2012 Can-Am ATV Factory Service & Work Shop Manual
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Outlander™ (1-UP)
Renegade™
SOOR/1000
TABLE OF CONTENTS
SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
INTRODUCTION........................................................................................................ XI
VEHICLE INFORMATION............................................................................................ XI
ENGINE EMISSIONS INFORMATION............................................................................. XI
MANUAL INFORMATION ........................................................................................... XII
FASTENER INFORMATION ........................................................................................ XVI
01 MAINTENANCE
01 - BREAK-IN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
02- PERIODIC MAINTENANCE SCHEDULE....................................................................... 9
GENERAL ...................................................................................................... 9
MAINTENANCE SOON MESSAGE......................................................................... 9
SEVERE DUSTY CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAINTENANCE SCHEDULE ................................................................................ 9
03 - PERIODIC MAINTENANCE PROCEDURES ................................................................. 11
GENERAL.................................................................................................... 11
PROCEDURES ............................................................................................... 11
ENGINE (AIR INTAKE SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE (EXHAUST SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ENGINE (LUBRICATION SYSTEM) ........................................................................ 15
ENGINE (COOLING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ENGINE (CYLINDER HEAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
GEARBOX ................................................................................................. 21
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ..................................................... 23
FUEL SYSTEM............................................................................................ 24
ELECTRICAL SYSTEM.................................................................................... 26
DRIVE SYSTEM........................................................................................... 26
CHASSIS (WHEELS AND TIRES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CHASSIS (STEERING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CHASSIS (SUSPENSION) ................................................................................. 29
CHASSIS (BRAKES) ....................................................................................... 31
CHASSIS (BODY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CHASSIS (FRAME) ........................................................................................ 33
04 - PRESEASON PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
05 - STORAGE PROCEDURE....................................................................................... 37
GENERAL .................................................................................................... 37
PROCEDURES ............................................................................................... 37
FUEL SYSTEM............................................................................................ 37
ENGINE ................................................................................................... 37
ELECTRICAL SYSTEM.................................................................................... 38
DRIVE SYSTEM........................................................................................... 38
CHASSIS .................................................................................................. 38
06 - SPECIAL PROCEDURES ....................................................................................... 41
GENERAL .................................................................................................... 41
WHAT TO DO IF WATER IS IN THE CVT................................................................. 41
WHAT TO DO IF WATER IS IN THE AIR FILTER HOUSING.............................................. 41
WHAT TO DO IF VEHICLE IS ROLLED OVER............................................................ 41
WHAT TO DO IF VEHICLE IS SUBMERGED IN WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
02 ENGINE, CVT AND GEARBOX
01- ENGINE REMOVAL AND INSTALLATION .................................................................. 43
GENERAL .................................................................................................... 44
PROCEDURES ............................................................................................... 44
ENGINE REMOVAL ....................................................................................... 44
02 ENGINE, CVT AND GEARBOX (cont'd}
II
01- ENGINE REMOVAL AND INSTALLATION (cont'd}
PROCEDURES (cont'd)
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ENGINE MOUNTS REPLACEMENT ...................................................................... 49
02- AIR INTAKE SYSTEM .......................................................................................... 51
GENERAL .................................................................................................... 52
PROCEDURES ............................................................................................... 52
AIR FILTER................................................................................................ 52
AIR FILTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
03 - EXHAUST SYSTEM............................................................................................ 57
GENERAL .................................................................................................... 58
PROCEDURES ............................................................................................... 58
SPARK ARRESTER........................................................................................ 58
MUFFLER ................................................................................................. 58
HEAT SHIELD............................................................................................. 60
Y-EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
HEAD PIPE (FRONT CYLINDER) .......................................................................... 60
04- LUBRICATION SYSTEM....................................................................................... 63
GENERAL .................................................................................................... 66
INSPECTION................................................................................................. 66
ENGINE OIL PRESSURE.................................................................................. 66
TROUBLESHOOTING ...................................................................................... 66
PROCEDURES ............................................................................................... 67
OIL COOLER.............................................................................................. 67
OIL PRESSURE SWITCH (OPS) ........................................................................... 68
ENGINE OIL PRESSURE REGULATOR................................................................... 69
OIL PUMP ................................................................................................ 70
ENGINE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .• . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
REED VALVE.............................................................................................. 73
05 - COOLING SYSTEM . .- .......................................................................................... 75
GENERAL .................................................................................................... 80
PROCEDURES ............................................................................................... 80
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
COOLANT TEMPERATURE SENSOR (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
RADIATOR COOLING FAN RELAY (R1 ).. .. .. .. . .. .. .. .. . .. . .. .. .. .. . .. .. .. .. .. . .. .. . .. .. .. .. .. .. .. .. .. .. . 82
RADIATOR COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
WATER PUMP HOUSING................................................................................. 85
WATER PUMP IMPELLER................................................................................ 86
WATER PUMP SHAFT, ROTARY SEAL AND OIL SEAL .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 86
WATER PUMP GEARS .................................................................................... 93
06 - MAGNETO SYSTEM........................................................................................... 97
GENERAL .................................................................................................... 99
PROCEDURES ............................................................................................... 99
MAGNETO COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
STATOR .................................................................................................. 100
ROTOR ................................................................................................... 103
SPRAG CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
SPRAG CLUTCH GEAR .................................................................................. 106
STARTER DRIVE GEARS ................................................................................. 106
07- TOP END ........................................................................................................ 107
GENERAL ................................................................................................... 112
INSPECTION ................................................................................................ 112
LEAK TEST ............................................................................................... 112
02 ENGINE, CVT AND GEARBOX (cont'd)
07 -TOP END (cont'd)
TABLE OF CONTENTS
PROCEDURES .............................................................................................. 114
INTAKE MANIFOLD...................................................................................... 114
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CYLINDER HEAD........................................................................................ 118
CAMSHAFT.............................................................................................. 120
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
VALVES ................................................................................................... 124
VALVE GUIDES ........................................................................................... 126
CYLINDER ............................................................................................... 127
PISTON .................................................................................................. 129
PISTON RINGS ........................................................................................... 133
08 - TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
GENERAL................................................................................................... 137
TROUBLESHOOTING..................................................................................... 137
PROCEDURES .............................................................................................. 137
TIMING CHAIN TENSIONERS ........................................................................... 137
CAMSHAFT TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
TIMING CHAIN........................................................................................... 143
TIMING CHAIN GUIDE (TENSIONER SIDE) .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. . .. .. .. .. 145
09- BOTTOM END ................................................................................................. 147
GENERAL ................................................................................................... 151
PROCEDURES .............................................................................................. 151
ENGINE DRIVE SHAFT .................................................................................. 151
FRONT OIL SEAL (ENGINE DRIVE SHAFT) .. . .. . . .. .. .. .. . .. .. .. . . .. .. . .. .. . . .. .. . . . . . .. .. .. .. .. .. .. .. . 153
REAR OIL SEAL (ENGINE DRIVE SHAFT) ............................................................... 153
PTO COVER OIL SEAL .................................................................................. 153
PTO COVER .............................................................................................. 154
DRIVE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
CRANKCASE .............................................................................................. 157
CRANKSHAFT ............................................................................................ 161
10- CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ................................................... 171
GENERAL................................................................................................... 174
PROCEDURES .............................................................................................. 174
CVT COVER .............................................................................................. 174
DRIVE BELT.............................................................................................. 175
DRIVE PULLEY........................................................................................... 176
DRIVEN PULLEY......................................................................................... 184
CVT AIR GUIDE.......................................................................................... 193
11 - GEARBOX AND 4X4 COUPLING UNIT (800R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
GENERAL................................................................................................... 198
OVERVIEW............................................................................................... 198
TROUBLESHOOTING..................................................................................... 198
PROCEDURES .............................................................................................. 198
GEARBOX POSITION INDICATOR SWITCHES .......................................................... 198
4WD INDICATOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
GEARBOX OIL SEALS ................................................................................... 200
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
OUTPUT SHAFT AND COUPLING MECHANISM .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. .. .. .. .. 205
GEARBOX ................................................................................................ 210
12- GEARBOX AND 4X4 COUPLING UNIT (1000) ............................................................ 229
GENERAL................................................................................................... 231
GEARBOX OVERVIEW ................................................................................... 231
Ill
TABLE CONTENTS
02 ENGINE, CVT AND GEARBOX (cont'd)
12- GEARBOX AND 4X4 COUPLING UNIT (1000) (cont'd)
TROUBLESHOOTING ..................................................................................... 231
PROCEDURES .............................................................................................. 232
VEHICLE SPEED SENSOR (VSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
GEARBOX POSITION SENSOR (GBPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
4WD INDICATOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
GEARBOX OIL SEALS ................................................................................... 238
GEARBOX................................................................................................ 240
13- SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
GENERAL................................................................................................... 256
PROCEDURES .............................................................................................. 256
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
SHIFT ROD ............................................................................................... 257
SHIFT PLATE ............................................................................................. 258
03 ELECTRONIC MANAGEMENT SYSTEMS
01 -ENGINE MANAGEMENT SYSTEM (EMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
GENERAL................................................................................................... 262
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
02 - CONTROLLER AREA NETWORK (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
GENERAL................................................................................................... 263
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
03 - COMMUNICATION TOOLS AND B.U.D.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
GENERAL................................................................................................... 265
TROUBLESHOOTING ..................................................................................... 265
DIAGNOSTIC TIPS ....................................................................................... 265
PROCEDURES .............................................................................................. 266
MULTI-PURPOSE INTERFACE-2 (MPI-2) ................................................................. 266
B.U.D.S ................................................................................................... 267
04- DIAGNOSTIC SYSTEM AND FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
GENERAL................................................................................................... 271
MONITORING SYSTEM ................................................................................. 271
FAULT CODES ........................................................................................... 272
FAULT CODE DIAGNOSTIC.............................................................................. 276
FAULT CODE TABLE..................................................................................... 280
04 fUEl
IV
01 - ELECTRONIC FUEL INJECTION (EFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
GENERAL................................................................................................... 299
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
ADJUSTMENT ............................................................................................. 300
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
CLOSED THROTTLE AND IDLE ACTUATOR RESET.................................................... 301
TROUBLESHOOTING ..................................................................................... 302
DIAGNOSTIC TIPS ....................................................................................... 302
PROCEDURES .............................................................................................. 302
ENGINE CONTROL MODULE (ECM) .................................................................... 302
FUEL INJECTOR......................................................................................... 307
FUEL RAIL............................................................................................... 309
THROTILE CABLE ....................................................................................... 310
THROTILE BODY ........................................................................................ 311
THROTILE POSITION SENSOR (TPS) ................................................................... 314
IDLE AIR CONTROL VALVE (IACV) ...................................................................... 316
TABLE OF CONTENTS
04 FUEL SYSTEM (cont'd)
01 -ELECTRONIC FUEL INJECTION (EFI) (cont'd)
PROCEDURES (cont'd)
CRANKSHAFT POSITION SENSOR (CPS) ............................................................... 317
MANIFOLD ABSOLUTE PRESSURE AND TEMPERATURE SENSOR (MAPTS) ......................... 318
CTS (COOLANT TEMPERATURE SENSOR) ............................................................. 321
02 - FUEL TANK AND FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
GENERAL................................................................................................... 325
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
INSPECTION ................................................................................................ 326
FUEL TANK LEAK TEST .................................................................................. 326
FUEL SYSTEM PRESSURE TEST........................................................................ 327
TROUBLESHOOTING..................................................................................... 329
FUEL SYSTEM DIAGNOSTIC FLOW CHART............................................................ 329
PROCEDURES .............................................................................................. 330
FUEL HOSE AND OETIKER CLAMPS ................................................................... 330
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
FUEL PUMP ............................................................................................. 334
FUEL PUMP PREFILTER (STRAINER) . .. .. . .. .. .. . .. .. .. .. . .. . .. .. .. .. .. .. .. . .. .. . .. .. .. .. .. . .. . .. .. .. .. 338
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
FUEL TANK VENT VALVES ............................................................................... 340
05 ELECTRICAL SYSTEM
01 - POWER DISTRIBUTION AND GROUNDS................................................................. 343
GENERAL................................................................................................... 343
POWER DISTRIBUTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
FUSE BOX 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
FUSE BOX 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
GROUNDS ............................................................................................... 345
02- WIRING HARNESS AND CONNECTORS .................................................................. 347
GENERAL................................................................................................... 347
CONNECTOR ABBREVIATION DESCRIPTION .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . 347
WIRING HARNESS ARRANGEMENT.................................................................... 349
WIRING HARNESS ROUTING ........................................................................... 351
WIRING HARNESS SPLICE LOCATION .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 361
PROCEDURES .............................................................................................. 367
DEUTSCH CONNECTORS............................................................................... 367
PACKARD CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
PACKARD CONNECTOR (MULTIFUNCTION GAUGE} ................................................... 368
MOLEX CONNECTOR ................................................................................... 370
FURUKAWA CONNECTOR .............................................................................. 372
BATIERY AND STARTER CABLE TERMINALS.......................................................... 373
03 - IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
GENERAL................................................................................................... 375
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
TROUBLESHOOTING ..................................................................................... 375
DIAGNOSTIC GUIDELINES.............................................................................. 375
PROCEDURES .............................................................................................. 376
IGNITION SWITCH....................................................................................... 376
EMERGENCY ENGINE STOP SWITCH .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 376
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
SPARK PLUG............................................................................................. 380
04 - CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
GENERAL................................................................................................... 381
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
v
VI
04 - CHARGING SYSTEM (cont' d)
INSPECTION ................................................................................................ 382
CHARGING SYSTEM OUTPUT .......................................................................... 382
TROUBLESHOOTING ..................................................................................... 382
PROCEDURES .............................................................................................. 383
VOLTAGE REGULATOR/RECTIFIER ..................... ~ ................................................ 383
BATIERY ................................................................................................. 383
05 -STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
GENERAL................................................................................................... 385
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
TROUBLESHOOTING ..................................................................................... 385
DIAGNOSTIC GUIDELINES .............................................................................. 385
PROCEDURES .............................................................................................. 386
D2 DIODE (STARTER SOLENOID} ....................................................................... 386
START BUTTON.......................................................................................... 386
STARTER SOLENOID .................................................................................... 387
ELECTRIC STARTER..................................................................................... 390
06- DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) .................................................. 393
GENERAL ................................................................................................... 393
SYSTEM DESCRIPTION ................................................................................. 393
TROUBLESHOOTING ..................................................................................... 393
DIAGNOSTIC TIPS ....................................................................................... 393
PROCEDURES .............................................................................................. 393
KEY PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
07- ACCESSORIES ..................................................................... 395
GENERAL................................................................................................... 395
MULTIFUNCTION GAUGE (OUTLANDER} ............................................................... 395
MULTIFUNCTION GAUGE(RENEGADE} ......................................... ... . . . . . . . . . . . . . . . . . . . . . . 397
TROUBLESHOOTING ..................................................................................... 400
DIAGNOSTIC TIPS ....................................................................................... 400
DIAGNOSTIC GUIDELINES (GAUGE} .................................................................... 401
DIAGNOSTIC GUIDELINES (LIGHTS) .................................................................... 401
PROCEDURES .............................................................................................. 402
MULTIFUNCTION GAUGE (OUTLANDER AND RENEGADE MODELS) ................................. 402
12 VOLT POWER OUTLET ............................................................................... 407
HEADLIGHTS ............................................................................................ 407
TAILLIGHTS/BRAKE LIGHTS ............................................................................. 410
TURN SIGNALS/HAZARD(CE MODELS ONLY) .......................................................... 410
HORN (CE MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
WINCH ................................................................................................... 411
01- FRONT DRIVE .................................................................................................. 415
GENERAL ................................................................................................... 418
SYSTEM DESCRIPTION ................................................................................. 418
PROCEDURES .............................................................................................. 418
WHEEL HUB ............................................................................................. 418
FRONT DRIVE SHAFT ................................................................................... 419
DRIVE SHAFT BOOT ..................................................................................... 419
FRONT DIFFERENTIAL.................................................................................. 420
FRONT PROPELLER SHAFT............................................................................. 424
02- REAR DRIVE .................................................................................................... 427
GENERAL ................................................................................................... 430
06 DRIVE SYSTEM (cont'd)
02 - REAR DRIVE (cont' d)
PROCEDURES .............................................................................................. 430
WHEEL HUB............................................................................................. 430
DRIVE SHAFT ............................................................................................ 431
DRIVE SHAFT BOOT..................................................................................... 432
PROPELLER SHAFT ..................................................................................... 432
PROPELLER SHAFT U-JOINTS .......................................................................... 434
REAR FINAL DRIVE ...................................................................................... 435
07 CHASSIS
01 - WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
GENERAL ................................................................................................... 441
PROCEDURES ......................................................................... , ..................... 441
TIRES .................................................................................................... 441
WHEELS ................................................................................................. 443
02 - STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
GENERAL................................................................................................... 449
SYSTEM DESCRIPTION (FEATURES) .................................................................... 449
DPS SYSTEM DESCRIPTION (COMPONENTS) ......................................................... 450
ADJUSTMENT ............................................................................................. 451
TORQUE OFFSET RESET ................................................................................ 451
DPS ASSIST MODE ...................................................................................... 451
STEERING ALIGNMENT................................................................................. 452
TROUBLESHOOTING ..................................................................................... 453
TROUBLESHOOTING FLOW CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
PROCEDURES .............................................................................................. 459
HANDLEBAR GRIP ...................................................................................... 459
HANDLEBAR COVER.................................................................................... 459
HANDLEBAR............................................................................................. 459
STEERING CONNECTORS ............................................................................... 460
MULTIFUNCTION SWITCH .............................................................................. 461
THROTILE LEVER....................................................................................... 461
BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
STEERING COLUMN BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
TIE-ROD.................................................................................................. 465
KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
WHEEL BEARINGS ...................................................................................... 467
DPS UNIT................................................................................................ 468
PITMAN ARM............................................................................................ 479
03 - FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
GENERAL ................................................................................................... 487
PROCEDURES .............................................................................................. 487
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
SHOCK ABSORBER BUSHINGS ......................................................................... 487
SPRINGS ................................................................................................. 487
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
SUSPENSION ARM BUSHINGS ......................................................................... 490
BALL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
04 - REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
GENERAL ................................................................................................... 496
PROCEDURES .............................................................................................. 496
SHOCK ABSORBERS .................................................................................... 496
VII
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Upon purchasing this manual, you will receive a .PDF file containing an email address for further assistance. After contacting the provided email, you will receive a reply with a link to access the manual for your 2012 Can-Am ATV.
This comprehensive manual covers every aspect of your machine, detailing every nut and bolt. With hundreds of pages, it provides guidance on identifying and resolving various issues, from routine maintenance like oil changes to more complex tasks such as transmission swaps. The manual includes numerous illustrations to assist you and features easy-to-understand text throughout.
Utilize the search function to navigate the manual efficiently and print the necessary pages as needed. This Factory Service Repair Manual offers a step-by-step guide to maintaining and repairing your ATV, imparting the knowledge that factory-trained technicians possess. By following the instructions in this manual, any owner can confidently make informed decisions regarding their machine's maintenance and repair needs.
Rest assured, in addition to the high-quality service manual, we are committed to providing excellent customer service, ensuring your satisfaction with your purchase.
