2015-2016 Can-Am Spyder RT RTS Motorcycle Service & Repair Manual

SAFETY NOTICE SAFETY NOTICE This SHOP MANUAL covers all 2015-2016 Spyder RT, RT-S, RT Limited, and RT-S Special Series Can-Am roadsters. This manual covers all trim levels. This edition was primarily published to be used by technicians who are already familiar with service procedures relating to Bombardier Recreational Products Inc. (BRP) products. Mechanical technicians should attend continuous training courses given by B.R.P.T.I. Please note that the instructions will apply only if proper hand tools and special service tools are used. The content depicts parts and procedures appli- cable to the particular product at time of writing. SERVICE and WARRANTY BULLETINS may be published to update the content of this manual. Make sure to read and understand them. Dealer modifications that were carried out after manufac- turing of the product, whether or not authorized by BRP, are not included. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or ex- act replicas of the parts. The use of BRP parts is most strongly recom- mended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt. The engines and the corresponding components identified in this document should not be utilized on product(s) other than those mentioned in this document. It is understood that certain modifications may render use of the vehicle illegal under existing federal, provincial and state regulations. This manual emphasizes particular information de- noted by the 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 vehicle components or other property. NOTE: Indicates supplementary information required to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understand- ing of the information will promote its correct use. Always use common shop safety practice. It is understood that this manual may be trans- lated into another language. In the event of any discrepancy, the English version shall prevail. BRP disclaims liability for all damages and/or in- juries resulting from the improper use of the con- tents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional mechanic.

INTRODUCTION VEHICLE INFORMATION VEHICLE IDENTIFICATION NUMBER (V.I.N.)   rmo2008-001-091_a TYPICAL — VEHICLE SERIAL NUMBER LABEL 1. VIN (Vehicle Identification Number) 2. Model number rmo2013-003-037_a TYPICAL - LOCATION OF VIN 1. Swing arm (VIN label) 2. Lower frame (VIN stamped on left side) ENGINE IDENTIFICATION NUMBER (EIN) The engine identification number is located on the left rear of engine, near the alternator. rmo2014-005-008_a 1. Engine Identification Number (EIN) location EPA COMPLIANCE LABEL rmo2008-001-094 rmo2008-001-044_b TYPICAL 1. EPA exhaust emission label located under seat

SERVICE TOOLS INDEX ADAPTER HOSE (P/N 529 035 652) Page: 10 ALTERNATOR SHAFT ADAPTER (P/N 529 036 299) Page: 43 ALTERNATOR SHAFT HOLDER (P/N 529 036 298) Page: 43 CAMSHAFT LOCKING TOOL (P/N 529 036 288) Page: 52 CAMSHAFT TURNING TOOL (P/N 529 036 289) Page: 52 CENTER BOLT (P/N 529 036 290) Page: 124, 126, 153, 156 CLUTCH ASSEMBLY HOLDER (P/N 529 036 292) Page: 138–139, 166, 168 CLUTCH COVER HOLDING DEVICE (P/N 529 036 294) Page: 154, 157, 186, 210 CLUTCH HUB TURNING TOOL (P/N 529 036 291) Page: 144, 173 CRANKCASE SEAL PUSHER (P/N 529 036 092) Page: 204 CRANKSHAFT LOCKING BOLT (P/N 529 036 285) Page: 92, 95 CRANKSHAFT LOCKING BOLT (P/N 529 036 286) Page: 138, 166 ECM ADAPTER TOOL (P/N 529 036 166) Page: 12, 119, 201, 237, 240–241, 243 ENGINE LEAK DOWN TEST KIT (P/N 529 035 661) Page: 65 1

SERVICE TOOLS INDEX FLUKE 115 MULTIMETER (P/N 529 035 868) Page: 12–13, 37–38, 118–119, 204–205, 237, 240–241, 243 GEARBOX HOLDING DEVICE (P/N 529 036 296) Page: 214, 228, 232 HANDLE (P/N 420 877 650) Page: 203 HEXAGON SOCKET WRENCH (P/N 529 036 287) Page: 91, 95, 126, 137, 155, 166 INDEX SHIM HOLDING DEVICE (P/N 529 036 293) Page: 207, 209 MAIN SHAFT PROTECTOR (P/N 529 036 123) Page: 203 MAIN SHAFT SEAL INSTALLER (P/N 529 036 088) Page: 203 OIL SEAL INSTALLER (P/N 529 036 070) Page: 203–204 OIL SEAL INSTALLER (P/N 529 036 297) Page: 45 PISTON CIRCLIP INSTALLER (P/N 529 036 295) Page: 100 PRESSURE GAUGE (P/N 529 035 709) Page: 10 PROTECTION SLEEVE (P/N 529 036 071) Page: 203 VACUUM/PRESSURE PUMP (P/N 529 021 800) Page: 112–113, 115, 120 VALVE SPRING COMPRESSOR CUP (P/N 529 036 209) Page: 76 VALVE SPRING COMPRESSOR (P/N 529 035 724) Page: 76 2

Subsection 01 (MAINTENANCE SCHEDULE) MAINTENANCE SCHEDULE Maintenance is very important for keeping your vehicle in safe operating condition. Proper maintenance is the owner's responsibility. Perform periodic checks and follow the maintenance schedule. The maintenance schedule does not exempt the pre-ride inspection. WARNING Failure to properly maintain the vehicle according to the maintenance schedule and procedures can make it unsafe to operate. BREAK-IN INSPECTION - 5 000 KM (3,000 MI) Using BRP Utility and Diagnostic Software (B.U.D.S.), check fault codes and install required updates. Replace engine oil and oil filter. Check clutch fluid level (SM6 model only). Check brake fluid level. Check reverse mechanism operation. Check engine coolant level. Inspect throttle twist grip operation. Check lighting system (brake light, hazard warning light, turn signal lights, position lights, license plate light). Clean brake light switch. Check operation of control switches. Inspect the drive belt condition and its tension. Adjust if required. Check tightening torque of the front wheels lug nuts. Check tightening torque of the rear wheel axle nut. Check parking brake operation. Adjust as required. Check wheels wear. Align front wheels if required. Check tires pressure. Adjust as required. Check brake pads and discs condition. Check passenger handholds looseness. Check footrests looseness. Check body panels looseness. Check operation of storage compartment latches, hinges and key barrels. Check and retighten exhaust pipe, clamping rings, joints, and gaskets condition. rmr2014-006 1

Subsection 01 (MAINTENANCE SCHEDULE) EVERY 15 000 KM (9,300 MI) OR 1 YEAR (WHICHEVER COMES FIRST) Using BRP Utility and Diagnostic Software (B.U.D.S.), check fault codes and install required updates. Replace engine oil and oil filter. Check clutch fluid level (SM6 model only). Check brake fluid level. Replace every 2 years. Check brake hoses Check reverse mechanism operation. Check radiator, hoses and water pump. Check engine coolant level. Perform a pressure test of cooling system. Inspect throttle twist grip operation. Check lighting system (brake light, hazard warning light, turn signal lights, position lights, license plate light). Clean brake light switch. Check operation of control switches and passenger switches. Check condition of fuel hoses, fuel evaporation lines and canister. Check battery connections tightening. Inspect the drive belt condition and its tension. Adjust if required. Check and retighten exhaust pipe, clamping rings, joints, and gaskets condition. Check steering for abnormal play. Check tie-rods condition. Check shock absorbers for leaks or other damages. Check tightening torque of the front wheels lug nuts. Check tightening torque of the rear wheel axle nut. Check ball joints condition. Check front wheel bearings condition. Check parking brake operation. Adjust as required. Check wheels wear. Align front wheels if required. Check tires pressure. Adjust as required. Check brake pads and discs condition. Check passenger handholds looseness. Check footrests looseness. Check body panels looseness. Check operation of storage compartment latches, hinges and key barrels. EVERY 30 000 KM (19,000 MI) Replace air filter and clean air filter housing. Replace clutch fluid (SM6 model only). Replace the fuel filter (or every 5 years). 2 rmr2014-006

Subsection 01 (MAINTENANCE SCHEDULE) EVERY 45 000 KM (28,000 MI) Replace the Hydraulic Control Module (HCM) oil filter (SE6 model only). Replace the canister pre-filter. Replace engine coolant (or every 5 years). Replace the spark plugs. Check front suspension arms rubber bushings. rmr2014-006 3

Subsection XX (PRESEASON PREPARATION) PRESEASON PREPARATION Prior to use the vehicle, proper preparation is required after the storage period. Any worn, broken or damaged parts found during the storage procedure should have been replaced. If not, proceed with the replacement. PROCEDURES VEHICLE PREPARED AS PER STORAGE PROCEDURE Remove vehicle protective cover, muffler protective bag and clean the vehicle. Charge battery as required. Refer to CHARGING SYSTEM. Check the following items: – Tires: Look for damage, incorrect inflation and excessive tread wear. – Wheels and lug nuts: Look for damage. Check front wheel lug nuts if they are properly tighten. Be sure the rear wheel axle nut and cotter pin are in place. – Drive belt: Look for fraying, cuts, punctures and missing teeth. Verify alignment. For additional information, refer to DRIVE BELT AND REAR WHEEL subsection. – Leaks: Look under the vehicle for any leaks. – Brake pedal: Press and make sure you feel firm resistance. Pedal must fully return when released. – Throttle handle: Twist a few times. Be sure it operates freely and returns to idle position when released. – Clutch lever (SM5 model): Squeeze to be sure it operates easily and fully returns when released. Adjust if needed. Refer to CLUTCH (SM5) subsection. – Clutch oil level (SM5 model): Check clutch fluid level. Refer to CLUTCH (SM5) subsection. – Gearshift selector (SE5 model): Be sure gearshift selector operates normally in both di- rections and returns to center when released. Turn ignition key ON: 1. Check the gauges, indicator lamps, and mes- sages on the multifunction gauge cluster. 2. Ensure headlights, taillight, brake light, turn sig- nals, and hazards are working properly. 3. Ensure horn is working properly. 4. Start engine and verify steering operates freely. 5. Check that the engine stop button is working properly. 6. Start engine, release parking brake and ensure parking brake indicator is off on the multifunction gauge cluster. 7. Drive forward slowly a few feet then apply brake to test. VEHICLE NOT PREPARED AS PER STORAGE PROCEDURE Proceed with the same steps as specified in VE- HICLES PREPARED AS PER STORAGE PROCE- DURE above. Carry out these additional steps: – Check the level of engine coolant. Refer to COOLING SYSTEM subsection. – Check the brake fluid level. Refer to BRAKES subsection. – Lubricate the front suspension arms. Refer to FRONT SUSPENSION subsection. – Replace engine oil and filter. Refer to LUBRICA- TION SYSTEM subsection. – Replace HCM oil filter (SE5 model). Refer to HYDRAULIC CONTROL MODULE (SE5) subsection. – Models with a flat footrest: Release the latch underneath footrest. Pivot footrest by pushing down its front part. Flip back the footrest until it latches. The mechanism must work freely. rmr2013-005 1

Subsection 02 (STORAGE PROCEDURE) STORAGE PROCEDURE SERVICE PRODUCTS Description Part Number Page LONG LIFE ANTIFREEZE .............................................................. 219 702 685 ........................................... 1 XPS FUEL STABILIZER.................................................................. 413 408 601 ........................................... 1 XPS ROADSTER WASH ................................................................ 219 701 703 ........................................... 2 XPS STORAGE OIL (EXCEPT U.S. COUNTRY) ............................. 413 711 600 ........................................... 1 XPS STORAGE OIL (U.S. COUNTRY ONLY) ................................. 413 711 900 ........................................... 1 GENERAL If the vehicle is not ridden for at least 4 months, such as during the winter, proper storage is necessary to keep the vehicle in good condition. PROCEDURES FUEL SYSTEM Fuel System Protection With the new fuel additives, it is critical to use the XPS FUEL STABILIZER (P/N 413 408 601) or an equiv- alent to prevent fuel deterioration and fuel system gumming. Follow the manufacturer's instructions for proper use. Pour fuel stabilizer in fuel tank. Fill up fuel tank. NOTICE Engine should be run after fuel stabilizer is added to ensure fuel system components protection against varnish deposits. Do not drain fuel system. ENGINE Engine Oil and Filter Replacement Change engine oil and filter. Refer to LUBRICA- TION SYSTEM subsection. Engine Internal Lubrication Engine internal parts should be lubricated to pro- tect them from rust formation during the storage period. Proceed as follows: 1. Remove air filter housing cover. Refer to AIR INTAKE SYSTEM subsection. 2. Spray XPS STORAGE OIL (EXCEPT U.S. COUN- TRY) (P/N 413 711 600) or XPS STORAGE OIL (U.S. COUNTRY ONLY) (P/N 413 711 900) into throttle body (5 seconds in each openings) while crank- ing in drowned mode (throttle wide open and depress start button). 3. Reinstall air filter housing cover. NOTE: Do not run engine during storage period. CLUTCH SYSTEM (SM6) Clutch Fluid Level Inspection Check clutch fluid level. Refill if necessary. COOLING SYSTEM Coolant Inspection Check coolant level. Test coolant density using an antifreeze hydrome- ter. NOTE: Follow manufacturer's instructions for proper use. Use LONG LIFE ANTIFREEZE (P/N 219 702 685) or a blend of 50% antifreeze with 50% distilled water to provide the optimum cooling, corrosion protection and antifreeze protection. NOTICE Do not use tap water, straight antifreeze or straight water in the system. Tap water contains minerals and impurities which build up in the system. Straight water will cause the system to freeze while straight antifreeze will cause system temperature prob- lems. Change coolant if necessary. Refer to COOLING SYSTEM subsection. ELECTRICAL SYSTEM Battery Charging Slow charge the battery once a month at the rec- ommended charging rate of 2 A. It is not necessary to remove the battery. rmr2014-007 1

2015-2016 Can-Am Spyder RT RTS Motorcycle Service & Repair Manual

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