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
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CAN AM COMMandER 800R 1000 Series ATV Service Repair Manual 2013-2014
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Description
Rebuild, maintain, and troubleshoot your Can Am Commander 800R or 1000 series ATV with this detailed service repair manual. Whether you're replacing worn clutch plates, servicing the engine, or diagnosing electrical gremlins, this manual walks you through every job step by step. Full diagrams, torque specs, and part callouts keep you on track.
Covers 2013–2014 models completely. Includes engine teardown and reassembly, fuel system repair, suspension work, transmission service, and brake maintenance. One download, instant access, no subscription. Start your repair today.
