2013-2015 Can-Am Maverick 1000R UTV Service & Repair Manual

2014-2016 Can-Am Maverick 2-Seater Series This manual may cover later years than listed above. I have combined the Base service manual with the Maverick, Maverick Xxc and Maverick Xmr supplemental manuals into one easy to use full maintenance and repair master collection. This manual is fully searchable, just hold down the control key and the F key to search on any word. If you bought this manual from any other seller, they are reselling my work. Please leave them negative feedback & email me at bestshopmanuals@gmail.com. Our goal is to be one of the BEST sellers on eBay and the internet by providing you with the BEST customer service and the BEST manuals on the market. Thank you for choosing us.

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 ......................................................................................... 5 02 – PERIODIC MAINTENANCE SCHEDULE....................................................................... 7 03 – PERIODIC MAINTENANCE PROCEDURES ................................................................... 9 GENERAL ...................................................................................................... 9 PROCEDURES ................................................................................................. 9 ENGINE (AIR INTAKE SYSTEM) ............................................................................ 9 ENGINE (EXHAUST SYSTEM) ............................................................................ 10 ENGINE (LUBRICATION SYSTEM)........................................................................ 11 ENGINE (COOLING SYSTEM) ............................................................................ 13 ENGINE (TOP END) ....................................................................................... 18 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ..................................................... 19 GEARBOX................................................................................................. 20 FUEL SYSTEM ............................................................................................ 21 ELECTRICAL SYSTEM .................................................................................... 22 DRIVE SYSTEM ........................................................................................... 23 CHASSIS (WHEELS AND TIRES) ......................................................................... 25 CHASSIS (STEERING SYSTEM) .......................................................................... 25 CHASSIS (SUSPENSION) ................................................................................. 26 CHASSIS (BRAKES) ....................................................................................... 27 CHASSIS (PASSENGER HANDHOLDS) ................................................................... 29 CHASSIS (TOW HITCH) ................................................................................... 29 04 – STORAGE PROCEDURE....................................................................................... 31 GENERAL .................................................................................................... 31 PROCEDURES ............................................................................................... 31 FUEL SYSTEM ............................................................................................ 31 ENGINE ................................................................................................... 31 ELECTRICAL SYSTEM .................................................................................... 32 DRIVE SYSTEM ........................................................................................... 32 CHASSIS .................................................................................................. 32 05 – PRESEASON PREPARATION ................................................................................. 33 06 – SPECIAL PROCEDURES ....................................................................................... 35 GENERAL .................................................................................................... 35 ROLLED OVER VEHICLE ................................................................................. 35 SUBMERGED VEHICLE................................................................................... 35 02 ENGINE, CVT AND GEARBOX 01 – ENGINE REMOVAL AND INSTALLATION .................................................................. 37 PROCEDURES ............................................................................................... 38 ENGINE REMOVAL ....................................................................................... 38 ENGINE INSTALLATION .................................................................................. 40 ENGINE MOUNTS ........................................................................................ 40 02 – AIR INTAKE SYSTEM.......................................................................................... 41 GENERAL .................................................................................................... 42 PROCEDURES ............................................................................................... 42 AIR FILTER ................................................................................................ 42 AIR FILTER HOUSING .................................................................................... 42 I

TABLE OF CONTENTS 02 ENGINE, CVT AND GEARBOX (cont’d) 03 – EXHAUST SYSTEM............................................................................................ 45 GENERAL .................................................................................................... 46 PROCEDURES ............................................................................................... 46 SPARK ARRESTER ........................................................................................ 46 MUFFLER ................................................................................................. 46 “Y” EXHAUST PIPE....................................................................................... 46 RESONATOR.............................................................................................. 47 HEAD PIPE (FRONT CYLINDER).......................................................................... 47 HEAD PIPE (REAR CYLINDER) ........................................................................... 49 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 OIL NOZZLES ............................................................................................. 60 05 – COOLING SYSTEM ............................................................................................ 63 GENERAL .................................................................................................... 66 PROCEDURES ............................................................................................... 66 THERMOSTAT ............................................................................................ 66 RADIATOR ................................................................................................ 66 COOLANT TEMPERATURE SENSOR (CTS) .............................................................. 68 RADIATOR COOLING FAN RELAY (R1) ................................................................... 68 RADIATOR COOLING FAN ............................................................................... 68 WATER PUMP HOUSING ................................................................................. 70 WATER PUMP IMPELLER ................................................................................ 71 WATER PUMP SHAFT AND SEALS ...................................................................... 71 WATER PUMP GEARS .................................................................................... 78 06 – MAGNETO SYSTEM........................................................................................... 81 PROCEDURES ............................................................................................... 83 MAGNETO COVER ....................................................................................... 83 STATOR ................................................................................................... 84 ROTOR.................................................................................................... 86 SPRAG CLUTCH .......................................................................................... 87 SPRAG CLUTCH GEAR ................................................................................... 88 STARTER DRIVE GEARS.................................................................................. 89 07 – INTAKE MANIFOLD ............................................................................................ 91 PROCEDURES ............................................................................................... 92 PLENUM BRACKET....................................................................................... 92 INTAKE MANIFOLD....................................................................................... 92 08 – TOP END......................................................................................................... 95 GENERAL .................................................................................................... 99 INSPECTION................................................................................................. 99 LEAK TEST ................................................................................................ 99 PROCEDURES .............................................................................................. 101 VALVE COVER ........................................................................................... 101 ROCKER ARM ........................................................................................... 101 CAMSHAFT .............................................................................................. 104 CYLINDER HEAD ........................................................................................ 105 II

TABLE OF CONTENTS 02 ENGINE, CVT AND GEARBOX (cont’d) 08 – TOP END (cont’d) PROCEDURES (cont’d) VALVE SPRINGS ......................................................................................... 107 VALVES................................................................................................... 109 VALVE GUIDES........................................................................................... 111 CYLINDER ............................................................................................... 112 PISTON .................................................................................................. 114 PISTON RINGS........................................................................................... 117 09 – TIMING CHAIN ................................................................................................ 119 GENERAL ................................................................................................... 121 TROUBLESHOOTING ..................................................................................... 121 PROCEDURES .............................................................................................. 121 TIMING CHAIN TENSIONERS ........................................................................... 121 CAMSHAFT TIMING GEARS ............................................................................ 123 TIMING CHAIN........................................................................................... 127 TIMING CHAIN GUIDE (TENSIONER SIDE) ............................................................. 129 10 – BOTTOM END ................................................................................................. 131 GENERAL ................................................................................................... 135 PROCEDURES .............................................................................................. 135 ENGINE DRIVE SHAFT .................................................................................. 135 FRONT OIL SEAL (ENGINE DRIVE SHAFT) ............................................................. 137 REAR OIL SEAL (ENGINE DRIVE SHAFT) ............................................................... 138 PTO COVER OIL SEAL .................................................................................. 139 PTO COVER.............................................................................................. 139 DRIVE GEARS ........................................................................................... 142 CRANKCASE ............................................................................................. 143 CRANKSHAFT............................................................................................ 147 11 – CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ................................................... 155 GENERAL ................................................................................................... 158 PROCEDURES .............................................................................................. 158 CVT COVER .............................................................................................. 158 DRIVE BELT .............................................................................................. 159 DRIVE PULLEY........................................................................................... 160 DRIVEN PULLEY ......................................................................................... 168 CVT AIR GUIDE .......................................................................................... 175 12 – GEARBOX AND 4X4 COUPLING UNIT .................................................................... 177 GENERAL ................................................................................................... 179 GEARBOX OVERVIEW................................................................................... 179 TROUBLESHOOTING ..................................................................................... 179 PROCEDURES .............................................................................................. 179 VSS (VEHICLE SPEED SENSOR) ........................................................................ 179 GBPS (GEARBOX POSITION SENSOR) ................................................................. 181 4WD INDICATOR SWITCH .............................................................................. 183 ACTUATOR .............................................................................................. 184 GEARBOX OIL SEALS ................................................................................... 185 GEARBOX................................................................................................ 187 13 – SHIFTER ........................................................................................................ 203 PROCEDURES .............................................................................................. 204 SHIFT LEVER ............................................................................................ 204 SHIFTER CABLE ......................................................................................... 205 SHIFT PLATE ............................................................................................. 206 III

TABLE OF CONTENTS 03 ELECTRONIC MANAGEMENT SYSTEM 01 – ENGINE MANAGEMENT SYSTEM (EMS) ................................................................ 209 GENERAL ................................................................................................... 210 SYSTEM DESCRIPTION ................................................................................. 210 02 – CONTROLLER AREA NETWORK (CAN) ................................................................... 211 GENERAL ................................................................................................... 211 SYSTEM DESCRIPTION ................................................................................. 211 03 – COMMUNICATION TOOLS AND B.U.D.S. ................................................................ 213 GENERAL ................................................................................................... 213 REQUIRED TOOLS ...................................................................................... 213 TROUBLESHOOTING ..................................................................................... 213 DIAGNOSTIC TIPS ....................................................................................... 213 PROCEDURES .............................................................................................. 214 MULTI-PURPOSE INTERFACE-2 (MPI-2)................................................................. 214 B.U.D.S. SOFTWARE .................................................................................... 215 04 – DIAGNOSTIC SYSTEM AND FAULT CODES ............................................................. 219 GENERAL ................................................................................................... 219 MONITORING SYSTEM ................................................................................. 219 FAULT CODES ........................................................................................... 220 FAULT CODE DIAGNOSTIC.............................................................................. 225 SPECIFIC FAULTS........................................................................................ 229 04 FUEL SYSTEM 01 – INTELLIGENT THROTTLE CONTROL (iTC)................................................................ 231 GENERAL ................................................................................................... 231 SYSTEM DESCRIPTION ................................................................................. 231 SYSTEM MAIN FEATURES .............................................................................. 231 SYSTEM OTHER FEATURES ............................................................................ 231 PROCEDURES .............................................................................................. 232 SPORT/NORMAL SWITCH .............................................................................. 232 SEAT BELT SWITCH ..................................................................................... 232 OVERRIDE SWITCH ..................................................................................... 232 THROTTLE ACCELERATOR SENSOR (TAS) ............................................................. 232 02 – ELECTRONIC FUEL INJECTION (EFI) ...................................................................... 235 GENERAL ................................................................................................... 235 SYSTEM DESCRIPTION ................................................................................. 235 ADJUSTMENT ............................................................................................. 236 IDLE SPEED ............................................................................................. 236 TROUBLESHOOTING ..................................................................................... 237 DIAGNOSTIC TIPS ....................................................................................... 237 PROCEDURES .............................................................................................. 237 ENGINE CONTROL MODULE (ECM) .................................................................... 237 FUEL INJECTOR ......................................................................................... 243 FUEL RAIL ............................................................................................... 247 THROTTLE BODY........................................................................................ 248 THROTTLE POSITION SENSOR (TPS) ................................................................... 249 CRANKSHAFT POSITION SENSOR (CPS) ............................................................... 251 MANIFOLD AIR PRESSURE AND TEMPERATURE SENSOR (MAPTS) ................................. 252 CTS (COOLANT TEMPERATURE SENSOR) ............................................................. 255 KNOCK SENSOR (KS) .................................................................................... 256 03 – FUEL TANK AND FUEL PUMP .............................................................................. 259 GENERAL ................................................................................................... 261 SYSTEM DESCRIPTION ................................................................................. 261 INSPECTION................................................................................................ 262 FUEL TANK LEAK TEST.................................................................................. 262 IV

TABLE OF CONTENTS 04 FUEL SYSTEM (cont’d) 03 – FUEL TANK AND FUEL PUMP (cont’d) INSPECTION (cont’d) FUEL PUMP PRESSURE TEST .......................................................................... 262 TROUBLESHOOTING ..................................................................................... 265 FUEL SYSTEM DIAGNOSTIC FLOW CHART ............................................................ 265 PROCEDURES .............................................................................................. 266 FUEL HOSE AND OETIKER CLAMPS ................................................................... 266 FUEL TANK .............................................................................................. 266 FUEL PUMP ............................................................................................. 268 FUEL LEVEL SENDER ................................................................................... 272 FUEL TANK VENT VALVE ................................................................................ 273 05 ELECTRICAL SYSTEM 01 – POWER DISTRIBUTION AND GROUNDS ................................................................. 275 GENERAL ................................................................................................... 275 POWER DISTRIBUTION DIAGRAM ..................................................................... 275 FUSE BOX 1 ............................................................................................. 276 FUSE BOX 2 ............................................................................................. 276 GROUND................................................................................................. 277 02 – WIRING HARNESSES AND CONNECTORS .............................................................. 279 GENERAL ................................................................................................... 279 WIRING HARNESS AND SPLICE LOCATION............................................................ 279 PROCEDURES .............................................................................................. 279 DEUTSCH CONNECTORS ............................................................................... 279 PACKARD CONNECTORS ............................................................................... 281 PACKARD CONNECTOR (MULTIFUNCTION GAUGE) ................................................... 282 MOLEX CONNECTOR ................................................................................... 283 FURUKAWA CONNECTOR .............................................................................. 286 BATTERY AND STARTER CABLE TERMINALS .......................................................... 287 03 – IGNITION SYSTEM ........................................................................................... 289 GENERAL ................................................................................................... 289 SYSTEM DESCRIPTION ................................................................................. 289 TROUBLESHOOTING ..................................................................................... 289 DIAGNOSTIC GUIDELINES .............................................................................. 289 PROCEDURES .............................................................................................. 289 IGNITION SWITCH ....................................................................................... 289 IGNITION COIL .......................................................................................... 290 SPARK PLUG............................................................................................. 291 04 – CHARGING SYSTEM ......................................................................................... 293 GENERAL ................................................................................................... 293 SYSTEM DESCRIPTION ................................................................................. 293 INSPECTION................................................................................................ 293 CHARGING SYSTEM OUTPUT .......................................................................... 293 TROUBLESHOOTING ..................................................................................... 294 PROCEDURES .............................................................................................. 294 VOLTAGE REGULATOR/RECTIFIER ..................................................................... 294 BATTERY ................................................................................................. 294 05 – STARTING SYSTEM .......................................................................................... 297 GENERAL ................................................................................................... 297 SYSTEM DESCRIPTION ................................................................................. 297 TROUBLESHOOTING ..................................................................................... 297 DIAGNOSTIC GUIDELINES .............................................................................. 297 PROCEDURES .............................................................................................. 298 D2 DIODE (STARTER SOLENOID) ....................................................................... 298 V

TABLE OF CONTENTS 05 ELECTRICAL SYSTEM (cont’d) 05 – STARTING SYSTEM (cont’d) PROCEDURES (cont’d) START BUTTON.......................................................................................... 298 STARTER SOLENOID .................................................................................... 299 ELECTRIC STARTER ..................................................................................... 300 06 – DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) .................................................. 303 GENERAL ................................................................................................... 303 SYSTEM DESCRIPTION ................................................................................. 303 TROUBLESHOOTING ..................................................................................... 303 DIAGNOSTIC TIPS ....................................................................................... 303 PROCEDURES .............................................................................................. 303 KEY PROGRAMMING ................................................................................... 303 07 – LIGHTS, GAUGE AND ACCESSORIES..................................................................... 305 GENERAL ................................................................................................... 305 TROUBLESHOOTING ..................................................................................... 305 DIAGNOSTIC TIPS ....................................................................................... 305 PROCEDURES .............................................................................................. 305 CONSOLE SWITCHES ................................................................................... 305 MULTIFUNCTION GAUGE (LCD AND ANALOG/DIGITAL)............................................... 306 12 VOLT POWER OUTLET............................................................................... 309 HEADLIGHTS ............................................................................................ 309 TAILLIGHTS/BRAKE LIGHTS............................................................................. 311 WINCH ................................................................................................... 311 TURN SIGNALS/HAZARD(EC MODELS ONLY) .......................................................... 313 HORN (EC MODELS ONLY) ............................................................................. 313 06 DRIVE SYSTEM 01 – FRONT DRIVE.................................................................................................. 315 GENERAL ................................................................................................... 318 SYSTEM DESCRIPTION ................................................................................. 318 PROCEDURES .............................................................................................. 318 WHEEL HUB ............................................................................................. 318 FRONT DRIVE SHAFT ................................................................................... 318 DRIVE SHAFT BOOT..................................................................................... 319 FRONT DIFFERENTIAL .................................................................................. 319 FRONT PROPELLER SHAFT ............................................................................. 324 PROPELLER SHAFT U-JOINTS .......................................................................... 324 02 – REAR DRIVE.................................................................................................... 327 PROCEDURES .............................................................................................. 330 WHEEL HUB ............................................................................................. 330 DRIVE SHAFT ............................................................................................ 331 DRIVE SHAFT BOOT..................................................................................... 331 PROPELLER SHAFT ..................................................................................... 332 PROPELLER SHAFT U-JOINTS .......................................................................... 333 REAR FINAL DRIVE ...................................................................................... 334 07 CHASSIS 01 – WHEELS AND TIRES ......................................................................................... 339 PROCEDURES .............................................................................................. 339 TIRES .................................................................................................... 339 WHEELS ................................................................................................. 341 02 – STEERING SYSTEM .......................................................................................... 343 GENERAL ................................................................................................... 344 VI

TABLE OF CONTENTS 07 CHASSIS (cont’d) 02 – STEERING SYSTEM (cont’d) ADJUSTMENT ............................................................................................. 344 STEERING ALIGNMENT ................................................................................. 344 TROUBLESHOOTING ..................................................................................... 346 DIAGNOSTIC TIPS ....................................................................................... 346 PROCEDURES .............................................................................................. 346 STEERING WHEEL ...................................................................................... 346 STEERING COLUMN .................................................................................... 347 RACK AND PINION ...................................................................................... 348 TIE-ROD ENDS........................................................................................... 349 KNUCKLES ............................................................................................... 350 WHEEL BEARINGS ...................................................................................... 351 03 – FRONT SUSPENSION ........................................................................................ 353 GENERAL ................................................................................................... 354 PROCEDURES .............................................................................................. 354 SHOCK ABSORBER ..................................................................................... 354 SPRINGS ................................................................................................. 355 LOWER SUSPENSION ARM ............................................................................ 355 UPPER SUSPENSION ARM ............................................................................. 356 SUSPENSION ARM BUSHINGS ......................................................................... 357 BALL JOINTS ............................................................................................ 358 04 – REAR SUSPENSION .......................................................................................... 359 GENERAL ................................................................................................... 360 PROCEDURES .............................................................................................. 360 SHOCK ABSORBERS .................................................................................... 360 SPRINGS ................................................................................................. 361 ANTI-SWAY BAR ......................................................................................... 361 UPPER SUSPENSION ARM ............................................................................. 362 LOWER SUSPENSION ARM ............................................................................ 363 SUSPENSION ARM BUSHINGS ......................................................................... 363 REAR TOE LINK ......................................................................................... 364 05 – BRAKES ......................................................................................................... 365 GENERAL ................................................................................................... 367 INSPECTION................................................................................................ 367 BRAKE SYSTEM PRESSURE VALIDATION .............................................................. 367 PROCEDURES .............................................................................................. 368 BRAKE LIGHT SWITCH .................................................................................. 368 MASTER CYLINDER ..................................................................................... 368 CALIPER ................................................................................................. 370 BRAKE PADS ............................................................................................ 371 BRAKE DISC ............................................................................................. 372 WHEEL SCRAPER (REAR WHEELS ONLY) ............................................................. 372 06 – BODY ............................................................................................................ 375 PROCEDURES .............................................................................................. 396 PLASTIC RIVET .......................................................................................... 396 DECALS .................................................................................................. 396 UPPER CONSOLE ....................................................................................... 396 LOWER CONSOLE ...................................................................................... 396 LATERAL CONSOLE PANELS ........................................................................... 397 GLOVE BOX ............................................................................................. 397 FUEL TANK COWL....................................................................................... 398 SEAT COVER............................................................................................. 398 VII

TABLE OF CONTENTS 07 CHASSIS (cont’d) 07 – FRAME .......................................................................................................... 399 PROCEDURES .............................................................................................. 401 CAGE..................................................................................................... 401 FRAME................................................................................................... 402 08 TECHNICAL SPECIFICATIONS 01 – MAVERICK 1000R ............................................................................................. 403 09 WIRING DIAGRAM 01 – WIRING DIAGRAM INFORMATION ........................................................................ 413 GENERAL ................................................................................................... 413 WIRING DIAGRAM LOCATION .......................................................................... 413 WIRING DIAGRAM CODES.............................................................................. 413 VIII

SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to cor- rectly service and repair the 2013 Can-Am ™ Mav- erick SSV as describe d in the model list in the IN- TRODUCTION. This edition was primarily published to be used by mechanical technicians who are already familiar with all service procedures relating to BRP products. 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 service 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: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates an instruction which, if not followed, could result in severe damage to vehicle components or other property. NOTE: Indicates supplementary information required to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understand- ing of the information 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 service 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 carried 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 contents of this publication. tmr2013-002 IX

2013-2015 Can-Am Maverick 1000R UTV Service & Repair Manual

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