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

2013 Shop Manual Maverick™ 1000R Series

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

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

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