2012-2014 Can Am Outlander Renegade G2 Service & Repair Manual

2013 Shop Manual Outlander™ 500/650/800R/1000 Renegade™ 500/800R/1000

Legal deposit: National Library of Quebec National Library of Canada 2012 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. (BRP) © Bombardier Recreational Products Inc. (BRP) 2012 Printed in Canada Technical Publications Bombardier Recreational Products Inc. (BRP) Valcourt QC Canada ® ™ Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates. * Trademarks of Bombardier Inc., used under license. Can-Am™ DPS™ Outlander™ D.E.S.S.™ Rotax ® Renegade™ XPS™ TTI™ This document contains the trademarks of the following companies: Loctite ® is a trademark of Loctite Corporation Snap-on ® is a trademark of Snap-on Tools Corporation Visco-lok ® is a trademark of GKN Viscodrive GmbH

TABLE OF CONTENTS SAFETY NOTICE ........................................................................................................ X INTRODUCTION ........................................................................................................ XI VEHICLE INFORMATION ............................................................................................ XI ENGINE EMISSIONS INFORMATION............................................................................. XII MANUAL INFORMATION........................................................................................... XII FASTENER INFORMATION ....................................................................................... XVII 01 MAINTENANCE 01 – BREAK-IN INSPECTION ......................................................................................... 7 02 – PERIODIC MAINTENANCE SCHEDULE....................................................................... 9 GENERAL ...................................................................................................... 9 MAINTENANCE SOON MESSAGE ......................................................................... 9 SEVERE DUSTY CONDITIONS ............................................................................. 9 MAINTENANCE SCHEDULE.............................................................................. 10 03 – PERIODIC MAINTENANCE PROCEDURES ................................................................. 13 GENERAL .................................................................................................... 13 PROCEDURES ............................................................................................... 13 ENGINE (AIR INTAKE SYSTEM) .......................................................................... 13 ENGINE (EXHAUST SYSTEM) ............................................................................ 16 ENGINE (LUBRICATION SYSTEM)........................................................................ 17 ENGINE (COOLING SYSTEM) ............................................................................ 19 ENGINE (CYLINDER HEAD) .............................................................................. 23 GEARBOX................................................................................................. 23 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ..................................................... 25 FUEL SYSTEM ............................................................................................ 26 ELECTRICAL SYSTEM .................................................................................... 28 DRIVE SYSTEM ........................................................................................... 29 CHASSIS (WHEELS AND TIRES) ......................................................................... 30 CHASSIS (STEERING SYSTEM) .......................................................................... 31 CHASSIS (SUSPENSION) ................................................................................. 31 CHASSIS (BRAKES) ....................................................................................... 33 CHASSIS (BODY) ......................................................................................... 35 CHASSIS (FRAME) ........................................................................................ 35 04 – STORAGE PROCEDURE....................................................................................... 37 GENERAL .................................................................................................... 37 PROCEDURES ............................................................................................... 37 FUEL SYSTEM ............................................................................................ 37 ENGINE ................................................................................................... 37 ELECTRICAL SYSTEM .................................................................................... 38 DRIVE SYSTEM ........................................................................................... 38 CHASSIS .................................................................................................. 38 05 – PRESEASON PREPARATION ................................................................................. 41 06 – SPECIAL PROCEDURES ....................................................................................... 43 GENERAL .................................................................................................... 43 WHAT TO DO IF WATERIS IN THE CVT ................................................................. 43 WHAT TO DO IF WATER IS IN THE AIR FILTER HOUSING .............................................. 43 WHAT TO DO IF VEHICLE IS TURNED OVER............................................................ 43 WHAT TO DO IF VEHICLE IS IMMERSED IN WATER.................................................... 44 02 ENGINE, CVT AND GEARBOX 01 – ENGINE REMOVAL AND INSTALLATION .................................................................. 45 PROCEDURES ............................................................................................... 46 ENGINE REMOVAL ....................................................................................... 46 ENGINE INSTALLATION .................................................................................. 51 I

TABLE OF CONTENTS 02 ENGINE, CVT AND GEARBOX (cont’d) 01 – ENGINE REMOVAL AND INSTALLATION (cont’d) PROCEDURES (cont’d) ENGINE MOUNTS REPLACEMENT ...................................................................... 51 02 – AIR INTAKE SYSTEM.......................................................................................... 53 GENERAL .................................................................................................... 54 PROCEDURES ............................................................................................... 54 AIR FILTER ................................................................................................ 54 AIR FILTER HOUSING .................................................................................... 54 03 – EXHAUST SYSTEM............................................................................................ 59 GENERAL .................................................................................................... 60 PROCEDURES ............................................................................................... 60 SPARK ARRESTER ........................................................................................ 60 MUFFLER ................................................................................................. 60 HEAT SHIELD ............................................................................................. 61 Y-EXHAUST PIPE ......................................................................................... 62 HEAD PIPE (FRONT CYLINDER).......................................................................... 62 04 – LUBRICATION SYSTEM ....................................................................................... 65 INSPECTION................................................................................................. 68 ENGINE OIL PRESSURE .................................................................................. 68 TROUBLESHOOTING ...................................................................................... 68 PROCEDURES ............................................................................................... 69 OIL COOLER.............................................................................................. 69 OIL PRESSURE SWITCH (OPS)........................................................................... 70 ENGINE OIL PRESSURE REGULATOR ................................................................... 71 OIL PUMP ................................................................................................ 72 ENGINE OIL STRAINER .................................................................................. 74 REED VALVE .............................................................................................. 75 05 – COOLING SYSTEM ............................................................................................ 77 GENERAL .................................................................................................... 82 PROCEDURES ............................................................................................... 82 THERMOSTAT ............................................................................................ 82 RADIATOR ................................................................................................ 83 COOLANT TEMPERATURE SENSOR (CTS) .............................................................. 84 RADIATOR COOLING FAN RELAY (R1) ................................................................... 84 RADIATOR COOLING FAN ............................................................................... 85 WATER PUMP HOUSING ................................................................................. 87 WATER PUMP IMPELLER ................................................................................ 88 WATER PUMP SHAFT AND SEALS ...................................................................... 88 WATER PUMP GEARS .................................................................................... 95 06 – MAGNETO SYSTEM........................................................................................... 99 PROCEDURES .............................................................................................. 101 MAGNETO COVER ...................................................................................... 101 STATOR .................................................................................................. 102 ROTOR................................................................................................... 104 SPRAG CLUTCH ......................................................................................... 106 SPRAG CLUTCH GEAR .................................................................................. 107 STARTER DRIVE GEARS................................................................................. 108 07 – INTAKE MANIFOLD ........................................................................................... 109 PROCEDURES .............................................................................................. 110 INTAKE MANIFOLD...................................................................................... 110 08 – TOP END........................................................................................................ 111 GENERAL ................................................................................................... 115 INSPECTION................................................................................................ 115 LEAK TEST ............................................................................................... 115 II

TABLE OF CONTENTS 02 ENGINE, CVT AND GEARBOX (cont’d) 08 – TOP END (cont’d) PROCEDURES .............................................................................................. 117 VALVE COVER ........................................................................................... 117 ROCKER ARM ........................................................................................... 117 CAMSHAFT .............................................................................................. 119 CYLINDER HEAD ........................................................................................ 122 VALVE SPRINGS ......................................................................................... 124 VALVES................................................................................................... 126 VALVE GUIDES........................................................................................... 128 CYLINDER ............................................................................................... 129 PISTON .................................................................................................. 130 PISTON RINGS........................................................................................... 135 09 – TIMING CHAIN ................................................................................................ 137 TROUBLESHOOTING ..................................................................................... 139 PROCEDURES .............................................................................................. 139 TIMING CHAIN TENSIONERS ........................................................................... 139 CAMSHAFT TIMING GEARS ............................................................................ 141 TIMING CHAIN........................................................................................... 145 TIMING CHAIN GUIDE (TENSIONER SIDE) ............................................................. 147 10 – BOTTOM END ................................................................................................. 149 PROCEDURES .............................................................................................. 153 ENGINE DRIVE SHAFT .................................................................................. 153 FRONT OIL SEAL (ENGINE DRIVE SHAFT) ............................................................. 155 REAR OIL SEAL (ENGINE DRIVE SHAFT) ............................................................... 155 PTO COVER OIL SEAL .................................................................................. 156 PTO COVER.............................................................................................. 157 DRIVE GEARS ........................................................................................... 159 CRANKCASE ............................................................................................. 161 CRANKSHAFT............................................................................................ 165 11 – CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ................................................... 173 GENERAL ................................................................................................... 176 PROCEDURES .............................................................................................. 176 CVT COVER .............................................................................................. 176 DRIVE BELT .............................................................................................. 177 DRIVE PULLEY........................................................................................... 177 DRIVEN PULLEY ......................................................................................... 186 CVT AIR GUIDE .......................................................................................... 195 12 – GEARBOX AND 4X4 COUPLING UNIT (500/650/800R) ................................................ 197 GENERAL ................................................................................................... 200 OVERVIEW............................................................................................... 200 TROUBLESHOOTING ..................................................................................... 200 PROCEDURES .............................................................................................. 200 GEARBOX POSITION INDICATOR SWITCHES .......................................................... 200 4WD INDICATOR SWITCH .............................................................................. 202 GEARBOX OIL SEALS ................................................................................... 202 ACTUATOR .............................................................................................. 204 OUTPUT SHAFT AND COUPLING MECHANISM ....................................................... 206 GEARBOX................................................................................................ 212 13 – GEARBOX AND 4X4 COUPLING UNIT (1000)............................................................ 229 GENERAL ................................................................................................... 231 GEARBOX OVERVIEW................................................................................... 231 TROUBLESHOOTING ..................................................................................... 231 PROCEDURES .............................................................................................. 231 VEHICLE SPEED SENSOR (VSS) ........................................................................ 231 III

TABLE OF CONTENTS 02 ENGINE, CVT AND GEARBOX (cont’d) 13 – GEARBOX AND 4X4 COUPLING UNIT (1000) (cont’d) PROCEDURES (cont’d) GEARBOX POSITION SENSOR (GBPS) ................................................................. 234 4WD INDICATOR SWITCH .............................................................................. 236 ACTUATOR .............................................................................................. 236 GEARBOX OIL SEALS ................................................................................... 238 GEARBOX................................................................................................ 240 14 – SHIFTER ........................................................................................................ 255 PROCEDURES .............................................................................................. 256 SHIFT LEVER ............................................................................................ 256 SHIFT ROD............................................................................................... 257 SHIFT PLATE ............................................................................................. 257 03 ELECTRONIC MANAGEMENT SYSTEMS 01 – ENGINE MANAGEMENT SYSTEM (EMS) ................................................................ 261 GENERAL ................................................................................................... 262 SYSTEM DESCRIPTION ................................................................................. 262 02 – CONTROLLER AREA NETWORK (CAN) ................................................................... 263 GENERAL ................................................................................................... 263 SYSTEM DESCRIPTION ................................................................................. 263 03 – COMMUNICATION TOOLS AND B.U.D.S. ................................................................ 265 GENERAL ................................................................................................... 265 TROUBLESHOOTING ..................................................................................... 265 DIAGNOSTIC TIPS ....................................................................................... 265 PROCEDURES .............................................................................................. 266 MULTI-PURPOSE INTERFACE-2 (MPI-2)................................................................. 266 B.U.D.S. .................................................................................................. 267 04 – DIAGNOSTIC SYSTEM AND FAULT CODES ............................................................. 271 GENERAL ................................................................................................... 271 MONITORING SYSTEM ................................................................................. 271 FAULT CODES ........................................................................................... 272 FAULT CODE DIAGNOSTIC.............................................................................. 276 FAULT CODE TABLE ..................................................................................... 279 04 FUEL SYSTEM 01 – ELECTRONIC FUEL INJECTION (EFI) ...................................................................... 295 GENERAL ................................................................................................... 295 SYSTEM DESCRIPTION ................................................................................. 295 ADJUSTMENT ............................................................................................. 296 IDLE SPEED ............................................................................................. 296 CLOSED THROTTLE AND IDLE ACTUATOR RESET .................................................... 297 TROUBLESHOOTING ..................................................................................... 298 DIAGNOSTIC TIPS ....................................................................................... 298 PROCEDURES .............................................................................................. 298 ENGINE CONTROL MODULE (ECM) .................................................................... 298 FUEL INJECTOR ......................................................................................... 303 FUEL RAIL ............................................................................................... 306 THROTTLE CABLE ....................................................................................... 306 THROTTLE BODY........................................................................................ 307 THROTTLE POSITION SENSOR (TPS) ................................................................... 310 IDLE AIR CONTROL VALVE (IACV) ...................................................................... 312 CRANKSHAFT POSITION SENSOR (CPS) ............................................................... 313 MANIFOLD ABSOLUTE PRESSURE AND TEMPERATURE SENSOR (MAPTS) ......................... 314 CTS (COOLANT TEMPERATURE SENSOR) ............................................................. 317 IV

TABLE OF CONTENTS 04 FUEL SYSTEM (cont’d) 02 – FUEL TANK AND FUEL PUMP .............................................................................. 319 GENERAL ................................................................................................... 321 SYSTEM DESCRIPTION ................................................................................. 321 INSPECTION................................................................................................ 322 FUEL TANK LEAK TEST.................................................................................. 322 FUEL SYSTEM PRESSURE TEST ........................................................................ 323 TROUBLESHOOTING ..................................................................................... 325 FUEL SYSTEM DIAGNOSTIC FLOW CHART ............................................................ 325 PROCEDURES .............................................................................................. 326 FUEL HOSE AND OETIKER CLAMPS ................................................................... 326 FUEL TANK .............................................................................................. 326 FUEL PUMP ............................................................................................. 330 FUEL PUMP PREFILTER (STRAINER) ................................................................... 334 FUEL LEVEL SENDER ................................................................................... 335 FUEL TANK VENT VALVES ............................................................................... 336 05 ELECTRICAL SYSTEM 01 – POWER DISTRIBUTION AND GROUNDS ................................................................. 339 GENERAL ................................................................................................... 339 POWER DISTRIBUTION DIAGRAM ..................................................................... 339 FUSE BOX 1 ............................................................................................. 340 FUSE BOX 2 ............................................................................................. 341 GROUNDS ............................................................................................... 341 02 – WIRING HARNESS AND CONNECTORS .................................................................. 343 GENERAL ................................................................................................... 344 CONNECTOR ABBREVIATION DESCRIPTION .......................................................... 344 WIRING HARNESS ARRANGEMENT .................................................................... 345 WIRING HARNESS ROUTING ........................................................................... 347 WIRING HARNESS SPLICE LOCATION ................................................................. 357 PROCEDURES .............................................................................................. 363 DEUTSCH CONNECTORS ............................................................................... 363 PACKARD CONNECTORS ............................................................................... 364 PACKARD CONNECTOR (MULTIFUNCTION GAUGE) ................................................... 364 MOLEX CONNECTOR ................................................................................... 366 FURUKAWA CONNECTOR .............................................................................. 368 BATTERY AND STARTER CABLE TERMINALS .......................................................... 369 03 – IGNITION SYSTEM ........................................................................................... 371 GENERAL ................................................................................................... 371 SYSTEM DESCRIPTION ................................................................................. 371 TROUBLESHOOTING ..................................................................................... 371 DIAGNOSTIC GUIDELINES .............................................................................. 371 PROCEDURES .............................................................................................. 372 IGNITION SWITCH ....................................................................................... 372 EMERGENCY ENGINE STOP SWITCH .................................................................. 372 IGNITION COIL .......................................................................................... 374 SPARK PLUG............................................................................................. 376 04 – CHARGING SYSTEM ......................................................................................... 377 GENERAL ................................................................................................... 377 SYSTEM DESCRIPTION ................................................................................. 377 INSPECTION................................................................................................ 378 CHARGING SYSTEM OUTPUT .......................................................................... 378 TROUBLESHOOTING ..................................................................................... 378 PROCEDURES .............................................................................................. 379 VOLTAGE REGULATOR/RECTIFIER ..................................................................... 379 V

TABLE OF CONTENTS 05 ELECTRICAL SYSTEM (cont’d) 04 – CHARGING SYSTEM (cont’d) PROCEDURES (cont’d) BATTERY ................................................................................................. 379 05 – STARTING SYSTEM .......................................................................................... 381 GENERAL ................................................................................................... 381 SYSTEM DESCRIPTION ................................................................................. 381 TROUBLESHOOTING ..................................................................................... 381 DIAGNOSTIC GUIDELINES .............................................................................. 381 PROCEDURES .............................................................................................. 382 D2 DIODE (STARTER SOLENOID) ....................................................................... 382 START BUTTON.......................................................................................... 382 STARTER SOLENOID .................................................................................... 383 ELECTRIC STARTER ..................................................................................... 386 06 – DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) .................................................. 389 GENERAL ................................................................................................... 389 SYSTEM DESCRIPTION ................................................................................. 389 TROUBLESHOOTING ..................................................................................... 389 DIAGNOSTIC TIPS ....................................................................................... 389 PROCEDURES .............................................................................................. 389 KEY PROGRAMMING ................................................................................... 389 07 – LIGHTS, GAUGE AND ACCESSORIES..................................................................... 391 GENERAL ................................................................................................... 391 MULTIFUNCTION GAUGE - LCD (OUTLANDER) ........................................................ 391 MULTIFUNCTION GAUGE (ANALOG/DIGITAL) .......................................................... 394 1) ANALOG SPEEDOMETER ............................................................................ 395 2) MODE (M) BUTTON .................................................................................. 395 3) SET (S) BUTTON ...................................................................................... 395 4) ANALOG TACHOMETER (RPM) ...................................................................... 395 5) INDICATOR LAMPS ................................................................................... 395 6) MAIN DIGITAL DISPLAY .............................................................................. 395 7) MULTIFUNCTION DISPLAY ........................................................................... 395 8) FUEL LEVEL INDICATOR ............................................................................. 396 9) GEARBOX POSITION INDICATOR .................................................................... 396 10) ENGINE TEMPERATURE INDICATOR ............................................................... 396 11) NUMERICAL DISPLAY ............................................................................... 396 12) 2WD/4WD INDICATOR .............................................................................. 396 13) SECONDARY DIGITAL DISPLAY ..................................................................... 396 GAUGE SETUP........................................................................................... 396 MULTIFUNCTION GAUGE (RENEGADE) ................................................................ 396 TROUBLESHOOTING ..................................................................................... 399 DIAGNOSTIC TIPS ....................................................................................... 399 DIAGNOSTIC GUIDELINES (GAUGE) .................................................................... 400 DIAGNOSTIC GUIDELINES (LIGHTS) .................................................................... 400 PROCEDURES .............................................................................................. 401 MULTIFUNCTION GAUGE (OUTLANDER AND RENEGADE MODELS) ................................. 401 12 VOLT POWER OUTLET............................................................................... 406 HEADLIGHTS ............................................................................................ 406 TAILLIGHTS/BRAKE LIGHTS............................................................................. 409 TURN SIGNALS/HAZARD (CE MODELS ONLY) ......................................................... 409 HORN (CE MODELS ONLY) ............................................................................. 410 WINCH ................................................................................................... 410 VI

TABLE OF CONTENTS 06 DRIVE SYSTEM 01 – FRONT DRIVE.................................................................................................. 413 GENERAL ................................................................................................... 416 SYSTEM DESCRIPTION ................................................................................. 416 PROCEDURES .............................................................................................. 416 WHEEL HUB ............................................................................................. 416 FRONT DRIVE SHAFT ................................................................................... 417 DRIVE SHAFT BOOT..................................................................................... 417 FRONT DIFFERENTIAL .................................................................................. 418 FRONT PROPELLER SHAFT ............................................................................. 422 02 – REAR DRIVE.................................................................................................... 425 PROCEDURES .............................................................................................. 428 WHEEL HUB ............................................................................................. 428 DRIVE SHAFT ............................................................................................ 429 DRIVE SHAFT BOOT..................................................................................... 429 PROPELLER SHAFT ..................................................................................... 430 PROPELLER SHAFT U-JOINTS .......................................................................... 432 REAR FINAL DRIVE ...................................................................................... 433 07 CHASSIS 01 – WHEELS AND TIRES ......................................................................................... 439 PROCEDURES .............................................................................................. 439 TIRES .................................................................................................... 439 WHEELS ................................................................................................. 441 02 – STEERING SYSTEM .......................................................................................... 443 GENERAL ................................................................................................... 447 ADJUSTMENT ............................................................................................. 447 STEERING ALIGNMENT ................................................................................. 447 PROCEDURES .............................................................................................. 448 HANDLEBAR GRIP ...................................................................................... 448 HANDLEBAR COVER .................................................................................... 448 HANDLEBAR............................................................................................. 449 STEERING CONNECTORS............................................................................... 450 MULTIFUNCTION SWITCH .............................................................................. 450 THROTTLE LEVER ....................................................................................... 451 BRAKE LEVER ........................................................................................... 452 STEERING COLUMN BEARING ......................................................................... 452 STEERING COLUMN .................................................................................... 452 TIE-ROD.................................................................................................. 455 KNUCKLE ................................................................................................ 456 WHEEL BEARINGS ...................................................................................... 456 PITMAN ARM (WITHOUT A DPS) ....................................................................... 457 PITMAN ARM (WITH A DPS) ............................................................................ 457 03 – DYNAMIC POWER STEERING (DPS) ...................................................................... 459 GENERAL ................................................................................................... 460 SYSTEM DESCRIPTION (FEATURES).................................................................... 460 DPS SYSTEM DESCRIPTION (COMPONENTS) ......................................................... 461 ADJUSTMENT ............................................................................................. 461 TORQUE OFFSET RESET ................................................................................ 461 DPS ASSIST MODE...................................................................................... 462 TROUBLESHOOTING ..................................................................................... 463 TROUBLESHOOTING FLOW CHARTS .................................................................. 463 PROCEDURES .............................................................................................. 469 DPS UNIT ................................................................................................ 469 PITMAN ARM............................................................................................ 480 VII

2012-2014 Can Am Outlander Renegade G2 Service & Repair Manual

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