connections for leaks shop rag and start engine.
and check coolant level in the Momentarily increase engine RPM
reservoir. several times to purge accumulated
carbon out of the muffler.
Muffler Spark Arrester Stop engine and allow muffler to cool.
The muffler must be periodically Reinstall the clean out plug.
purged of accumulated carbon.
Gearbox Oil (570 Models)
WARNING
Never run engine in an enclosed Recommended Gearbox Oil
area. Never perform this opera-
tion immediately after the engine RECOMMENDED
QUANTITY
has been run because exhaust sys- PRODUCT
tem is very hot. Make sure that XPS SYNTHETIC
there are no combustible mate- Approximately
GEAR OIL 450 ml
rials in the area. Wear eye pro- (75W 140)
tection and gloves. Never stand (15 U.S. oz)
(P/N 293 600 140)
behind the vehicle while purging
exhaust system. Respect all appli- If the recommended oil is not available,
cable laws and regulations. use a 75W140 gearbox oil that meets
the API GL-5 specification.
Select a well-ventilated area and make
sure the muffler is cool. Gearbox Oil Level Verification
Place transmission on PARK position. NOTE: Prior checking the gearbox oil
Remove the clean out plug of the muf- level, ensure vehicle is on a level sur-
fler. face.
1. To access gearbox oil level plug, re-
– Seat
– Console
– RH footrest panel
126 ______________
5. Remove magnetic drain plug and

sealing ring. Discard sealing ring.
WARNING
The gearbox oil can be very hot.
6. Remove oil level plug and its O-ring.

NOTE: Allow oil to completely flow
out of gearbox.
vmr2015-063-102_a
1. Oil level plug
2. Remove the gearbox oil level plug.
vmo2012-012-056_a

2. Oil level plug
7. Clean magnetic drain plug and pay

vmo2012-012-056_a
attention to any debris present on
drain plug.
1. Drain plug
2. Oil level plug NOTE: Presence of excessive debris
provides an indication of a gearbox
3. Check oil level. problem.
The oil should be level with the bottom 8. Reinstall magnetic drain plug with a
of the oil level hole. NEW sealing ring.
NOTICE Operating the gearbox DRAIN PLUG
with an improper oil level may se-
verely damage gearbox. Gasket NEW
Tightening 20 N•m ± 2 N•m
Gearbox Oil Replacement torque (15 lbf•ft ± 1 lbf•ft)
Gearbox Oil Draining Procedure
9. Dispose gearbox oil as per your local
1. Start engine and operate vehicle to environmental regulations.
warm-up the gearbox oil.
NOTE: Running engine at idle is not Gearbox Oil Filling Procedure
sufficient, vehicle transmission must 1. Fill the gearbox through the oil level
be operated. hole until the oil reaches the bottom
2. Position vehicle on a level surface. of the oil level hole.
3. Place a drain pan under the gearbox 2. Install the oil level plug with its
drain plug area. O-ring. Tighten plug as per table.
4. Clean drain plug area.
______________ 127
OIL LEVEL PLUG

Tightening 5 N•m ± 0.6 N•m
torque (44 lbf•in ± 5 lbf•in)
Throttle Cable
Throttle Cable Lubrication
The throttle cable must be lubricated
with silicone based lubricant or an
equivalent. V07I0GY 1 2 3 4
WARNING 1. Cable protector

Always use a silicone-based lubri- 3. Lock nut
cant. Using another lubricant (like 4. Throttle lever housing
a water-based lubricant) could Screw in the throttle cable adjuster.
cause the throttle lever/cable to
become sticky and stiff. Remove inner housing protector.
Open the throttle lever housing.
V07I0HY 1
V07I0FY
Remove the cable from the throttle
1. Remove these screws lever housing.
NOTE: Slide cable in clip slot and re-
Separate the housing. move the end of cable from clip.
Slide rubber protector back to expose
throttle cable adjuster.
128 ______________
V07I0JY
V07I0IY TYPICAL
NOTE: Place a rag around the throttle

Remove the throttle body side cover. cable adjuster to prevent the lubricant
from splashing.
Add lubricant until it runs out at throttle
body end of the throttle cable.
Reinstall and adjust the cable.
Throttle Cable Adjustment

Slide rubber protector back to expose
throttle cable adjuster.
vmo2006-007-032_a
1. Throttle body
2. Side cover screws
Insert the needle of the lubricant can in

the end of throttle cable adjuster.
CAUTION Always wear ap-

propriate skin and eye protection.
Chemicals can cause a skin rash and V07I0GY 1 2 3 4
eye injury. 1. Cable protector
3. Lock nut
4. Throttle lever housing
Loosen lock nut then turn the adjuster

to obtain correct throttle lever free play.
Measure throttle free play at the tip of
throttle lever.
______________ 129
570 Models Only
vmo2015-005-020_b
A. 2 mm (.079 in) 219001737-010_a
Tighten lock nut and reinstall protector. RH SIDE — REAR CYLINDER

1. Spark plug
With the shift lever on PARK position,
start the engine. All Models
Check if the throttle cable is adjusted
correctly by turning handlebar fully to
the right then fully to the left. If the
engine RPM increases, readjust the
throttle lever free play.
Spark Plugs
Spark Plug Access
Remove side panels.
Unplug spark plug cable(s). 219001737-011_a
LH SIDE — FRONT CYLINDER

Spark Plug Removal 1. Spark plug
Unscrew spark plugs one turn. Spark Plug Installation

Prior to installation, make sure that
CAUTION Always wear safety contact surfaces of cylinder heads and
goggles when using pressurized air. spark plugs are free of grime.
Clean spark plugs and cylinder heads Using a feeler gauge, set the spark plug
with pressurized air if possible. gap.
Unscrew spark plugs completely then
remove them. SPARK PLUG GAP
0.7 mm - 0.9 mm
450
(.028 in - .035 in)
0.7 mm to 0.8 mm
570
(.028 in to .031 in)
Apply a small amount of copper-based

anti-seize lubricant over spark plug
threads to prevent a possible seizure.
130 ______________
Screw spark plugs into cylinder heads Remove corrosion from battery cable
by hand and tighten with a torque terminals and battery posts using a
wrench and a proper socket. firm wire brush.
SPARK PLUG TORQUE Battery Installation
20 N•m ± 2.4 N•m (15 lbf•ft ± 2 lbf•ft) Battery installation is the reverse of the
removal procedure.
Battery NOTICE Always connect RED (+)
battery cable first.
CAUTION Never charge a bat-
tery while installed in vehicle. Fuses
These vehicles are equipped with a
VRLA battery (Valve Regulated Lead CAUTION Always turn the ig-
Acid). It is a maintenance-free type nition switch to OFF position before
battery, there is no need to add water replacing a defective fuse.
to adjust electrolyte level.
Fuse Inspection
NOTICE Never remove the battery Check if filament is melted.
sealing cap.
If filament is melted, replace damaged
Battery Removal fuse, refer to FUSE LOCATION tables
for proper rating.
Disconnect BLACK (-) cable first then
RED (+) cable.
NOTICE Always disconnect 1
BLACK (-) battery cable first.
Remove retaining screws, battery
holder then pull the battery out of 2
frame.
A15E0KY
TYPICAL
1. Fuse
2. Check if melted
NOTICE Do not use a higher rated

fuse as this can cause severe dam-
age.
vmo2015-005-018_a
1. Battery holder Front Fuse Box Location

2. Retaining screws
Pull upwards and front to remove the
Battery Cleaning gauge support from its location.
Clean battery, battery casing and bat-
tery posts using a solution of baking
soda and water.
______________ 131
FRONT FUSE BOX

NO. DESCRIPTION RATING
Key Switch,
F8 Starter Solenoid, 10 A
Clock
F9 Cooling Fan 20 A
DC
Outlet/Light/Accessories,
vmo2015-005-019_a F12 20 A
Euro Control (CE),
1. Gauge support 2WD/4WD
Fuse Links and Fuse Box 2

The fuse links and fuse box 2 are lo-
cated behind the RH side panel
vmo2015-005-022_a
1. Front fuse box

2. Front fuse box cover
NOTE: Check inside fuse box cover to

know fuses location.
NOTICE Do not store any objects vmr2016-132-004_a
in the front service compartment. 1. Fuse links
Front Fuse Box Description

FRONT FUSE BOX
NO. DESCRIPTION RATING
R1 Fan Relay -
R2 Main Relay -
R3 Accessories Relay -
vmr2015-044-004_a
R4 Fuel Pump Relay - FUSE BOX 2
R8 Brake Relay -
F4 Gauge (Speedo) 10 A
Injectors/Ignition,
ECM,
F5 10 A
Fuel Pump,
VSS
132 ______________
Rear Fuse Identification Headlight Beam Aiming

FUSE LINK IDENTIFICATION Turn adjustment knobs to adjust beam
height and side orientation to specifica-
Fuse 1 Main 16 awg tion.
links 2 Fan/accessories 16 awg
FUSE IN FUSE BOX 2
IDENTIFICATION
DPS/ACS
Fuse 3 (dynamic power 40 A
steering)
Lights
Always check light operation after re- vmr2015-050_008_a
placement.
LOW BEAM
1. Adjustment knobs
Headlight Bulb Replacement
NOTICE Never touch glass portion Taillight/Brake Light Bulb
of a halogen bulb with bare fingers, Replacement
it shortens its operating life. If glass 1. Unplug connector from bulb.
is touched, clean it with isopropyl al- 2. Rotate light bulb counterclockwise
cohol which will not leave a film on to remove it from taillight.
the bulb.
1. Remove cover.
2. Unplug connector.
3. Remove bulb.
vmr2015-050_014_a
3. Remove bulb socket from taillight.

Installation is the reverse of the re-
moval procedure.
Drive Shaft Boot and

Protector
Drive Shaft Boot and Protector
vmr2015-050_010_a
Inspection
1. Cover
2. Connector Visually inspect drive shaft protectors
and boots conditions.
4. Properly reinstall removed parts in
the reverse order of their removal. Check protectors for damage or rub-
bing against shafts.
5. Validate headlight operation.
______________ 133
Check boots for cracks, tears, leaking Push and pull the wheels from the up-
grease etc. per edge to feel the play.
Repair or replace damaged parts as See an authorized Can-Am dealer if
necessary. there is any play.
vmo2015-005-050_a
TYPICAL — FRONT OF VEHICLE

1. Drive shaft boots
2. Drive shaft protector
tmo2011-001-131_a
TYPICAL
Wheels and Tires

Tire Pressure
WARNING
Tire pressure greatly affects vehi-
cle handling and stability. Insuf-
ficient pressure may cause tire to
vmo2015-005-041_a
deflate and rotate on wheel. Over-
TYPICAL — REAR OF VEHICLE pressure may burst the tire. Al-
1. Drive shaft boots ways follow recommended pres-
2. Drive shaft protector
sure. NEVER set tire pressure
below minimum. It could cause
Wheel Bearing the tire to dislodge from the rim.
Since tires are low-pressure types,
Wheel Bearing Inspection a manual pump should be used.
Place vehicle on a level surface.
Apply the parking brake. Check pressure when tires are cold
before using the vehicle. Tire pres-
Lift and support vehicle. sure changes with temperature and
Secure vehicle on jack stands. altitude. Recheck pressure if one of
these conditions has changed.
WARNING
injury or death.
134 ______________
For your convenience, a pressure WARNING

gauge is supplied in tool kit.
– Replace tires only with the same
TIRE PRESSURE type and size as original tires.
FRONT REAR – For unidirectional tread pat-
tern, ensure that the tires are
1-UP
48.3 kPa 48.3 kPa installed in the correct direction
(7 PSI) (7 PSI) of rotation.
48.3 kPa 48.3 kPa – Tires should be replaced, by an
2-UP
(7 PSI) (7 PSI) experienced person, in accor-
dance with tire industry stan-
On 1-UP models, NEVER exceed dards and tools.
90 km/h (55 MPH) if total load is more
than 164 kg (360 lb) Wheel Removal
On 2-UP models, NEVER exceed Place vehicle on a level surface.
90 km/h (55 MPH) if total load is more Apply the parking brake.
than 132 kg (290 lb)
Loosen lug nuts then lift vehicle.
On 2-UP models, NEVER exceed 90
km/h with a passenger. Secure vehicle on jack stands.
Remove nuts then remove wheel.
Although the tires are specifically de-
signed for off-road use, a flat may still Wheel Installation
occur. Therefore, it is recommended
to carry a tire pump and a repair kit. At installation, it is recommended to
apply anti-seize lubricant on threads.
Tire Inspection If tires are unidirectional, make sure to
Check tire for damage and wear. Re- install wheel according to tire rotation.
place if necessary. Carefully tighten nuts in a criss-cross
Do not rotate tires. The front and rear sequence then apply final torque.
tires have a different size. The tires are TORQUE
directional and their rotation must be
kept in a specific direction for proper 100 N•m ± 10 N•m
Wheel nut
operation. (74 lbf•ft ± 7 lbf•ft)
Tire Replacement NOTICE Always use the recom-

Tires replacement should be per- mended wheel nuts according to the
formed by an authorized Can-Am type of wheel. Using a different nut
dealer. could cause damage to the rim or
studs.
______________ 135
Suspension Inspection
Shock Absorbers
Inspect shock absorber for oil leaks or
other damage.
Check tightness of fasteners.
See an authorized Can-Am dealer as
necessary.
Ball Joints
Inspect ball joint boots for cracks.
vmo2008-001-002_a
TYPICAL — ALUMINUM WHEEL

1. Wheel nut (closed end type) WARNING
The ball joint must be replaced if
Steering the boot is cracked.
Steering Inspection Front A-Arms

Tie-Rods Check A-arms for cracks, bending or
other damage.
Inspect tie-rod boots for cracks.
See an authorized Can-Am dealer as
necessary.
WARNING
The tie-rod must be replaced if the Rear Trailing Arms
boot is cracked. Check trailing arms for distortion,
cracks or bending.
Suspension See an authorized Can-Am dealer if any
problem is detected.
Front Suspension Lubrication
Lubricate front A-arms at grease fit- Brakes
tings.
Brake Fluid Reservoir Level
SUSPENSION GREASE Verification
BRP SUSPENSION With vehicle on a level surface, check
recommended GREASE brake fluid in reservoirs for proper
product (P/N 293 550 033) level.
NOTE: A low level may indicate leaks
Rear Suspension Lubrication or worn brake pads.
Lubricate rear stabilizer bar links and Front Brake Reservoir
pivot bushing at grease fittings.
Turn steering in the straight-ahead po-
SUSPENSION GREASE sition to ensure reservoir is level.
Check the brake fluid level, the reser-
BRP SUSPENSION
voir is full when the fluid reaches of the
recommended GREASE
top of window.
product (P/N 293 550 033)
Visually inspect lever boot condition.
136 ______________
Check for cracks, tears, etc. Replace if NOTICE Brake fluid can damage
damaged. plastic and painted surface. Wipe
off and clean any spillage.
Reinstall reservoir cap and tighten
screws.
NOTE: Ensure filler cap diaphragm is
pushed inside the cap before closing
the brake fluid reservoir.
Recommended Brake Fluid

Always use brake fluid meeting the
specification DOT 4 only.
vmo2012-012-046_a WARNING
TYPICAL To avoid damage to the braking
system, do not use other brake
Rear Brake Reservoir fluid types.
Remove the seat.
With vehicle on a level surface, liquid Brake Inspection
should be between MIN. and MAX.
level marks of brake pedal fluid reser- CAUTION The brakes can be
voir. very hot after prolonged use of the
vehicle and can cause burns. Wait
for the brakes to cool down.
The brake inspection, maintenance
and repair should be performed by an
authorized Can-Am dealer.
However, verify the following between
visits to your dealer:
– Brake fluid level
– Brake system for fluid leaks
vmo2015-005-026_b
– Brake cleanliness.
1. Rear brake fluid reservoir
Adding Brake FLuid

WARNING
The brake fluid replacement or
Clean filler cap. brake system maintenance and
repairs should be performed by an
WARNING authorized Can-Am dealer.
Clean filler cap before removing.
Remove screws retaining the reservoir

cap.
Remove reservoir cap.
Add fluid as required using a clean fun-
nel. Do not overfill.
______________ 137
VEHICLE CARE
Post-Operation Care Non Compatible Cleaning Products
When vehicle is used in salt-water en- NON-COMPATIBLE
vironment (beach area, launching and MATERIAL
CLEANING
loading boats etc.), rinsing the vehi- TYPE
PRODUCTS
cle with fresh water is necessary to
preserve vehicle and its components. ANY PETROLEUM
Metallic parts lubrication is highly rec- BASE CLEANING
ommended. Use XPS LUBE (P/N 293 PRODUCTS
600 016) or an equivalent. This must
be performed at the end of each oper- XP-S ATV
ating day. Finishing Spray
Polypropylene (P/N 219 701 704)
When vehicle is operated in muddy
conditions, rinsing the vehicle is rec- XP-S ATV Cleaning
ommended to preserve vehicle and its Kit (P/N 219 701 713)
components and to keep lights clean. (it contains the above
XP-S ATV Finishing
Vehicle Cleaning and Spray)
Protection
NOTICE Never use a high pres-
sure washer to clean the vehicle.
USE LOW PRESSURE ONLY (like a
garden hose).
Pay attention to certain areas where
mud or debris can accumulate and po-
tentially cause wear, interferences or
promote corrosion.
Wash the vehicle with a soapy water
solution.
NOTICE Never clean polypropy-
lene body parts with any petroleum
vbs2012-006-002_a
base cleaning products, as it will al-
ter the glossy finish. DO NOT USE ON POLYPROPYLENE
138 ______________
VEHICLE CARE
Compatible Cleaning Products

MATERIAL COMPATIBLE
TYPE CLEANING PRODUCT
XPS ATV Wash
Polypropylene (P/N 219 701 702)
Soapy water
vbs2012-006-001
SAFE FOR POLYPROPYLENE
______________ 139
STORAGE AND PRESEASON PREPARATION
When a vehicle is not in use for more
than (4) months, proper storage is a ne-
cessity.
When using your vehicle after storage,
a preparation is required.
See an authorized Can-Am dealer, re-
pair shop or person of your own choos-
ing to have your vehicle prepared for
either storage or the preseason.
140 ______________
TECHNICAL
INFORMATION
______________ 141
VEHICLE IDENTIFICATION
The main components of your vehicle MFD. DATE FAB: 12/2003 1234 2
(engine and frame) are identified using VIN / NIV: 2BPS1234X2V000123 1
different serial numbers. It may some- MANUFACTURED BY / FABRIQUÉ PAR :
times become necessary to locate
MADE IN/FABRIQUÉ AU: MEXICO / MEXIQUE
these numbers for warranty purposes TYPE: ATV / VTT 704903901
or to trace your vehicle in the event of 704903901_a
loss. These numbers are also required
LABEL 2
by the authorized Can-Am dealer to 1. VIN (Vehicle Identification Number)
complete warranty claims properly. 2. Model
We strongly recommend that you take
note of all the serial numbers on your Engine Identification
vehicle and supply them to your insur-
ance company. Number (EIN)
Vehicle Identification
Number
vmr2015-005-001_a
vmo2014-020-004_a
TYPICAL BACK OF 450 ENGINE

1. Label 1 (on the frame under the seat in the 1. EIN (Engine Identification Number)
middle)
2. Label 2 (stamped onto frame behind RH
front wheel)
MFD. DATE FAB: 12/2003 1234 2

704 903 974
EN 15997
VIN / NIV: 2BPS1234X2V000123 1
Representative:
BRP Europe N.V.,
Skaldenstraat 125, TYPE:
Ghent, Belgium, 9042. ATV / VTT
704903974_a
LABEL 1
2. Model number
vmr2015-005-002_a
RH SIDE OF 570 ENGINE

142 ______________
NOISE EMISSION CONTROL SYSTEM REGULATION
(CANADA/UNITED STATES)
Tampering with Noise Control Sys-
tem Is Prohibited!
U.S. Federal law and Canadian provin-
cial laws may prohibit the following
acts or the causing there of:
1. The removal or rendering inoper-
ative by any person other than for
purposes of maintenance, repair or
replacement of any device or ele-
ment of design incorporated into
any new vehicle for the purpose of
noise control prior to its sale or de-
livery to the ultimate purchaser or
while it is in use or
2. The use of the vehicle after such
device or element of design has
been removed or rendered inoper-
ative by any person.
Among those Acts Presumed to
Constitute Tampering Are the Acts
Listed Below:
1. Removal or alteration or the punc-
turing of the muffler or any engine
component which conducts re-
moval of engine exhaust gases.
2. Removal or alteration or the punc-
turing of any part of the intake sys-
tem.
3. Replacing any moving parts of the
vehicle or parts of the exhaust or in-
take system, with parts other than
those specified by the manufac-
turer.
4. Lack of proper maintenance.
______________ 143
NOISE EMISSION AND VIBRATION VALUES (ALL
COUNTRIES EXCEPT CANADA/UNITED STATES)
MODEL 450 570
NOISE EMISSION AND VIBRATION VALUES1
83 dB @ 3600 RPM 81 dB @ 4000 RPM
Sound pressure (LpA) (Uncertainty (KpA) (Uncertainty (KWA)
3dB) 3dB)
Noise
95 dB @ 3600 RPM 96 dB @ 4000 RPM
Sound power level
(Uncertainty (KWA) (Uncertainty (KWA)
(LWA)
3dB) 3dB)
<2.5 m/s2 @ 3600 <2.5 m/s2 @ 4000
Hand-arm system
RPM RPM
Vibration
<0.5 m/s2 @ 3600 <0.5 m/s2 @ 4000
Whole body at seat
RPM RPM
1: Noise emission and Vibration values are measured in accordance with Standard EN 15997:2011 on
a paved surface, at Neutral.
144 ______________
The EC-Declaration of Conformity does not appear in this version of the
Operator's Guide.
Please refer to the printed version that was delivered with your vehicle.
ddd2009-001 EN
SPECIFICATIONS
450 Models
ENGINE 450
ROTAX 450, 4-stroke, Single Over Head
Engine type
Camshaft (SOHC), liquid cooled
Number of cylinder 1
Number of valves 4 valves (mechanical adjustment)
0.06 mm to 0.14 mm
Intake
(.0024 in to .0055 in)
Valve clearance
0.11 mm to 0.19 mm
Exhaust
(.0043 in to .0075 in)
Bore 94 mm (3.7 in)
Displacement 426.8 cm³ (26.04 in³)

Spark arrester approved by USDA
Exhaust system
Forest Service
Engine air filter Synthetic paper filter with foam
LUBRICATION SYSTEM 450

Type Wet sump with replaceable oil filter
Capacity 3 L (3.2 qt (U.S. liq.))
(oil change with filter) (engine/transmission)
For the summer season, use XPS 4-stroke
Lubrication
synth. blend oil (P/N 293 600 121).
Engine oil For all seasons, use XPS 4-stroke
synthetic oil (P/N 293 600 112).
Recommended
If not available, use a 4-stroke
SAE 5W 40 engine oil that meets
the requirements for API service
classification SJ, SL, SM or SN
146 ______________
SPECIFICATIONS
COOLING SYSTEM 450

Finland,
Norway Use Long life antifreeze (P/N 619
and 590 204)
Sweden
All other Use Long life antifreeze (P/N 219
Type
Coolant countries 702 685)
Alternative,
or if not
Ethyl glycol/distilled water
available
mix (50%/50%).
Capacity 2.9 L (3.1 qt (U.S. liq.))
TRANSMISSION 450
Type
Transmission)
GEARBOX 450
Type
neutral and reverse
ELECTRICAL SYSTEM 450

Without
400 W @ 6000 RPM
Magneto generator output DPS
Quantity 1
Make and
NGK LMAR8D-J or equivalent
Spark plug type
0.7 mm to 0.9 mm
Gap
(.028 in to .035 in)
Forward 8000 RPM
______________ 147
SPECIFICATIONS

Voltage 12 Vdc
Nominal
Battery 18 A•h
rating
Power
starter 0.7 KW
output
High HS1 35 W
Headlights
Low HS1 35 W
Taillights P21/5W
Refer to FUSES in the
Fuses
MAINTENANCE section
FUEL SYSTEM 450

Electronic Fuel Injection (EFI), 46
Fuel delivery Type mm throttle body, 1 injector
per cylinder
Fuel pump Type Electrical (in fuel tank)
Idle speed 1250 RPM (not adjustable)
Inside
North 87 (R+M)/2 or higher
Fuel Minimum America
octane
rating Outside
North 92 RON or higher
America
148 ______________
SPECIFICATIONS
DRIVE SYSTEM 450

Drive system type Selectable 2WD/4WD
Front 500 ml (17 U.S. oz)
Capacity
Rear 250 ml (8.5 U.S. oz)
XPS synthetic gear oil
Front differential oil/ Front (75W 90) (P/N 93 600 043)
rear final drive oil OR synthetic oil 75W 90 API GL5)
Type XPS synthetic gear oil (75W
140) (P/N 293 600 140)
Rear
or a 75W140 API GL-5 synthetic
gear oil
Straight gear Visco-Lok†
Base
auto-locking front differential
Front drive
All models except Straight gear Visco-lok† QE
Base auto-locking front differential
Rear drive Bevel Straight gear / final drive
Castrol CV joint grease (P/N 293
CV joint grease
550 062)
Propeller shaft grease (P/N 293
Propeller shaft grease
550 063)
STEERING 450
1-UP 205.7 cm (81 in)
Turning radius
2-UP 233.7 cm (92 in)
Total toe (vehicle on ground) 2.5 mm ± 12.7 mm (.1 in ± .5 in)
Camber angle (vehicle on ground) 0°
FRONT SUSPENSION 450

Double A-arm with dive-control
Suspension type
geometry
Suspension travel 229 mm (9 in)
Quantity 2
Shock absorber
Type Oil
Preload adjustment type 5 positions cam
______________ 149
SPECIFICATIONS
REAR SUSPENSION 450

Trailing arm Independant (TTI)
Suspension type
with external stabilizer bar
Suspension travel 220 mm (8.8 in)
Quantity 2
Shock absorber
Type Oil
BRAKES 450
Dual 214 mm cross drilled
Front brakes Type disc brakes with hydraulic
twin-piston calipers
Single 214 mm cross drilled
Rear brake Type disc brake with hydraulic
twin-piston caliper
Brake fluid
Type DOT 4
Minimum brake disc thickness 4.0 mm (.157 in)
TIRES 450
1-UP 48.3 kPa (7 PSI)
Front
2-UP 48.3 kPa (7 PSI)
Pressure
1-UP 48.3 kPa (7 PSI)
Rear
2-UP 48.3 kPa (7 PSI)
Front 635 x 203 x 305 mm (25 x 8 x 12 in)
Standard
Rear 635 x 254 x 305 mm (25 x 10 x 12 in)
Tire size
Front 660 x 203 x 305 mm (26 x 8 x 12 in)
Pro
Rear 660 x 254 x 305 mm (26 x 10 x 12 in)
150 ______________
SPECIFICATIONS
WHEELS 450
Base Steel
Type All except base
Cast Aluminum
model
Front 305 x 152 mm (12 x 6 in)
Rim size
Rear 305 x 191 mm (12 x 7.5 in)
Wheel nut torque 100 N•m (74 lbf•ft)
DIMENSIONS 450
1-UP 211 cm (83 in)
Overall length
2-UP 231 cm (91 in)
1-UP 124 cm (49 in)
Overall height
2-UP 133 cm (52.5 in)
1-UP 129.5 cm (51 in)
Wheelbase
2-UP 149.9 cm (59 in)
Front 97.4 cm (38 in)
Wheel track
Rear 92.3 cm (36 in)
All models
26.7 cm (10.5 in)
Ground clearance except Pro
Pro 29.2 cm (11.5 in)
LOADING CAPACITY AND WEIGHT 450

1-UP 308 kg (678 lb)
Dry weight
2-UP 324 kg (715 lb)
Front rack capacity 54 kg (120 lb)
Rear rack capacity 109 kg (240 lb)
Rear storage compartment loading capacity 10 kg (22 lb)
Total vehicle load allowed (including driver, all 1-UP 235 kg (517 lb)
other loads and added accessories) 2-UP 272 kg (600 lb)
Towing capacity 590 kg (1,300 lb)
Tongue capacity 23 kg (50 lb)
______________ 151
SPECIFICATIONS
570 Models
ENGINE 570
ROTAX® 570, 4-stroke, 2 cylinders
Engine type
(V-twin), liquid cooled
4 valves/cylinder (mechanical
Valve train adjustment), single over head
camshaft (SOHC) with timing chain
0.06 mm to 0.14 mm
Intake
(.0024 in to .0055 in)
Valve clearance
0.11 mm to 0.19 mm
Exhaust
(.0043 in to .0075 in)
Bore 84 mm (3.31 in)
Displacement 570 cm³ (34.8 in³)
Spark arrestor approved by
Exhaust system
USDA Forest Service
Air filter Synthetic paper filter with foam
LUBRICATION SYSTEM 570
Wet sump. Replaceable

Type
cartridge oil filter
Capacity (oil change with
2.0 L (2.1 qt (U.S. liq.))
filter)
For the summer season,
use XPS 4-stroke synth.
blend oil (P/N 293 600 121).
Engine oil For all seasons, use XPS 4-stroke
Recommended synthetic oil(P/N 293 600 112).
If not available, use a 5W40 motor
oil that meets the requirements
for API service classification
SJ, SL, SM or SN
152 ______________
SPECIFICATIONS
COOLING SYSTEM 570

Finland,
Norway Use Long life antifreeze (P/N 619
and 590 204)
Sweden
All other Use long life antifreeze (P/N 219
Type
Coolant countries 702 685)
Alternative,
or if not
Ethyl glycol/distilled water
available
mix (50%/50%).
Capacity 3.4 L (.9 U.S. gal.)
TRANSMISSION 570
Type
Transmission)
GEARBOX 570
Type
neutral and reverse
Gearbox oil XPS synthetic gear oil (75W 140)

Recommended (P/N 293 600 140) or a 75W140
API GL-5 synthetic gear oil

Without
400 W @ 6000 RPM
Magneto generator output DPS
Quantity 2
Make and
NGK DCPR8E or equivalent
Spark plug type
0.7 mm to 0.8 mm
Gap
(.028 in to .031 in)
Forward 8000 RPM
______________ 153
SPECIFICATIONS

Voltage 12 Vdc
Nominal
Battery 18 A•h
rating
Power
starter 0.7 KW
output
High HS1 35 W
Headlights
Low HS1 35 W
Taillights P21/5W
Refer to FUSES in the
Fuses
MAINTENANCE section
FUEL SYSTEM 570

Electronic Fuel Injection (EFI), 46
Fuel delivery Type mm throttle body, 1 injector
per cylinder
Fuel pump Type Electrical (in fuel tank)
Idle speed 1400 RPM (not adjustable)
Inside
North 87 (R+M)/2 or higher
Fuel Minimum America
octane
rating Outside
North 92 RON or higher
America
154 ______________
SPECIFICATIONS
DRIVE SYSTEM 570

Drive system type Selectable 2WD/4WD
Front 500 ml (17 U.S. oz)
Capacity
Rear 250 ml (8.5 U.S. oz)
XPS synthetic gear oil (75W
Front differential oil/ Front 90) (P/N 293 600 043)
rear final drive oil OR synthetic oil 75W 90 API GL5)
Type XPS synthetic gear oil (75W
140) (P/N 293 600 140)
Rear
or a 75W140 API GL-5
synthetic gear oil
Straight gear Visco-Lok†
Base
auto-locking front differential
Front drive
All models except Straight gear Visco-lok† QE
Base auto-locking front differential
Rear drive Bevel straight gear / final drive
Castrol CV joint grease (P/N 293
CV joint grease
550 062)
Propeller shaft grease(P/N 293
Propeller shaft grease
550 063)
STEERING 570
1-UP 212 cm (83 in)
Turning radius
2-UP 239 cm (94 in)
Total toe (vehicle on ground) 2.5 mm ± 12.7 mm (.1 in ± .5 in)
Camber angle (vehicle on ground) 0°
FRONT SUSPENSION 570

Double A-arm with dive-control
Suspension type
geometry
Suspension travel 229 mm (9 in)
Quantity 2
Shock absorber
Type Oil
______________ 155
SPECIFICATIONS
REAR SUSPENSION 570

Trailing arm Independant (TTI) with
Suspension type
external stabilizer bar
Suspension travel 220 mm (8.8 in)
Quantity 2
Shock absorber
Type Oil
BRAKES 570
Dual 214 mm cross drilled
Front brakes Type disc brakes with hydraulic
twin-piston calipers
Single 214 mm cross drilled
Rear brake Type disc brake with hydraulic
twin-piston caliper
Brake fluid
Type DOT 4
Minimum brake disc thickness 4.0 mm (.157 in)
TIRES 570
1-UP 48.3 kPa (7 PSI)
Front
2-UP 48.3 kPa (7 PSI)
Pressure
1-UP 48.3 kPa (7 PSI)
Rear
2-UP 48.3 kPa (7 PSI)
Front 635 x 203 x 305 mm (25 x 8 x 12 in)
Base
XT 635 x 254 x 305 mm (25 x
Rear
10 x 12 in)
Tire size
Mossy Oak† Front 660 x 203 x 305 mm (26 x 8 x 12 in)
Hunting
Edition 660 x 254 x 305 mm (26 x
Rear
Pro 10 x 12 in)
156 ______________
SPECIFICATIONS
WHEELS 570
Base Steel
Type All except base
Cast Aluminum
model
Front 305 x 152 mm (12 x 6 in)
Rim size
Rear 305 x 191 mm (12 x 7.5 in)
Wheel nut torque 100 N•m (74 lbf•ft)
DIMENSIONS 570
1-UP 211 cm (83 in)
Overall length
2-UP 231 cm (91 in)
1-UP 124 cm (49 in)
Overall height
2-UP 133 cm (52.5 in)
1-UP 129.5 cm (51 in)
Wheelbase
2-UP 149.9 cm (59 in)
Front 97.4 cm (38 in)
Wheel track
Rear 92.3 cm (36 in)
All models
except
Mossy Oak
26.7 cm (10.5 in)
Hunting
Edition and
Ground clearance Pro
Mossy Oak
Hunting
29.2 cm (11.5 in)
Edition
Pro

1-UP 319 kg (704 lb)
Dry weight
2-UP 336 kg (741 lb)
Front rack capacity 54 kg (120 lb)
Rear rack capacity 109 kg (240 lb)
Rear storage compartment loading capacity 10 kg (22 lb)
______________ 157
SPECIFICATIONS
Total vehicle load allowed (including driver, all 1-UP 235 kg (517 lb)
other loads and added accessories) 2-UP 272 kg (600 lb)
Towing capacity 590 kg (1,300 lb)
Tongue capacity 23 kg (50 lb)
158 ______________
TROUBLESHOOTING
______________ 159
TROUBLESHOOTING GUIDELINES
ENGINE DOES NOT TURN

1. Ignition switch is in the OFF position.
– Place switch to the ON position.
2. Emergency engine stop switch.
– Make sure that emergency engine stop switch is in ON position.
3. Transmission is not set on PARK or NEUTRAL.
– Set transmission either in PARK or in NEUTRAL or press the brake lever.
4. Burnt fuse.
– Check main, ignition or ECM fuse condition.
5. Weak battery or loose connections.
– Check charging system.
– Check connections and terminals condition.
– Have the battery checked.
– Contact an authorized Can-Am dealer.
6. Weak starter or loose connections.
– Check starter connections.
– Check starter relay.
ENGINE TURNS OVER BUT FAILS TO START

1. Flooded engine (spark plug wet when removed).
– (Drowned mode) If the engine does not start and it is fuel-flooded, this
special mode can be activated to prevent fuel injection and to cut ignition
while cranking. Proceed as follows:
• Insert key in ignition switch and turn to ON position.
• Move shift lever in park position.
• Press completely and HOLD throttle lever.
• Press the engine START button.
The engine should be cranked for 20 seconds. Release engine START but-
ton.
Release throttle lever and start/crank engine again to allow starting.
If it does not work:
• Clean the spark plug caps area then remove them.
• Remove the spark plugs.
• Unplug injector electrical connector.
• Crank engine several times.
• Install new spark plugs if possible or clean and dry spark plugs.
• Start engine as explained above.
If engine continues to flood, seek service from an authorized Can-Am dealer,
repair shop or person of your own choosing for maintenance, repair or
replacement. Please refer to the US EPA Emissions-related warranty con-
tained herein for information about warranty claims.
NOTE: Make sure to verify that there is no fuel in engine oil, if so, replace
engine oil.
160 ______________
ENGINE TURNS OVER BUT FAILS TO START (cont’d)

2. No fuel to the engine (spark plug dry when removed).
– Check fuel tank level.
– A failure of the fuel pump may have occurred.
– Check fuel pump fuse and relay.
– Seek service from an authorized Can-Am dealer, repair shop or person of your
own choosing for maintenance, repair or replacement. Please refer to the US
EPA Emissions-related warranty contained herein for information about war-
ranty claims.
3. Spark plug/ignition (no spark).
– Remove spark plug then reconnect to ignition coil.
– Start engine with spark plug grounded to the engine away from spark plug
hole. If no spark appears, replace spark plug.
– If trouble persists, seek service from an authorized Can-Am dealer, repair
shop or person of your own choosing for maintenance, repair or replace-
ment. Please refer to the US EPA Emissions-related warranty contained
herein for information about warranty claims.
4. Multifunction gauge CHECK ENGINE indicator lamp is on and display
shows CHECK ENGINE.
ranty claims.
5. Engine is under a protection (limp home) mode.
– Multifunction gauge CHECK ENGINE indicator lamp is on and display shows
CHECK ENGINE, seek service from an authorized Can-Am dealer, repair
shop or person of your own choosing for maintenance, repair or replace-
ment. Please refer to the US EPA Emissions-related warranty contained
herein for information about warranty claims..
ENGINE LACKS ACCELERATION OR POWER

1. Fouled or defective spark plug.
– Refer to ENGINE TURNS OVER BUT FAILS TO START.
2. Lack of fuel to engine.
– Refer to ENGINE TURNS OVER BUT FAILS TO START.
3. Engine is overheating. (CHECK ENGINE indicator light will turn on and HI
TEMP will appear in the multifunction display.)
– Refer to ENGINE OVERHEATS.
4. Air filter/housing clogged or dirty.
– Check air filter and clean if necessary.
– Check deposits in air filter housing drain.
– Check the position of the air intake tube.
5. CVT dirty or worn-out.
______________ 161
ENGINE LACKS ACCELERATION OR POWER (cont’d)

– Check multifunction gauge display for messages.
CHECK ENGINE or LIMP HOME, seek service from an authorized Can-Am
dealer, repair shop or person of your own choosing for maintenance, repair
or replacement. Please refer to the US EPA Emissions-related warranty
contained herein for information about warranty claims.
ENGINE OVERHEATS
1. Low coolant in cooling system.
– Check engine coolant, refer to ENGINE COOLANT in MAINTENANCE sec-
tion.
2. Dirty radiator fins.
– Clean radiator fins, refer to RADIATOR in MAINTENANCE section.
3. Cooling fan inoperative.
– Check cooling fan fuse or relay, refer to MAINTENANCE section. If the fuse
is good, seek service from an authorized Can-Am dealer, repair shop or per-
son of your own choosing for maintenance, repair or replacement. Please re-
fer to the US EPA Emissions-related warranty contained herein for informa-
tion about warranty claims..
ENGINE BACKFIRE
1. Exhaust system leakage.
ranty claims.
2. Engine is running too hot.
– Refer to ENGINE LACKS ACCELERATION OR POWER.
3. Ignition timing is incorrect or there is an ignition system failure.
ranty claims.
ENGINE MISFIRE
1. Fouled/defective/worn spark plug.
– Clean/verify spark plug and heat range. Replace as required.
2. Water in fuel.
– Drain fuel system and refill with fresh fuel.
VEHICLE CANNOT REACH FULL SPEED

1. Engine.
– Refer to ENGINE LACKS ACCELERATION OR POWER.
162 ______________
VEHICLE CANNOT REACH FULL SPEED (cont’d)

2. Parking Brake.
– Ensure parking brake is completely removed.
3. Air filter/housing plugged or dirty.
– Check air filter and clean if necessary.
– Check deposits in air filter housing drain.
– Check the position of the air intake tube.
– Check multifunction gauge display for messages.
CHECK ENGINE or LIMP HOME, seek service from an authorized Can-Am
dealer, repair shop or person of your own choosing for maintenance, repair
or replacement. Please refer to the US EPA Emissions-related warranty
contained herein for information about warranty claims.
SHIFT LEVER IS HARD TO MOVE

1. Transmission gears are in a position that prevents the shift lever to work.
– Rock the vehicle back and forth to move the gears in the transmission and al-
low the shift lever to be set.
THE RPM INCREASES BUT THE VEHICLE DOES NOT MOVE

1. The transmission is on PARK or NEUTRAL position.
– Select the R, HI or LO position.
3. Water in the CVT housing.
REDUCED POWER STEERING ASSIST

1. When DPS is subjected to sustained severe steering conditions, the assis-
tance provided by the DPS motor may be reduced to protect the system.
– Once the load is reduced, the normal steering assistance will return.
2. CHECK ENGINE INDICATOR LAMP is ON and display shows CHECK DPS
own choosing for maintenance, repair or replacement.
______________ 163
MULTIFUNCTION GAUGE MESSAGES
PILOT LAMP(S)
MESSAGE DESCRIPTION
ON
Displayed when brake is applied for more than 15 seconds
BRAKE None
(while riding).
Low battery voltage, check battery voltage and charging
LO BATT VOLT Check engine
system.
High battery voltage, check battery voltage and charging
HIGH BATT VOLT Check engine
system.
LOW OIL (1) Check engine Engine low oil pressure, stop engine immediately.
Engine is overheating, refer to ENGINE OVERHEATS in
HI TEMP Check engine
TROUBLESHOOTING section.
Serious fault on the engine that can change the normal
LIMP HOME Check engine operation of the engine, CHECK ENGINE indicator lamp
will also blink, refer to TROUBLESHOOTING section.
Engine fault, CHECK ENGINE indicator lamp will also be
CHECK ENGINE Check engine
ON, refer to TROUBLESHOOTING section.
Communication error between speedometer and engine
ECM NOT RECOGNIZED Check engine
control module (ECM).
CHECK DPS (models Indicates that the DPS (Dynamic Power Steering) does not
Check engine
with DPS) work properly. See an authorized Can-Am dealer.
MAINTENANCE
None Displayed in gauge when vehicle is due for a maintenance.
REQUIRED (2)
Throttle position sensor does not work properly. Seek
service from an authorized Can-Am dealer, repair shop or
TPS FAULT PRESS
person of your own choosing for maintenance, repair or
OVERRIDE BUTTON TO Check engine
replacement. Please refer to the US EPA Emissions-related
LIMP HOME
warranty contained herein for information about warranty
claims.
NOTICE (1) If the message and the check engine light stay on after engine
starting, stop engine. Check engine oil level. Refill if necessary. If the oil
level is good, seek service from an authorized Can-Am dealer, repair shop
or person of your own choosing for maintenance, repair or replacement.
Please refer to the US EPA Emissions-related warranty contained herein for
information about warranty claims. . Do not use the vehicle until repaired.
(2) To
erase the MAINTENANCE REQUIRED message, proceed as follows:
1. From main display (vehicle speed), press SET and HOLD.
2. Alternate between LOW beam and HIGH beam 3 times.
NOTE: Step 2 must be completed within 2 seconds.
3. Release SET button.
164 ______________
WARRANTY
______________ 165
BRP LIMITED WARRANTY USA AND CANADA: 2017
CAN-AM® ATV
SCOPE OF THE LIMITED WARRANTY
Bombardier Recreational Products Inc. ("BRP")* warrants its 2017 Can-Am ATV
sold by authorized Can-Am ATV dealers (as hereinafter defined) in the United
States of America ("USA") and in Canada from defects in material or workmanship
for the period and under the conditions described below. This limited warranty will
become null and void if: (1) the ATV was used for racing or any other competitive
activity, at any point, even by a previous owner; or (2) the ATV has been altered
or modified in such a way so as to adversely affect its operation, performance or
durability, or has been altered or modified to change its intended use.
Non-factory installed parts and accessories are not covered under this limited war-
ranty. Please refer to the applicable parts and accessories limited warranty text.
LIMITATIONS OF LIABILITY
THIS WARRANTY IS EXPRESSLY GIVEN AND ACCEPTED IN LIEU OF ANY
AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING
WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FIT-
NESS FOR A PARTICULAR PURPOSE TO THE EXTENT THAT THEY CANNOT
BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION
TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSE-
QUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS
WARRANTY SOME STATES/PROVINCES DO NOT ALLOW FOR THE DIS-
CLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A
RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU
SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS
WHICH MAY VARY FROM STATE TO STATE, OR PROVINCE TO PROVINCE.
Neither the distributor, any BRP dealer nor any other person has been authorized
to make any affirmation, representation or warranty regarding the product, other
than those contained in this limited warranty, and if made, shall not be enforceable
against BRP. BRP reserves the right to modify this limited warranty at any time, be-
ing understood that such modification will not alter the warranty conditions appli-
cable to the products sold while this warranty is in effect.
EXCLUSIONS – ARE NOT WARRANTED

The following are not warranted under any circumstances:
– Normal wear and tear;
– Routine maintenance items, tune ups, adjustments;
– Damage caused by failure to provide proper maintenance and/or storage, as de-
scribed in the Operator's Guide;
– Damage resulting from removal of parts, improper repairs, service, mainte-
nance, modifications or use of parts not manufactured or approved by BRP
or resulting from repairs done by a person that is not an authorized servicing
Can-Am ATV dealer;
– Damage caused by abuse, abnormal use, neglect or operation of the product
in a manner inconsistent with the recommended operation described in the
Can-Am ATV Operator’s Guide;
– Damage resulting from accident, submersion, fire, theft, vandalism or any act of
God;
166 ______________
– Operation with fuels, oils or lubricants which are not suitable for use with the
product (see the Operator’s Guide);
– Damages from rust, corrosion or exposure to the elements;
– Damage resulting from water or snow ingestion;
– Incidental or consequential damages, or damages of any kind including without
limitation towing, storage, telephone, rental, taxi, inconvenience, insurance
coverage, loan payments, loss of time, loss of income.
WARRANTY COVERAGE PERIOD

This limited warranty will be in effect from (1) the date of delivery to the first retail
consumer or (2) the date the product is first put into use, whichever occurs first and
for the applicable period below:
SIX (6) CONSECUTIVE MONTHS, for private use or commercial use owners. For
emission-related components; please also refer to the US EPA EMISSION-RE-
LATED WARRANTY contained herein.
The repair or replacement of parts or the performance of service under this war-
ranty does not extend the life of this warranty beyond its original expiration date.
CONDITIONS TO HAVE WARRANTY COVERAGE

This warranty coverage is available only if each of the following conditions has
been fulfilled:
– The 2017 Can-Am ATV must be purchased as new and unused by its first owner
from a Can-Am ATV dealer authorized to distribute Can-Am ATVs in the country
in which the sale occurred (“Can-Am ATV dealer”);
– The BRP specified pre-delivery inspection process must be completed and doc-
umented and signed by the purchaser;
– The 2017 Can-Am ATV must have undergone proper registration by an autho-
rized Can-Am ATV dealer;
– The 2017 Can-Am ATV must be purchased in the country in which the purchaser
resides;
– Routine maintenance outlined in the Operator’s Guide must be timely per-
formed in order to maintain warranty coverage. BRP reserves the right to make
warranty coverage contingent upon proof of proper maintenance.
BRP will not honor this limited warranty to any private use owner or commercial
use owner if one of the preceding conditions has not been met. Such limitations
are necessary in order to allow BRP to preserve both the safety of its products,
and also that of its consumers and the general public.
WHAT TO DO TO OBTAIN WARRANTY COVERAGE

The customer must cease using the Can-Am ATV upon the appearance of an anom-
aly. The customer must notify a servicing BRP dealer within three (3) days of the
appearance of a defect, and provide it with reasonable access to the product and
reasonable opportunity to repair it. The customer must also present to the autho-
rized BRP dealer, proof of purchase of the product and must sign the repair/work
order prior to starting the repair in order to validate the warranty repair. All parts re-
placed under this limited warranty become the property of BRP.
______________ 167
WHAT BRP WILL DO
BRP’s obligations under this warranty are limited to, at its sole discretion, repairing
parts found defective under normal use, maintenance and service, or replacing
such parts with new genuine Can-Am ATV parts without charge for parts and
labor, at any authorized BRP dealer during the warranty coverage period under the
conditions described herein. No claim of breach of warranty shall be cause for
cancellation or rescission of the sale of the Can-Am ATV to the owner.
In the event that service is required outside of the country of original sale, the
owner will bear responsibility for any additional charges due to local practices
and conditions, such as, but not limited to, freight, insurance, taxes, license fees,
import duties, and any and all other financial charges, including those levied by
governments, states, territories and their respective agencies.
BRP reserves the right to improve or modify products from time to time without as-
suming any obligation to modify products previously manufactured.
ADDITIONAL SUPPLIER WARRANTIES

A GPS receiver may be supplied by BRP as standard equipment on certain 2017
Can-Am ATV's. The GPS receiver is covered under BRP’s limited warranty policy.
Additional warranty coverage if offered by the GPS receiver “supplier” that is
longer than BRP's limited warranty is to be dealt by the dealer or consumer directly
with the GPS receiver “supplier”.
TRANSFER
If the ownership of a product is transferred during the warranty coverage period,
this limited warranty, subject to its terms and conditions, shall also be transferred
and be valid for the remaining coverage period provided BRP or an authorized
Can-Am ATV Distributor/Dealer receives a proof that the former owner agreed to
the transfer of ownership, in addition to the co-ordinates of the new owner.
CONSUMER ASSISTANCE
In the event of a controversy or a dispute in connection with this limited warranty,
BRP suggests that you try to resolve the issue at the dealership level. We recom-
mend discussing the issue with the authorized dealer's service manager or owner.
If the matter still remains unresolved, contact BRP by filling out the customer con-
tact form at www.brp.com or contact BRP by mail at one of the addresses listed
under the CONTACT US section of this guide.
* In the USA, products are distributed and serviced by BRP US Inc.

© 2016 Bombardier Recreational Products Inc. All rights reserved.
® Registered trademark of Bombardier Recreational Products Inc.
168 ______________
US EPA EMISSION-RELATED WARRANTY
Bombardier Recreational Products Inc. (“BRP”)* warrants to the ultimate pur-
chaser and each subsequent purchaser that this new vehicle, including all parts of
its exhaust emission control system and its evaporative emission control system,
meets two conditions:
1. It is designed, built, and equipped so it conforms at the time of sale to the ulti-
mate purchaser with the requirements of 40 CFR 1051 and 40 CFR 1060.
2. It is free from defects in materials and workmanship that may keep it from
meeting the requirements of 40 CFR 1051 and 40 CFR 1060.
Where a warrantable condition exists, BRP will repair or replace, as it elects, any
part or component with a defect in materials or workmanship that would increase
the engine’s emissions of any regulated pollutant within the stated warranty
period at no cost to the owner, including expenses related to diagnosing and
repairing or replacing emission-related parts. All defective parts replaced under
this warranty become the property of BRP.
For all emission-related warranty claims, BRP is limiting the diagnosis and repair of
emission-related parts to the authorized Can-Am dealers, unless for emergency re-
pairs as required by item 2 of the following list.
As a certifying manufacturer, BRP will not deny emission-related warranty claims
based on any of the following:
1. Maintenance or other service BRP or BRP's authorized facilities performed.
2. Engine/equipment repair work that an operator performed to correct an unsafe,
emergency condition attributable to BRP as long as the operator tries to restore
the engine/equipment to its proper configuration as soon as possible.
3. Any action or inaction by the operator unrelated to the warranty claim.
4. Maintenance that was performed more frequently than BRP specify.
5. Anything that is BRP fault or responsibility.
6. The use of any fuel that is commonly available where the equipment operates
unless BRP written maintenance instructions state that this fuel would harm
the equipment’s emission control system and operators can readily find the
proper fuel. See maintenance information section and fuel requirements of
fueling section.
Emission-Related Warranty Period

The emission-related warranty is valid for the following period whichever comes
first:
HOURS MONTHS KILOMETERS
Exhaust emission-related components 500 30 5000
Evaporative emission-related components N/A 24 N/A
______________ 169
Components Covered
The emission-related warranty covers all components whose failure would in-
crease an engine’s emissions of any regulated pollutant, including the following
listed components:
1. For exhaust emissions, emission-related components include any engine parts
related to the following systems:
– Air-induction system
– Fuel system
– Ignition system
– Exhaust gas recirculation systems
2. The following parts are also considered emission-related components for
exhaust emissions:
– Aftertreatment devices
– Crankcase ventilation valves
– Sensors
– Electronic control units
3. The following parts are considered emission-related components for evapora-
tive emissions:
– Fuel tank
– Fuel cap
– Fuel line
– Fuel line fittings
– Clamps*
– Pressure relief valves*
– Control valves*
– Control solenoids*
– Electronic controls*
– Vacuum control diaphragms*
– Control cables*
– Control linkages*
– Purge valves
– Vapor hoses
– Liquid/vapor separator
– Carbon canister
– Canister mounting brackets
– Carburetor purge port connector
4. Emission-related components also include any other part whose only purpose
is to reduce emissions or whose failure will increase emissions without signifi-
cantly degrading engine/equipment performance.
*As related to the evaporative emission control system
170 ______________
Limited Applicability
As a certifying manufacturer, BRP may deny emission-related warranty claims
for failures that have been caused by the owner’s or operator’s improper main-
tenance or use, by accidents for which the manufacturer has no responsibility,
or by acts of God. For example, an emission-related warranty claim need not be
honored for failures that have been directly caused by the operator’s abuse of the
engine/equipment or the operator’s use of the engine/equipment in a manner for
which it was not designed and are not attributable to the manufacturer in any way.
* In the USA, products are distributed and serviced by BRP US Inc.
______________ 171
BRP INTERNATIONAL LIMITED WARRANTY: 2017
CAN-AM® ATV
1) SCOPE OF THE LIMITED WARRANTY
Bombardier Recreational Products Inc. ("BRP")* warrants its 2017 Can-Am
ATV sold by Can-Am ATV distributors or dealers authorized by BRP to distribute
Can-Am ATVs ("Can-Am ATV Distributor/Dealer") outside of the United States
of America ("USA"), Canada, member states of the European Economic Area
(which is comprised of the states of the European Union plus Norway, Iceland
and Liechtenstein) ("EEA"), Turkey, member states of the Commonwealth of
the Independent States (including Ukraine and Turkmenistan) ("CIS") and Turkey,
from defects in material or workmanship for the period and under the conditions
described below.
This limited warranty will become null and void if: (1) The ATV was used for racing
or any other competitive activity, at any point, even by a previous owner; or (2)
the ATV has been altered or modified in such a way so as to adversely affect its
operation, performance or durability, or has been altered or modified to change its
intended use.
2) LIMITATIONS OF LIABILITY
TO THE EXTENT PERMITTED BY LAW, THIS WARRANTY IS EXPRESSLY
GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EX-
PRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TO THE
EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES
ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY.
INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM
COVERAGE UNDER THIS WARRANTY. SOME JURISDICTIONS DO NOT AL-
LOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED
ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY
GIVES YOU SPECIFIC RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY. (FOR PROD-
UCTS PURCHASED IN AUSTRALIA SEE CLAUSE 4 BELOW).
Neither the Can-Am ATV Distributor/Dealer nor any other person has been autho-
rized to make any affirmation, representation or warranty regarding the product,
other than those contained in this limited warranty, and if made, shall not be
enforceable against BRP.
BRP reserves the right to modify this warranty at any time, being understood that
such modification will not alter the warranty conditions applicable to the products
sold while this warranty is in effect.
3) EXCLUSIONS – ARE NOT WARRANTED

The following are not warranted under this limited warranty under any circum-
stances:
– Damage caused by negligence or failure to provide proper maintenance and/or
storage, as described in the Operator's Guide;
172 ______________
– Damage resulting from removal of parts, improper repairs, service, main-
tenance, modifications or use of parts or accessories not manufactured or
approved by BRP which in its reasonable judgement are either incompatible
with the product or adversely affect its operation, performance and durability,
Can-Am ATV Distributor/Dealer;
– Damage caused by abuse, abnormal use, neglect, racing or operation of the
product in a manner inconsistent with the recommended operation described
in the Operator’s Guide;
– Damage resulting from accident, submersion, fire, snow or water ingestion,
theft, vandalism or any act of God;
– Damage resulting from rust, corrosion or exposure to the elements;
limitation towing, storage, transportation expenses, telephone, rental, taxi, in-
convenience, insurance coverage, loan payments, loss of time, loss of income;
or time missed for downtime experience due to service work.
4) WARRANTY COVERAGE PERIOD

This warranty will be in effect from (1) the date of delivery to the first retail con-
sumer or (2) the date the product is first put into use, whichever occurs first and
for a period of:
SIX (6) CONSECUTIVE MONTHS for private use or commercial use.
Note that the duration and any other modalities of the warranty coverage are sub-
ject to the applicable national or local legislation in the customer's country.
FOR PRODUCTS SOLD IN AUSTRALIA ONLY

Nothing in these Warranty terms and conditions should be taken to exclude,
restrict or modify the application of any condition, warranty, guarantee, right or
remedy conferred or implied under the Competition and Consumer Act 2010
(Cth), including the Australian Consumer Law or any other law, where to do so
would contravene that law, or cause any part of these terms and conditions to be
void. The benefits given to you under this limited warranty are in addition to other
rights and remedies that you have under Australian law.
Our goods come with guarantees that cannot be excluded under the Australian
Consumer Law. You are entitled to a replacement or refund for a major failure
and for compensation for any other reasonably foreseeable loss or damage. You
are also entitled to have the goods repaired or replaced if the goods fail to be of
acceptable quality and the failure does not amount to a major failure.
______________ 173
5) CONDITIONS TO HAVE WARRANTY COVERAGE
been fulfilled:
from a Can-Am ATV Distributor/Dealer authorized to distribute Can-Am ATVs in
the country in which the sale occurred;
umented;
– The product must have undergone proper registration by an authorized Can-Am
ATV Distributor/Dealer;
– The 2017 Can-Am ATV must be purchased in the country or union of countries in
which the purchaser resides; and
BRP will not honour this limited warranty to any private use owner or commercial
are necessary in order to allow BRP to preserve both the safety of its products, and
also that of its consumers and the general public.
6) WHAT TO DO TO OBTAIN WARRANTY COVERAGE

The customer must cease using the ATV upon the appearance of an anomaly. The
customer must notify a servicing Can-Am ATV Distributor/Dealer within two (2)
days of the appearance of a defect, and provide it with reasonable access to the
product and reasonable opportunity to repair it. The customer must also present
to the authorized Can-Am ATV Distributor/Dealer proof of purchase of the product
and must sign the repair/work order prior to starting the repair in order to validate
the warranty repair. All parts replaced under this limited warranty become the
property of BRP.
Note that the notification period is subject to the applicable national or local legisla-
tion in customer's country.
7) WHAT BRP WILL DO

To the extent permitted by law, BRP’s obligations under this warranty are lim-
ited to, at its sole discretion, repairing parts found defective under normal use,
maintenance and service, or replacing such parts with new genuine Can-Am ATV
parts without charge for parts and labour, at any authorized Can-Am ATV Distrib-
utor/Dealer during the warranty coverage period under the conditions described
herein. BRP's responsibility is limited to making the required repairs or replace-
ments of parts. No claim of breach of warranty shall be cause for cancellation or
rescission of the sale of the Can-Am ATV to the owner. You may have other legal
rights which may vary from country to country.
In the event that service is required outside of the country of original sale, the
owner will bear responsibility for any additional charges due to local practices
and conditions, such as, but not limited to, freight, insurance, taxes, license fees,
174 ______________
8) TRANSFER
this warranty shall also be transferred and be valid for the remaining coverage pe-
riod provided BRP or an authorized Can-Am ATV Distributor/Dealer receives a proof
that the former owner agreed to the transfer of ownership, in addition to the co-or-
dinates of the new owner.
9) CONSUMER ASSISTANCE
In the event of a controversy or a dispute in connection with this limited warranty,
BRP suggests that you try to resolve the issue at the Can-Am ATV Distribu-
tor/Dealer level. We recommend discussing the issue with the authorized
Can-Am ATV Distributor/Dealer's service manager or owner.
If the matter still remains unresolved, contact BRP by filling out the customer con-
tact form at www.brp.com or contact BRP by mail at one of the addresses listed
under the CONTACT US section of this guide.
* For the territory covered by this limited warranty, products are distributed and serviced by
Bombardier Recreational Products Inc. or its affiliates.
© 2016 Bombardier Recreational Products Inc. All rights reserved.
® Registered trademark of Bombardier Recreational Products Inc.
______________ 175
BRP LIMITED WARRANTY FOR THE EUROPEAN
ECONOMIC AREA, THE COMMONWEALTH OF
THE INDEPENDENT STATES AND TURKEY: 2017
CAN-AM® ATV
1) SCOPE OF THE LIMITED WARRANTY
Bombardier Recreational Products Inc. ("BRP")* warrants its 2017 Can-Am ATVs
sold by distributors or dealers authorized by BRP to distribute Can-Am ATVs
("Can-Am ATV Distributor/Dealer") in member states of the European Economic
Area (which is comprised of the member states of the European Union plus Nor-
way, Iceland and Liechtenstein) ("EEA"), in member states of the Commonwealth
of the Independent States (including Ukraine and Turkmenistan) ("CIS") and Turkey
from defects in material or workmanship for the period and under the conditions
described below.
This limited warranty will become null and void if: (1) The ATV was used for racing
or any other competitive activity, at any point, even by a previous owner; or (2)
the ATV has been altered or modified in such a way so as to adversely affect its
operation, performance or durability, or has been altered or modified to change its
intended use.
2) LIMITATIONS OF LIABILITY
TO THE EXTENT PERMITTED BY LAW, THIS WARRANTY IS EXPRESSLY
GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EX-
PRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TO THE
EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES
ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY.
INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM
COVERAGE UNDER THIS WARRANTY. SOME JURISDICTIONS DO NOT AL-
LOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED
ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY
GIVES YOU SPECIFIC RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY.
Neither the Can-Am ATV Distributor/Dealer nor any other person has been autho-
rized to make any affirmation, representation or warranty regarding the product,
other than those contained in this limited warranty, and if made, shall not be
enforceable against BRP.
BRP reserves the right to modify this warranty at any time, being understood that
such modification will not alter the warranty conditions applicable to the products
sold while this warranty is in effect.
3) EXCLUSIONS – ARE NOT WARRANTED

The following are not warranted under this limited warranty under any circum-
stances:
176 ______________
– Damage caused by negligence or failure to provide proper maintenance and/or
storage, as described in the Operator's Guide;
– Damage resulting from removal of parts, improper repairs, service, main-
tenance, modifications or use of parts or accessories not manufactured or
approved by BRP which in its reasonable judgement are either incompatible
with the product or adversely affect its operation, performance and durability,
Can-Am ATV Distributor/Dealer;
– Damage caused by abuse, abnormal use, neglect, racing or operation of the
product in a manner inconsistent with the recommended operation described
in the Operator’s Guide;
– Damage resulting from accident, submersion, fire, snow or water ingestion,
theft, vandalism or any act of God;
– Damage resulting from rust, corrosion or exposure to the elements;
limitation towing, transportation expenses, storage, telephone, rental, taxi, in-
convenience, insurance coverage, loan payments, loss of time, loss of income
or time missed for downtime experience due to service work.
4) WARRANTY COVERAGE PERIOD

This warranty will be in effect from (1) the date of delivery to the first retail con-
sumer or (2) the date the product is first put into use, whichever occurs first and
for a period of:
TWENTY-FOUR (24) CONSECUTIVE MONTHS for private use.
SIX (6) CONSECUTIVE MONTHS for commercial use or rental use.
The product is used commercially when it is used in connection with any work or
employment that generates income during any part of the warranty period. The
product is also used commercially when, at any point during the warranty period,
it is licensed for commercial use.
Note that the duration and any other modalities of the warranty coverage are sub-
ject to the applicable national or local legislation in the customer's country.
5) CONDITIONS TO HAVE WARRANTY COVERAGE

been fulfilled:
from a Can-Am ATV Distributor/Dealer authorized to distribute Can-Am ATVs in
the country in which the sale occurred;
umented;
– The product must have undergone proper registration by an authorized Can-Am
ATV Distributor/Dealer;
______________ 177
– The 2017 Can-Am ATV must be purchased within the EEA by an EEA resident,
in the CIS for residents of the countries comprised in such area and in Turkey for
residents of Turkey; and
BRP will not honour this limited warranty to any private use owner or commercial
are necessary in order to allow BRP to preserve both the safety of its products, and
also that of its consumers and the general public.
6) WHAT TO DO TO OBTAIN WARRANTY COVERAGE

The customer must cease using the ATV upon the appearance of an anomaly. The
customer must notify a servicing Can-Am ATV Distributor/Dealer within two (2)
months of the appearance of a defect and provide it with reasonable access to the
product and reasonable opportunity to repair it. The customer must also present
to the authorized Can-Am ATV Distributor/Dealer, proof of purchase of the product
and must sign the repair/work order prior to starting the repair in order to validate
the warranty repair. All parts replaced under this limited warranty become the
property of BRP.
Note that the notification period is subject to the applicable national or local legisla-
tion in customer's country.
7) WHAT BRP WILL DO

To the extent permitted by law, BRP’s obligations under this warranty are lim-
ited to, at its sole discretion, repairing parts found defective under normal use,
maintenance and service, or replacing such parts with new genuine Can-Am ATV
parts without charge for parts and labour, at any authorized Can-Am ATV Distrib-
utor/Dealer during the warranty coverage period under the conditions described
herein. BRP's responsibility is limited to making the required repairs or replace-
ments of parts. No claim of breach of warranty shall be cause for cancellation or
rescission of the sale of the Can-Am ATV to the owner. You may have other legal
rights which may vary from country to country.
In the event that service is required outside of the EEA, CIS or Turkey, the owner
will bear responsibility for any additional charges due to local practices and
conditions, such as, but not limited to, freight, insurance, taxes, license fees,
8) TRANSFER
this warranty shall also be transferred and be valid for the remaining coverage pe-
riod provided BRP or an authorized Can-Am ATV Distributor/Dealer receives a proof
that the former owner agreed to the transfer of ownership, in addition to the co-or-
dinates of the new owner.
178 ______________
CUSTOMER
INFORMATION
This page is
intentionally blank
______________
CHANGE OF ADDRESS/OWNERSHIP
NOTES
NOTES
______________
NOTES
NOTES
______________
ATV MODEL No.
VEHICLE
IDENTIFICATION NUMBER (V.I.N.)
ENGINE
IDENTIFICATION NUMBER (E.I.N.)
Owner:
NAME
No. STREET APT
CITY STATE/PROVINCE ZIP/POSTAL CODE
Purchase Date
YEAR MONTH DAY
Warranty Expiry Date

YEAR MONTH DAY
To be completed by the dealer at the time of the sale.
DEALER IMPRINT AREA
V00A2IL
Please verify with your dealer to ensure your vehicle has been registered with BRP.
WARNING
injury or death.
THIS VEHICLE CAN BE HAZARDOUS TO OPERATE.
A collision or rollover can occur quickly, even during
routine maneuvers such as turning and driving on hills
or over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if

you do not follow these instructions:
• BEFORE YOU OPERATE THIS VEHICLE, READ THIS

OPERATOR’S GUIDE, ALL ON PRODUCT SAFETY
LABELS AND WATCH THE SAFETY VIDEO.
OUTLANDER Series / OUTLANDER MAX Series

2017
• NEVER OPERATE THIS VEHICLE WITHOUT
PROPER INSTRUCTIONS. Complete a certified
training course.
• DO NOT EXCEED VEHICLE SEATING CAPACITY
• FOR MAX MODELS, NEVER CARRY MORE THAN
ONE PASSENGER. You increase your risk of losing
control if you carry more than a passenger.
Operator’s
• FOR 1UP MODELS, NEVER CARRY A
PASSENGER. You increase your risk of losing control
Guide
if you carry a passenger.
• NEVER OPERATE THIS VEHICLE ON A PAVED
SURFACE. You increase your risk of losing control
if you operate this vehicle on pavement.
• NEVER OPERATE THIS VEHICLE ON PUBLIC
Includes
ROADS. You can collide with another vehicle if you Safety, Vehicle
operate this vehicle on a public road. and Maintenance Information
• OPERATOR AND PASSENGER (MAX models)
SHOULD ALWAYS WEAR AN APPROVED HELMET,
eye protection, and protective clothing.
• NEVER USE WITH DRUGS OR ALCOHOL.
They slow reaction time and impair judgment.
• NEVER OPERATE THIS VEHICLE AT EXCESSIVE
SPEEDS. You increase your risk of losing control if you
operate this vehicle at speeds too fast for the terrain,
visibility conditions, or your experience.
• NEVER ATTEMPT WHEELIES, JUMPS, OR OTHER
STUNTS.
OUTLANDER Series/ TM
OUTLANDER MAX Series

TM TM
2017
WARNING
Read this guide thoroughly. It contains important safety information.
Minimum recommended age: Operator: 16 years old. Keep this Operator’s Guide in the vehicle.
2 1 9 0 0 1 7 3 3 Original Instructions

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SAFETY NOTICE

CAUTION Indicates a hazardous situation

ment. TYPICAL — VEHICLE SERIAL NUMBER DECAL UNDER SEAT

TYPICAL — VEHICLE SERIAL NUMBER DECAL ON RH SIDE

BACK OF 450 ENGINE

Replacement or repair of any emission related

MANUAL INFORMATION MANUAL LAYOUT

This manual uses technical terms which may be

Section 06 ENGINE Page heading

Subsection title MAGNETO

Loctite 243 Drop represents a

Bold face number

Document number for 55 Page number

NOTICE Pay attention to torque specifications.

Remove starting pulley no. 2. TYPICAL Italic bold face type-

Bold face number following part

4.8 8.8 9.8 10.9 12.9

FASTENER FASTENER GRADE/TORQUE

FASTENER INFORMATION Threadlocker Application for

1. Clean threads (bolt and nut) with solvent.

1. Clean threads (bolt and hole) with solvent.

Threadlocker Application for Stud

1. Adjust screw to proper setting.

NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

Application for Stripped Thread Repair 1 2

1. Clean shaft external contact surface.

Threadlocker Application for Case-In

1. Clean inner housing diameter and outer gasket

PERIODIC MAINTENANCE SCHEDULE

SEVERE DUSTY CONDITIONS

MAINTENANCE SCHEDULE LEGEND

EVERY 1 500 KM (1,000 MI) OR 50 HOURS (whichever comes first)

EVERY 3 000 KM (2,000 MI) OR 100 HOURS (whichever comes first)

EVERY 6 000 KM (4,000 MI) OR 200 HOURS (whichever comes first)

EVERY 12 000 KM (8,000 MI) OR 5 YEARS (whichever comes first)

Replace engine coolant

GENERAL – Riding on dry dirt covered surfaces

3. Check air filter dirty chamber for cleanliness.

1. Air filter cover

4. Remove air filter.

TYPICAL - SOME PARTS REMOVED FOR CLARITY

vmo2015-005-015_a Cleaning the Paper Filter

Cleaning the Foam Filter

TYPICAL - SOME PARTS REMOVED FOR CLARITY

Select a well-ventilated area and make sure the

CAUTION Never perform this operation

Installing the Engine Air Filter

start engine. TYPICAL — ALL MODELS

4. Remove carbon deposits from the spark ar-

TYPICAL NOTICE Use a soft brush and be careful to

2. Remove and discard the tail pipe retaining

Verifying the Engine Oil Level

1. Clean spark arrester

5. Inspect mesh of spark arrester for any damage.

For installation, reverse the removal procedure. TYPICAL - RH SIDE OF ENGINE

For all season, use:

Replacing the Engine Oil Filter

TYPICAL - SOME PARTS REMOVED FOR CLARITY

Allow oil to drain completely from the crankcase.

7. Reinstall remaining parts if applicable.

NOTICE Always use ethylene-glycol an-

Do not use tap water, straight antifreeze or 2. Remove pressure cap.

1. Leak indicator hose

Checking the Engine Coolant Specific