TABLE OF CONTENTS
SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
INTRODUCTION......................................................................................................... X
VEHICLE INFORMATION........................................................................................... .. X
ENGINE EMISSIONS INFORMATION............................................................................. XII
MANUAL INFORMATION .......................................................................................... XIII
FASTENER INFORMATION....................................................................................... XVII
01 MAINTENANCE
01 - BREAK-IN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
02- PERIODIC MAINTENANCE SCHEDULE....................................................................... 9
03 - PERIODIC MAINTENANCE PROCEDURES ................................................................. 11
GENERAL.................................................................................................... 11
PROCEDURES .................................... . .......................................................... 11
ENGINE (AIR INTAKE SYSTEM) .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. 11
ENGINE (EXHAUST SYSTEM) .......................................................................... .. 12
ENGINE (LUBRICATION SYSTEM) ........................................................................ 13
ENGINE (COOLING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE (TOP END) ....................................................................................... 21
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ............................................... .... .. 21
GEARBOX ................................................................................................. 22
FUEL SYSTEM............................................................................................ 24
ELECTRICAL SYSTEM.................................................................................... 25
DRIVE SYSTEM........................................................................................... 25
CHASSIS (WHEELS AND TIRES) ......................................................................... 27
CHASSIS (STEERING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CHASSIS (SUSPENSION) ................................................................................. 28
CHASSIS (BRAKES) ....................................................................................... 30
CHASSIS (PASSENGER HANDHOLDS) ................................................................... 31
CHASSIS (TOW HITCH) ........................................................................ . .......... 32
04- STORAGE PROCEDURE....................................................................................... 33
GENERAL .................................................................................................... 33
PROCEDURES ............................................................................................... 33
FUEL SYSTEM............................................................................................ 33
ENGINE ................................................................................... . ........... . ... 33
ELECTRICAL SYSTEM......................................................................... . .......... 34
DRIVE SYSTEM........................................................................................... 34
CHASSIS . .................................................................................... . ............ 34
05 - PRESEASON PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
06- SPECIAL PROCEDURES ....................................................................................... 37
GENERAL .................................................................................................... 37
ROLLED OVER VEHICLE................................................................................. 37
SUBMERGED VEHICLE................................................................................... 37
02 ENGINE, CVT AND GEARBOX
01 -ENGINE REMOVAL AND INSTALLATION.................................................................. 39
PROCEDURES ............................................................................................... 40
ENGINE REMOVAL ....................................................................................... 40
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ENGINE MOUNTS ............................................ . ........................................... 42
02- AIR INTAKE SYSTEM .......................................................................................... 43
GENERAL .................................................................................................... 45
PROCEDURES ............................................................................................... 45
AIR FILTER................................................................................................ 45
AIR FILTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
TABLE OF CONTENTS
02 ENGINE, CVT AND GEARBOX (cont'd)
II
03- EXHAUST SYSTEM............................................................................................ 47
GENERAL .................................................................................................... 48
PROCEDURES ............................................................................................... 48
SPARK ARRESTER................................................................................ . ....... 48
MUFFLER................................................................................................. 48
"Y" EXHAUST PIPE....................................................................................... 48
HEAD PIPE (FRONT CYLINDER) .......................................................................... 49
HEAD PIPE (REAR CYLINDER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
04 - LUBRICATION SYSTEM....................................................................................... 51
INSPECTION................................................................................................. 54
ENGINE OIL PRESSURE.................................................................................. 54
TROUBLESHOOTING...................................................................................... 54
PROCEDURES............................................................................................... 55
OIL COOLER.............................................................................................. 55
OIL PRESSURE SWITCH (OPS) ........................................................................... 55
ENGINE OIL PRESSURE REGULATOR................................................................... 56
OIL PUMP ................................................................................................ 57
ENGINE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
05- COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
GENERAL .................................................................................................... 66
PROCEDURES ........................................................................... . ....... . ........... 66
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
COOLANT TEMPERATURE SENSOR (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
RADIATOR COOLING FAN RELAY (R1 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
RADIATOR COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
WATER PUMP HOUSING................................................................................. 71
WATER PUMP IMPELLER................................................................................ 72
WATER PUMP SHAFT AND SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
WATER PUMP GEARS .................................................................................... 79
06 - MAGNETO SYSTEM........................................................................................... 83
PROCEDURES ............................................................................................... 85
MAGNETO COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
STATOR ............................................................................ . ...................... 86
ROTOR .................................................................................................... 88
SPRAG CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
SPRAG CLUTCH GEAR................................................................................... 90
STARTER DRIVE GEARS .................................................................................. 91
07 - INTAKE MANIFOLD............................................................................................ 93
PROCEDURES ............................................................................................... 94
PLENUM BRACKET....................................................................................... 94
INTAKE MANIFOLD ..................... ... ............................................................... 94
08- TOP END ......................................................................................................... 97
GENERAL ................................................................................................... 101
INSPECTION ................................................................................................ 101
LEAK TEST............................................................................................... 101
PROCEDURES .............................................................................................. 104
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
ROCKER ARM ........................................................................................... 104
CAMSHAFT.............................................................................................. 107
CYLINDER HEAD ........................................................................................ 109
VALVE SPRINGS ......................................................................................... 112
VALVES ................................................................................................... 113
02 ENGINE, CVT AND GEARBOX (cont'd)
08 - TOP END (cont' d)
PROCEDURES (cont'd)
TABLE OF CONTENTS
VALVE GUIDES ........................................................................................... 115
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
PISTON .................................................................................................. 118
PISTON RINGS ........................................................................................... 122
09 - TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
GENERAL................................................................................................... 127
TROUBLESHOOTING ..................................................................................... 127
PROCEDURES .............................................................................................. 127
TIMING CHAIN TENSIONERS ........................................................................... 127
CAMSHAFT TIMING GEARS ............................................................................ 129
TIMING CHAIN ........................................................................................... 133
TIMING CHAIN GUIDE (TENSIONER SIDE) ................. . ........................................... 135
10- BOTTOM END ................................................................................................. 137
GENERAL................................................................................................... 141
PROCEDURES .............................................................................. . ............... 141
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
FRONT OIL SEAL (ENGINE DRIVE SHAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
REAR OIL SEAL (ENGINE DRIVE SHAFT) ............................................................... 143
PTO COVER OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
PTO COVER.............................................................................................. 145
DRIVE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
CRANKCASE............................................................................................. 149
CRANKSHAFT........................................................................................ . ... 153
11- CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ................................................... 161
GENERAL ................................................................................................... 164
PROCEDURES .............................................................................................. 164
CVT COVER .............................................................................................. 164
DRIVE BELT .............................................................................................. 165
DRIVE PULLEY ........................................................................................... 165
DRIVEN PULLEY ......................................................................................... 173
CVT AIR GUIDE................................................................................ . ......... 180
12- GEARBOX AND 4X4 COUPLING UNIT .................................................................... 183
GENERAL ................................................................................................... 185
GEARBOX OVERVIEW ................................................................................... 185
TROUBLESHOOTING ..................................................................................... 185
PROCEDURES ..................................................................................... . ........ 185
VSS (VEHICLE SPEED SENSOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
GBPS (GEARBOX POSITION SENSOR) ................................................................. 187
4WD INDICATOR SWITCH .............................................................................. 189
ACTUATOR .............................................................................................. 190
GEARBOX OIL SEALS ................................................................................... 191
GEARBOX................................................................................................ 193
13- SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
PROCEDURES .............................................................................................. 210
SHIFT LEVER ............................................................................................ 210
SHIFTER CABLE ......................................................................................... 211
SHIFT PLATE ............................................................................................. 212
03 ELECTRONIC MANAGEMENT SYSTEM
01- ENGINE MANAGEMENT SYSTEM (EMS) ................................................................ 215
GENERAL ................................................................................................... 216
SYSTEM DESCRIPTION ................................................................................. 216
Ill
TABLE OF CONTENTS
03 ELECTRONIC MANAGEMENT SYSTEM (cont'd)
02 - CONTROLLER AREA NETWORK (CAN} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
GENERAL ................................................................................................... 219
SYSTEM DESCRIPTION ................................................................................. 219
03- COMMUNICATION TOOLS AND B.U.D.S ................................................................. 221
GENERAL ................................................................................................... 221
TROUBLESHOOTING ..................................................................................... 221
DIAGNOSTIC TIPS ....................................................................................... 221
PROCEDURES .............................................................................................. 222
MPI-2 ..................................................................................................... 222
B.U.D.S. SOFTWARE .................................................................................... 223
04- DIAGNOSTIC SYSTEM AND FAULT CODES ............................................................. 227
GENERAL ................................................................................................... 227
MONITORING SYSTEM ................................................................................. 227
FAULT CODES ........................................................................................... 228
FAULT CODE DIAGNOSTIC .............................................................................. 233
SPECIFIC FAULTS ........................................................................................ 237
04 FUEL SYSTEM
IV
01 - INTELLIGENT THROTTLE CONTROL (iTC} ................................................................ 239
GENERAL ................................................................................................... 239
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
SYSTEM MAIN FEATURES .............................................................................. 239
SYSTEM OTHER FEATURES ............................................................................ 239
PROCEDURES .............................................................................................. 240
SPORT/NORMAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
SEAT BELT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
OVERRIDE SWITCH ..................................................................................... 240
THROTTLE ACCELERATOR SENSOR (TAS) ............................................................. 240
02- ELECTRONIC FUEL INJECTION (EFI} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
GENERAL ................................................................................................... 243
SYSTEM DESCRIPTION ................................................................................. 243
ADJUSTMENT ............................................................................................. 244
IDLE SPEED .. . .......................................................................................... 244
TROUBLESHOOTING ..................................................................................... 245
DIAGNOSTIC TIPS ....................................................................................... 245
PROCEDURES .............................................................................................. 245
ENGINE CONTROL MODULE (ECM) .................................................................... 245
FUEL INJECTOR ......................................................................................... 251
FUEL RAIL ............................................................................................... 255
THROTTLE BODY ........................................................................................ 256
THROTTLE POSITION SENSOR (TPS) ................................................................... 258
CRANKSHAFT POSITION SENSOR (CPS) ............................................................... 260
MANIFOLD AIR PRESSURE AND TEMPERATURE SENSOR (MAPTS) ................................. 261
CTS (COOLANT TEMPERATURE SENSOR) ............................................................. 264
03- FUEL TANK AND FUEL PUMP.............................................................................. 267
GENERAL ................................................................................................... 269
SYSTEM DESCRIPTION ................................................................................. 269
INSPECTION ................................................................................................ 270
FUEL TANK LEAK TEST .................................................................................. 270
FUEL PUMP PRESSURE TEST .......................................................................... 270
TROUBLESHOOTING ............ . ........................................................................ 273
FUEL SYSTEM DIAGNOSTIC FLOW CHART ............................................................ 273
PROCEDURES .............................................................................................. 274
FUEL HOSE AND OETIKER CLAMPS ................................................................... 274
TABLE OF CONTENTS
04 FUEL SYSTEM (cont'd)
03 - FUEL TANK AND FUEL PUMP (cont' d)
PROCEDURES (cont'd)
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
FUEL TANK VENT VALVE................................................................................ 281
05 ELECTRICAL SYSTEM
01 -POWER DISTRIBUTION AND GROUNDS................................................................. 283
GENERAL................................................................................................... 283
POWER DISTRIBUTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
FUSE BOX 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
FUSE BOX 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
GROUND ................................................................................................. 284
02 - WIRING HARNESSES AND CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
GENERAL................................................................................................... 285
WIRING HARNESS AND SPLICE LOCATION ............................................................ 285
PROCEDURES .............................................................................................. 285
DEUTSCH CONNECTORS ............................................................................... 285
PACKARD CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
PACKARD CONNECTOR (MULTIFUNCTION GAUGE) ................................................... 288
MOLEX CONNECTOR................................................................................... 289
FURUKAWA CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
BATTERY AND STARTER CABLE TERMINALS .......................................................... 293
03 - IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
GENERAL................................................................................................... 295
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
TROUBLESHOOTING..................................................................................... 295
DIAGNOSTIC GUIDELINES .............................................................................. 295
PROCEDURES .............................................................................................. 295
IGNITION SWITCH....................................................................................... 295
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
SPARK PLUG ............................................................................................. 297
04 - CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
GENERAL................................................................................................... 299
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
INSPECTION ................................................................................................ 299
CHARGING SYSTEM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
TROUBLESHOOTING ..................................................................................... 300
PROCEDURES .............................................................................................. 300
VOLTAGE REGULATOR/RECTIFIER ..................................................................... 300
BATTERY................................................................................................. 300
05- STARTING SYSTEM .......................................................................................... 303
GENERAL ................................................................................................... 303
SYSTEM DESCRIPTION ................................................................................. 303
TROUBLESHOOTING ..................................................................................... 303
DIAGNOSTIC GUIDELINES .............................................................................. 303
PROCEDURES .............................................................................................. 304
D2 DIODE (STARTER SOLENOID) ....................................................................... 304
START BUTTON.......................................................................................... 304
STARTER SOLENOID .................................................................................... 305
ELECTRIC STARTER ..................................................................................... 306
v
TABLE OF CONTENTS
05 ELECTRICAL SYSTEM (cont'd)
06- DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) .................................................. 309
GENERAL ................................................................................................... 309
SYSTEM DESCRIPTION ................................................................................. 309
TROUBLESHOOTING ..................................................................................... 309
DIAGNOSTIC TIPS .......................................................................... . ............ 309
PROCEDURES .............................................................................................. 309
KEY PROGRAMMING ................................................................................... 309
07 - LIGHTS, GAUGE AND ACCESSORIES ................................................................ . .... 311
GENERAL ................................................................................................... 311
TROUBLESHOOTING ..................................................................................... 311
DIAGNOSTIC TIPS ....................................................................................... 311
PROCEDURES .............................................................................................. 311
CONSOLE SWITCHES ................................................................................... 311
MULTIFUNCTION GAUGE (LCD AND ANALOG/DIGITAL) ............................................... 312
12 VOLT POWER OUTLET ............................................................................... 315
HEADLIGHTS ............................................................................................ 315
TAILLIGHTS/BRAKE LIGHTS ............................................................................. 317
WINCH ......................................................... . ......... . ............................... 318
TURN SIGNALS/HAZARD(EC MODELS ONLY) .......................................................... 319
HORN (EC MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
06 DRIVE SYSTEM
01 - FRONT DRIVE.................................................................. ... ............................. 321
GENERAL ................................................................................................... 324
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
PROCEDURES .............................................................................................. 324
WHEEL HUB ...................................................................... . .......... . ........... 324
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
DRIVE SHAFT BOOT..................................................................................... 325
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
FRONT PROPELLER SHAFT........................ . .............................. . ..................... 329
PROPELLER SHAFT U-JOINTS .................................................................. . ....... 330
02 - REAR DRIVE.................................................................................................... 333
PROCEDURES .............................................................................................. 336
WHEEL HUB ....................................................................................... . ..... 336
DRIVE SHAFT............................................................. . .............................. 337
DRIVE SHAFT BOOT..................................................................................... 337
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
PROPELLER SHAFT U-JOINTS.......................................................................... 338
REAR FINAL DRIVE...................................................................................... 340
07 CHASSIS
01 -WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
PROCEDURES .............................................................................................. 345
TIRES .................................................................................................... 345
WHEELS .............................................................................................. ... 347
02 - STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
GENERAL ................................................................................................... 351
ADJUSTMENT ............................................................................................. 351
DPS TORQUE OFFSET RESET .......................................................................... 351
STEERING ALIGNMENT ........................................................ . .......... . ............. 351
TROUBLESHOOTING ..................................................................................... 353
DIAGNOSTIC TIPS ....................................................................................... 353
VI
TABLE OF CONTENTS
07 CHASSIS (cont' d)
02 - STEERING SYSTEM (cont' d)
PROCEDURES .............................................................................................. 353
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
RACK AND PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
TIE-ROD ENDS ........................................................................................... 357
KNUCKLES ............................................................................................... 357
WHEEL BEARINGS ...................................................................................... 358
03- DYNAMIC POWER STEERING (DPS) ...................................................................... 359
GENERAL ................................................................................................... 361
SYSTEM DESCRIPTION (FEATURES) .................................................................... 361
SYSTEM DESCRIPTION (COMPONENTS) ............................................................... 361
ADJUSTMENT ............................................................................................. 362
TORQUE OFFSET RESET ................................................................................ 362
TROUBLESHOOTING..................................................................................... 363
PROCEDURES .............................................................................................. 364
DPS UNIT ................................................................................................ 364
DPS COUPLER........................................................................................... 372
04 - FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
GENERAL................................................................................................... 376
PROCEDURES .............................................................................................. 376
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
SHOCK ABSORBER BUSHINGS ......................................................................... 377
SPRINGS ................................................................................................. 377
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
SUSPENSION ARM BUSHINGS ......................................................................... 379
BALL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
05- REAR SUSPENSION.......................................................................................... 381
GENERAL................................................................................................... 382
PROCEDURES .............................................................................................. 382
SHOCK ABSORBERS .................................................................................... 382
SHOCK ABSORBER BUSHINGS ......................................................................... 383
SPRINGS ................................................................................................. 383
ANTI-SWAY BAR ......................................................................................... 384
TRAILING ARM .......................................................................................... 384
06- AIR CONTROLLED SUSPENSION (ACS) .................................................................. 387
GENERAL ................................................................................................... 390
SYSTEM DESCRIPTION (OPERATION) .................................................................. 390
SYSTEM DESCRIPTION (FEATURES) .................................................................... 394
SYSTEM DESCRIPTION (COMPONENTS) ............................................................... 394
TROUBLESHOOTING ..................................................................................... 396
DIAGNOSTIC TIPS ....................................................................................... 396
TROUBLESHOOTING GUIDELINES ..................................................................... 396
TROUBLESHOOTING WITH B.U.D.S .................................................................... 397
PROCEDURES .............................................................................................. 398
PNEUMATIC HOSE ...................................................................................... 398
ACS RELEASE VALVE .................................................................................... 399
ACS SOLENOID VALVE.................................................................................. 400
SUSPENSION CONTROL MODULE (SCM) .............................................................. 402
ACS RELAY (R5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
ACS COMPRESSOR ..................................................................................... 407
ACS AIR FILTER .......................................................................................... 410
SHOCK ABSORBERS .................................................................................... 410
VII
TABLE OF CONTENTS
07 CHASSIS (cont'd)
07- BRAKES ......................................................................................................... 413
GENERAL ................................................................................................... 415
INSPECTION ................................................................................................ 415
BRAKE SYSTEM PRESSURE VALIDATION.............................................................. 415
PROCEDURES .............................................................................................. 416
BRAKE LIGHT SWITCH .................................................................................. 416
MASTER CYLINDER ..................................................................................... 416
CALIPER ................................................................................................. 418
BRAKE PADS ............................................................................................ 419
BRAKE DISC ............................................................................................. 420
08- BODY ............................................................................................................ 421
PROCEDURES .............................................................................................. 431
PLASTIC RIVET .......................................................................................... 431
DECALS .................................................................................................. 431
UPPER CONSOLE ....................................................................................... 431
LOWER CONSOLE ...................................................................................... 431
LATERAL CONSOLE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
GLOVE BOX REMOVAL AND INSTALLATION........................................................... 432
FUEL TANK COWL....................................................................................... 433
SEAT COVER ............................................................................................. 433
09 - CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
ADJUSTMENT ............................................................................................. 441
CARGO BOX ADJUSTMENTS ........................................................................... 441
PROCEDURES .............................................................................................. 443
CARGO BOX GAS SHOCK............................................................................... 443
CARGO BOX............................................................................................. 443
10- FRAME .......................................................................................................... 445
PROCEDURES .............................................................................................. 448
CAGE ..................................................................................................... 448
FRAME ................................................................................................... 449
08 TECHNICAL SPECIFICATIONS
01- COMMANDER BOOR AND 1000 ............................................................................. 451
09 WIRING DIAGRAM
01 -WIRING DIAGRAM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
GENERAL ................................................................................................... 463
WIRING DIAGRAM LOCATION .......................................................................... 463
WIRING DIAGRAM CODES .............................................................................. 463
VIII
SAFETY NOTICE
This manual has been prepared as a guide to cor-
rectly service and repair the 2013 Can-Am™ Com-
mander SSV as described in the model list in the
INTRODUCTION.
This edition was primarily published to be used by
mechanical technicians who are already familiar
with all service procedures relating to BRP prod-
ucts. Mechanical technicians should attend train-
ing courses given by BRPTI.
Please note that the instructions in this manual
will apply only if proper hand tools and special ser-
vice tools are used.
The contents of this manual depicts parts and/or
procedures applicable to a particular product at
the time of writing. Service and warranty bulletins
may be published to update the content of this
manual. Dealer modifications that were carried
out after manufacturing 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
which, is denoted by the following wording and
symbols:
A WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.
A CAUTION Indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
tmr2013-002
SAFETY NOTICE
I.Tl•Ji[IJij Indicates an instruction which, if not
followed, could result in severe damage to ve-
hicle components or other property.
NOTE: Indicates supplementary information re-
quired to fully complete an instruction.
Although the mere reading of such information
does not eliminate the hazard, your understand-
ing of the information provided will promote its
correct use.
Always observe common shop safety practice.
Unless otherwise noted, the engine must be
stopped and the tether cord must be removed
prior to perform any services.
Torque wrench tightening specifications must be
strictly adhered to. Use the torque values and ser-
vice products as in the exploded views or in the
procedures when noted.
Locking devices when removed must be replaced
(e.g.: locking tabs, elastic stop nuts, self-locking
fasteners, cotter pins, etc.).
Hoses, cables and locking ties removed during a
procedure must be reinstalled as per factory stan-
dards.
When ordering parts always refer to the specific
model PARTS CATALOGS.
We strongly recommend that any services be car-
ried out and/or verified by a highly skilled profes-
sional mechanic.
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 of this publication.
IX
INTRODUCTION
INTRODUCTION
This Shop Manual covers the following BRP made
2013 Can-Am side by side vehicles.
MODEL
ENGINE
MODEL NUMBER
TYPE
Commander
810
6CDA, 6CDB, 6CDC, 6TDA,
BOOR 6DDA, 6DDB, 6DDC
6ADA, 6ADB, 6PDA, 6BDA,
Commander
6BDB,6BDD,6BDE,6BD~
1000
1010 6BDG, 6BDH, 6EDA,
6EDB, 6EDC, 6EDD, 6GDA,
6GDB, 6GDC, 6GDD
The information and component/system descrip-
tions contained in this manual are correct at time
of writing. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
Due to late changes, there may be some differ-
ences between the manufactured product and the
description and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
VEHICLE INFORMATION
VEHICLE IDENTIFICATION
NUMBER (VIN)
tmr2011 -002-001_a
TYPICAL
1. VIN {Vehicle Identification Number) location
The VIN (Vehicle Identification Number) decal is lo-
cated under the glove box on the passenger side.
X
VIN Decal Description
3
\ I
'--~---------------~~
tmr2011-Q02-005_a
TYPICAL- VEHICLE IDENTIFICATION NUMBER LABEL
1. VIN {Vehicle Identification Number)
2. Model number
3. Manufacturing date
ENGINE IDENTIFICATION
NUMBER (EIN)
tmr2011-002-002_a
TYPICAL - RH SIDE OF ENGINE
1. Engine Identification Number {EIN)
2
LIFTING AND SUPPORTING THE
VEHICLE
Front of Vehicle
1. Place vehicle on a flat non slippery ground.
2. Ensure vehicle shift lever is set to PARK.
3. Install an hydraulic jack under front skid plate.
4. Lift front of vehicle and install a jack stand on
each side under frame section in front of the lip
for center skid plate.
tmr2013-002
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This comprehensive manual covers every aspect of your machine, providing detailed guidance for tasks ranging from an oil change to a transmission swap. With hundreds of pages, it includes numerous illustrations and easy-to-understand text to assist you. The manual also features a search function, allowing you to easily navigate and print necessary pages.
Designed as a Factory Service Repair Manual, it offers a step-by-step approach to maintaining and repairing your vehicle, imparting the expertise of factory-trained technicians. By utilizing the knowledge within this manual, any owner can confidently make informed decisions regarding the maintenance and repair of their machine.
Our commitment extends beyond providing a high-quality service manual; we also ensure excellent customer service, guaranteeing your satisfaction.
