2011 Can-Am Outlander 800 XT Service & Repair Manual

TABLE OF CONTENTS SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX GENERAL INFORMATION........................... . ............................................................. IX VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X ENGINE EMISSIONS INFORMATION ...... ........ . ............................................................. X SELF-LOCKING FASTENERS PROCEDURE .. . ... . ... . . .. . . ... . .. . ... . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . . .. . . XI LOCTITE® APPLICATION PROCEDURE......................................................................... XI TIGHTENING TORQUES ............... . ......................................................................... XIV MANUAL INFORMATION .............. .. ............ .. .......................................................... XVI 01 MAINTENANCE 01 - MAINTENANCE CHART...................... .. ...... .... . ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE CHART .............. ...... .... .. . . .. . . . .. . . . . . .. . . . . . . . . . . . . . . . .. .. .. . .. .. . . . . .. . . . . . . . . . . . .. .. . . . . 1 02 - PRE SEASON PREPARATION.................................... .. ....... ... ............. .. .................. 5 03 - STORAGE PROCEDURES ........................................................... . ................ .. ....... 7 FUEL STABILIZER ... . .. ........... .... .. ... .. .. .. .... ... . ..... .. .. .. . ............ . ........... . ... . ..... .. ...... 7 ENGINE LUBRICATION..... ... ...... ... .. .. ... .. .......... .. ..... ........... ...... .. ................... ...... .. .. .. 7 RAGS INSTALLATION .. ..... ........... ... ... . ...... . ...... . ........ . .... .... . .. ...... . . .. .. . . . . .. . . . . . . .. . . . . 7 COOLANT DENSITY...................................... .. . .......... . ........... .. . . .......... .. ................... 8 DRIVE AND DRIVEN PULLEYS PROTECTION ... .... ... .. .... . ...... . ................... ... ..... .... .... . ........ 8 VEHICLE CLEANING................................ .... ... ... .. ...... ... ...... .... ..... .... .. .. ... ...... .. .. ... ... ... 8 VEHICLE PROTECTION..................................................................... .............. ..... ... .... 8 04- SPECIAL PROCEDURES ....................................................................................... 9 TURN OVER ................................................................ ..... ........... . ................. . ........ 9 ATV IMMERSION . . . . . . ... .. .. . . . .. .. . .. . . . . .. .. .. . . . .. .. . .. ... .. . ... . .. ... .. . . . . .. .. .. . . .. . .. .. .. .. .. .. . .. . . . .. .. . .. . 9 02 TROUBLESHOOTING 01 - TROUBLESHOOTING CHART.............................................................................. 11 ELECTRICAL SYSTEM. ... .................................................................. ........ ..... .. . . .. .. . .. 11 COOLING SYSTEM . . . . . . . . . . . . .. . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . .. . . . . . . . . . . . . . 12 MAGNETO SYSTEM ... . .. .. ................ .. ... ... .. . .... .. .... .... ............ .. ... ............ .. ... . . ............ 13 LUBRICATION ......... . ..... ....... ..... .. .. . .. .................. . ...... . ........ . ..... . ................ ........ ..... 14 CYLINDER AND HEAD . . . .. . . .. . .. . . . . . .. .. .. . .. . .. .. .. .. . .. .. . .. .. .. .. .. .. .. . ... .. .. . .. .. . .. . .. .. . . .. . . .. . . .. . . 15 CRANKSHAFT............... . ....... ... ... . ....... ..... ............. . ........... .. ..... . ...... . .. ....... ......... .. .. 15 GEARBOX................... ... .... . ........... ... ................ . ....... ... .............. ... .... .. .. ........ ... . 15 COUPLING UNIT..... . ...... . ...... .. . .... . ....................... ....... ... .... .. . ... ....... ...... ......... ........ 17 CVT .......... .... .... .. .. ... .. . . .. ....... . ..... ...... .. . ... ... ...... ... .... . ...... .. ...... . .. . .. . .. . ... . ..... . .... . 17 ENGINE GENERAL .... .. .... . ... . .. . . . . . .. . . . . . . . . .. . . . .. . . . .. .. .. . . . .. . . .. . . . . .. .. . . . . . .. . . . . . . . . . . . . . . 20 03 ENGINE AND GEARBOX (V490N660N810) 01 - ENGINE REMOVAL AND INSTALLATION................................................................ 25 GENERAL.. .... . ...... ...... ... ..... ......... . ...... ..... .... ...... .... ............. .............. ... .......... 26 PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . .. . .. . . .. .. . . .. . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 26 ENGINE REMOVAL .. . . . . . .. . .. .. . .. . . .. . . .. .. . . . . . .. .. . .. . . . .. .. . . . .. .. . .. . . . .. .. . . . .. . .. . . .. .. . . . . . . .. . .. .. . . .. . . . . 26 ENGINE INSTALLATION .. . . .. .. . . . . . . .. . . . . .. . . .. .. .. . . . . .. .. . . . . . .. . . . . . .. . . . . .. . . .. . .. . . .. . .. .. . . . . . . . . .. . .. .. . . . 32 ENGINE MOUNT REPLACEMENT. .. . ........... ... ............. .. .. ... .... ... ..... .. . ...... . .. .. ........ ... ...... 33 02 - AIR INTAKE SYSTEM................................................ ..... . ................ ........... .. ..... 35 GENERAL ...................................................................................................... 37 PROCEDURES ....................................................... ......... ....................... ..... .... 37 AIR FILTER........................................................... .............. . ............ . . . . . .. .. . . 37 AIR FILTER HOUSING . . . . .. . .. .. . . . .. .. . .. . . . . . . . . .. . . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . . .. . . . . . . . . .. . . . .. . . .. . .. .. . . . 37 RESTRICTOR............ .. .. .. . . . .. . . . . . .. . . . . . .. . .. .. . .. . .. .. . . . .. . . .. . . . .. ... .. .... . .. .. . . . . . . . . . . . . . . . ...... 39 03 - EXHAUST SYSTEM.......................................................................................... 41 GENERAL ...................................................................................................... 42 PROCEDURES ................................................................................................ 42

TABLE OF CONTENTS II FRONT EXHAUST PIPE .............. .. ... .. ........... ... ... ........ ..... .. ..................... .. .... . .. .. ... . 42 MUFFLER ..................... .. ... .. ... .... ... ...... ......... .. . ... .. ...... . ... . .. . ... ..... .... ... .. ..... .. ...... ... 43 "Y" EXHAUST PIPE ............. .. ....... ... .... .... .............. .. ....... . ............... . .... . ..... .. 43 FUEL TANK PROTECTOR .. .. . .. . .. .. .. .. . .. . .. . . . . .. . . .. .. .. .. . . .. .. .. .. .. .. .. .. .. . .. . .. . . . . .. . . 44 04 - LUBRICATION SYSTEM...................... . .............................................................. 45 COMPONENTS .............................. ..... ............................................................ 46 ENGINE LUBRICATION ...................................................................................... 47 GENERAL ........................................ .. .. ..... . .................................................. .. 48 MAINTENANCE ................................................................................ .... ... . ...... 48 ENGINE OIL ................. . ..... ... .. . .... . .... ................ ........................ . ......... ... .. . . .. . . . .. . .. . 48 INSPECTION ............................................ . ..................................................... 49 ENGINE OIL PRESSURE....... .. .. .......... . .. .. .. . .. .. . . .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. . .. 49 PROCEDURES .............................................................................................. . . 49 OIL FILTER ........ .. ...... .. .. . .... ·· ····· ........... . ..... 49 OIL PRESSURE SWITCH (OPS) .. . ............ ............ . .. ... .. .. .. . . . .. . . . .. .. .... .. .. . .... .. . .. ..... ... .... . .. 50 ENGIN E OIL PRESSURE REGULATOR .. .. .. .......... .. .... .... ..... ... .. . .. ... .. .. .. .. . ........... ... ... ... . .. 51 OIL PUMP .... .. . . . . . . . . . . .. . . . . . . . . .. . . . .. . .. .. . . . . . .. . .. . .. .. ... .. .. .. . .. .. .. . . . ... . .. .. .. 52 ENGINE OIL STRAIN ER . . . . . .. .. . .. .. . .. .. . . . .. .. . .. . . . . . .. . . . . .. .. .. . .. .. . . 54 REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 05 - COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 GENERAL .. . ........................................ ... .. . ........ . ............................................ 58 INSPECTION .................................................................................................. 58 COOLING SYSTEM LEAK TEST.. . .................. . ... . ............. . ...... .. ......... ... ... . ......... .... 58 MAINTENANCE ........................................... ...... ...... . ...................................... 59 COOLANT REPLACEMENT........ .... .. ... .. ................... . ... . .. ....... ... ....... ............ . .............. 59 PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 THERMOSTAT . . . . .. . . . .. .. . . . .. . .. .. .. . . . .. .. . . . . .. . . . . . . . . .. . .. .. .. . .. . .. .. . .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . . 60 RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 RADIATOR... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 COOLANT TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 COOLANT TEMPERATURE SENSOR (CTS) ...... . ... .. ... ..... ........ . . .. . .... . ....... ..... .... .. .. . ...... .... . 62 RADIATORFANRELAY(R1) .............. ............ .. ... .. ..... .... ... .... .. .... .. .. ... ...... .. .. 62 RADIATOR FAN .. . ....... ..... ....... .... ... .. .. .. .......... . ...... .... .. .. .. .. . ......... . ......... . .... ... . ....... .. 63 WATER PUMP HOUSING ....... ............. ..... .... ...... .. ..... ..... .... .. ....... .. . 65 WATER PUMP IMPELLER . . . . . . . . .. . . . .. . .. .. .. .. . . . . .. . . . .. .. . .. . . .. .. . .. . .. .. .. .. . .. .. .. . .. .. . . . .. . .. .. . .. .. . . . 66 WATER PUMP SHAFT AND SEALS .. . .. . . . .. .. . . . .. . . . .. .. . .. .. . .. . . . .. .. . .. . . .. . . . . . . . . . . 66 06- MAGNETO SYSTEM .. .................................................. . .. . ................................. 71 GENERAL ................ ......... .... .................................................... . .................... 73 PROCEDURES .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 73 MAGNETO COVER .. . . . . . . . . . . . . . .. .. .. . .. . . . . .. .. . . .. . .. . . . . . . . . . .. .. . . . . .. .. .. .. .. . . .. . . .. . . . .. .. . .. .. . .. . .. .. 73 STATOR .. · · ··· .. ... ···· ··· · ···· · ····· ··· ··· ······ ......... ......... .... .. .. .... ·· ··· ···· ···· 74 ROTOR ....... .... .. ... . . .. . .... . ... ... ... ...... ... ......... ... ..... ... ... ... . .... .. .. ...... .. . ..... .. .. . . .. 75 SPRAG CLUTCH .. . ................ . .... ........ .... ... ...... .. .......... . ... .. .. . .... .. .. .. ......... . .... . ...... . .... 76 SPRAG CLUTCH GEAR .. .. . ..... .. 77 STARTER DRIVE GEARS . .. .. .. .. . .. . .. .. . .. .. .. .. . .. .. . . . . .. .. .. . .. .. .. . .. . .. .. .. . .. . .. .. .. . . . .. . . .. . . . . .. . . . .. .. 77 07 - INTAKE MANIFOLD, CYLINDER HEAD AND CYLINDER ......................... .. ... . ................ 79 GEI\JERAL.......................................................... .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . 84 MAINTENANCE ..... ..... .................................................................................... 84 VALVE ADJUSTMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 LEAK TEST.. ......... . .......... . . .. .. . .. .. . . . . . . . . . . . . .. .. . .. .. .. . .. .. . .. .. .. . .. . .. .. .. . .. . .. .. .. .. . .. . . 85 PROCEDURES .................................... . ................................. ... .... .... ... .. ...... .... 87 INTAKE MANIFOLD ... .... ..... . ...... .......... .. . ......... .... ....... . ... . ..... . .... ...... . .... . 87 VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 CAMSHAFT TIMING GEAR. .. ... .. .... ... .. . ....... ..................................... ... .................... .... . 90

TABLE OF CONTENTS ROCKER ARM.... . . . . . . . . . . . .. . . .. . . . .. . . . .. .. .. . . . . . . .. . . . . .. . . . .. . . . .. .. . .. .. . .. . . .. . . .. . . .. . . . . .. . . . . . .. . .. .. 92 TIMING CHAIN.. . .... .. .. .... .. ....... .. .. . .. . . .. · · · ···· ... .... ···· · · · · ····· 93 CYLINDER HEAD ..... .. .... .... . ............ ... . ...... . .. . ...... .... . .. ..... .. . .. . .. ... .... .. . .... ..... . ... . .... . ... 94 CAMSHAFT ...... . . .... ... .... . .... ... .... . .... . .. -· ........ .. .. .......... ...... ...... . ..... . ...... ... ..... 95 VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 VALVE GUIDE .... .. .. ..... .. ... ... .. .. ... ... .. .. ... .... .... ... . .. .. .... .... ... ..... ... .. .. ... .............. .... ..... 104 CYLINDER ....... . .. .. . .. . ... ... ............ ..... ... ....... .. ........... .... .. .... ..... .... ........ ........... ... . PISTON ......... .... ............... . .... . .. ............ . ..... ..... . . PISTON RINGS .. . . . .. . . . .. . . ......... . ......... . ........ .. ................ .......... .. 08 - BOTTOM END .................................... ... ................................. ... .. ................. . GENERAL ... ... ....... ............... . .......... ... .................................... ....... ..... . ..... ... . . PROCEDURES ... ................................. .. .............................. . ... ...... ................ . ENGINE DRIVE SHAFT .......... ... ....... . .... . .. . .. .... ....... . ............... .. ..... ........ . ...... .. . .... .. . 105 106 111 113 117 117 117 PTO COVER OIL SEAL........ ... ...... .. .... .. .. . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . . . . .. .. . . .. . . 119 PTO COVER ..... .................... .. . .. . .. ... ... .. ..... ......... ............. .. .. ... ..... ... .... ..... ... ......... 119 DRIVE GEARS .. . ... ......... .... . ... ..... ..... ...... ..... ....... ........... ... ...... ........ ..... ... ...... . ... .... 122 TIMING CHAIN....... .. . . .... . ... .. .. .......... ... .. .... .. ..... .. ....... .. .. .. ... .... 123 TIMING CHAIN GUIDE.... .... ... . ... ... ... ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 CRANKCASE .......... ..... ............. . ............. .. .......... . .......... ... .... . ...... . ..... .. ... .. ...... .. . CRANKSHAFT ...... ..... . .......... ..................... .. .... . .. .. . .. .................. ......... .. . ... .. .. . . 09 - GEARBOX AND 4X4 COUPLING UNIT ........................ .. ...... ..... . ...... ........ .. ........... . GENERAL . . ................................................................... .. . ...... ......... . .. .. ... .... . . MAINTENANCE .............................................................. . ............................. . 124 128 135 138 138 GEARBOX OIL CHANGE . . . .. . .. . . . . . .. . . . . . . . . . . . . .. . . . . . .. . . . . .. . . . . . . .. . . . .. .. .. . .. . . . . . . . . . . . . . .. . . .. . . . 138 PROCEDURES ............................. ... ............................................................... 139 GEARBOX POSITION INDICATOR SWITCHES.... .. ... .. ...... .... .. . . .... .. . ...... .. .......... . ..... .. ........ 139 4WD INDICATOR SWITCH ... . ......... .. 140 OIL SEALS . ..... ................ ... . ... . ... . .. . . .. ...... ... . .. . ... .......... .... .. ....... ... .... ... . .. .. .. .. .... . ... 140 ACTUATOR ............. ........ .......... . ... ...... .... ...... .. . .. ..... .. . . 142 OUTPUT SHAFT AND COUPLING MECHANISM . .. . . ... . . .. . . . .. .. . . . . .. . . . ... . .. 144 GEARBOX . . . .. .. . .. .. . . . . . . . . . . .. . . . .. . . . . . . . .. .. . .. .. . . . .. . . . . . . . . . . . . . . . .. .. . . . . . . .. .. . . . .. . .. . . .. . .. 149 10 - SHIFTER ... . .. . ..................... ......... ...... .. ............ ..... .. ...... ......... ....................... 167 GENERAL ...... ... ......................... .... ... . .. ..... ............ ... .... .. .............. . ................ 168 PROCEDURES ................... ... ............................................................... ... ... . ... 168 TRANSMISSION LEVER ........... . .... . .. .. . ... ..... ....... . LINK ROD.............. . . . .. .... .. . ........... .. . . 168 169 SHIFTING PLATE..... .. . .. ... ... . . .. . .. ....... ............ ...... .. ... .. ... ........ .. .... .... . ...... .. . . ... .... ..... 170 04 ENGINE MANAGEMENT (V490N660N810) 01 - OVERVIEW................................................................................................... 173 OPERATING PRINCIPLE .................................................................................... 174 AIR INDUCTION ........................... . ...... .. . .. . FUEL SYSTEM ................ . ............. .... . .......... .. 174 174 ELECTRICAL SYSTEM .... _ . . . . . . . . . . . .. . . .. . .. . .. . . . . .. . . . .. . . . . .. . . . .. .. . .. .. . . . .. . . . 176 ENGINE MANAGEMENT SYSTEM ...................... .... ................ . .......... ........... .. ... .. 178 ELECTRONIC FUEL INJECTION .............. .. . .. .. .. ....... .. . IGNITION ........... ........................... .. ...... .. . ENGINE MODES OF OPERATION .... . ........ ....... ... ......... .... ..... . .... ... . .... . .. . . .. . 178 178 179 MONITORING SYSTEM ............. . ...... . .. . ... . .. · · ··· · ······ ·· ······ · · · ·· ·· ··· ··· ······ ··· ·· .. .. . 180 DIAGNOSTIC MODE .................. ................ ........ . . . .. .... .. .... ... .... .... ... .. . ...... .. ... 180 ENGINE MANAGEMENT SYSTEM FLOW CHART. .. ...... . . . . . . . . . . . . . . . . . . . .. . . . . .. .. . . . .. . . . . . . . . . . .. . .. . . . 181 02 - EMS DIAGNOSTIC....... .. ..... ............................................................................ 183 GENERAL ................... .... .............................................................................. 183 FAULT CODES ........ . .. ... .. ... .... ..... ... .. .. .. ... .. .. ... .. .. .... ... .. ..... .. ..... .... . .. ..... ... .. ..... ... . . . . FAULT CODE TABLE ...... .. ... ... ... ... .. ...... .. ..... ...... ... .... .. .... ... .... ...... . .... ..... ............... . 184 185 Ill

TABLE OF CONTENTS 03 - ADJUSTMENT AND REPAIR PROCEDURES ............... . .............. ............................. 193 GENERAL ..................................................................................................... 193 FUEL SYSTEM...................................................................................................... 193 ELECTRICAL SYSTEM............................................................................................. 194 BASIC ADJUSTMENTS . .. . ........... .................. ....... . . ......... . ...... ............ ...... . . ...... 197 IDLE SPEED ........ ..... ..... ................. ... .......... ...................... . ................ .. ............... 197 THROTTLE CABLE................................................................................................. 197 CLOSED THROTTLE AND IDLE ACTUATOR RESET............................................................ 198 IGNITION TIMING.................................................................................................. 199 REPAIR PROCEDURES ..................................................................................... 199 MAIN RELAY (R2) .. ....... ......................................................................................... 199 D1 DIODE (ECM) ........ ..... ...................................................................................... 199 ENGINE CONTROL MODULE (ECM)............................................................................. 200 FUEL INJECTOR ........... ...................... ..................................... ............ ................. 203 FUEL RAIL.......................................................................................................... 206 THROTTLE BODY .................................................................................................. 207 THROTTLE POSITION SENSOR (TPS)................................ . .. . .. . ............. ...................... .. 210 IDLE BYPASS LVE (IBV) ...... ......... . ......................................................................... 212 CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 214 CAMSHAFT POSITION SENSOR (CAPS)......................................................................... 215 MANIFOLD AIR PRESSURE AND TEMPERATURE SENSOR (MAPTS) ....................................... 216 COOLANT TEMPERATURE SENSOR (CTS)...................................... ................................ 218 05 FUEL SYSTEM 01 - FUEL TANK AND FUEL P UMP . . ....... .............. . ........... .................................... ..... 219 GENERAL..................................................................................................... 221 INSPECTION ........... ........................................ ........ .... . ............................ ... .. 221 FUEL TANK LEAK TEST ............................................................................................ 221 FUEL PRESSURE TEST..................................................................................... 224 PROCEDURES .. . . .. ....... . ......... ..... .......... . . .............. . ..... ..... . ............................. 225 FUEL HOSE AND OET1KER CLAMPS ........................................................................... 225 IN-LINE FUEL FIER ........................................................................................... 225 FUEL TANK......................................................................................................... 226 FUEL PUMP ................................................................... ........... ......................... 228 FUEL SYSTEM DIAGNOSTIC FLOW CHART ........................................................... 230 06 ELECTRICAL SYSTEM IV 01 - COMM UNICATION TOOLS AND B.U.D.S. SOFTWARE .......... ..................................... 231 COMMUNICATION TOOLS ................................................................................ 231 MULTI-PURPOSE INTERFACE (MPI) ...................................................... . ..... ................. 231 MULTI-PURPOSE INTERFACE-2 (MPl-2) ................................................................. ....... 232 B.U.D.S. SOFTWARE ........... . ............. . .. ..... . ..................... ........... .............. .............. 233 02 - IGNITION SYSTEM ...... .. ... . ..... . .. ... . .. ........... .... . .. ... .. . .. . . . .... . ..... . .. .. . ...... ............ 235 GENERAL ..................................................................................................... 235 PROCEDURES ........ ... .. ........... ....... .. . . ............................................................ 235 IGNITION SWITCH................................................................................................. 235 ENGINE RUN/STOP SWITCH .. ............ ....................................................................... 237 IGNITION COIL............................ ...... . . ................................................................ 238 SPARK PLUG ........ ............................................ ................................................... 240 03 - CHARGING SYSTEM .... ..... ................. . .. . . ... ....................... . ..... . ....... . ............... 243 GEIERAL ..................................................................................................... 243 PROCEDURES ............................................................................................... 244 VOLTAGE REGULATOR/RECTIFIER ....................................... .......................... ............. 244 STATOR ............................................................................................................. 246 BATTERY............................................................................................................ 248 MAIN GROUND .................................................................................................... 251

TABLE OF CONTENTS 04 - STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 GENERAL............. . ..... ... ..... . .......... ....... ............ . ...... ... .. .............. .. .... .. .......... 253 PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 FUSES ... 254 D2 DIO DE (STARTER SOLENOID). ...... .. .. . .... ....... .. . .. .. . . . . . . .. . . . . . .. .. . . . .. . . . . . . . . . . . . . . .. . . 254 START BUTTON ... . ..... ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 STARTING SOLENOID .... .. ... . . . . . . .. . .. . .. . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . .. . .. . . . . . . . .. . . . .. . . . . .. 256 ELECTRIC STARTER .. .. .. .. .. .. .. .. . . . . . . . .. . .. .. . . . .. .. .. .. . .. . . . . .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. . 258 05 - DIGITALLY ENCODED SECURITY SYSTEM (DESS) ....... . ................................ ... ........ 261 GENERAL.. ....... . . . . .. . .. .. .. .. . .. .. . . . .. . . . .. . .. . .. . .. . . . . . . . .. .. .. .. . .. . .. . .. . .. . . . . . .. . .. . .. 261 DESS KEY PROGRAMMING... ........ ... .... .... .. ....... ...... ... .. ....... .. .... ...... ..... .. .. .. . ..... ... ..... 261 TROUBLESHOOTING....... . . . . . . . . . . ... . . . . . . . . . . . . . .. . .. . . . . . . . . . .. . ............ .. .. . . . . .. . . . . . . . . . . . . 262 06- LIGHTS, GAUGE AND ACCESSORIES .............. ..... .............. .... ... .......... .. .. ... . ... .. ... . 263 GENERAL . .................. . .................. .. ............ . ............... . ... ... ........... .. ...... ....... 263 PROCEDURES .. .. .. .. . . . .. . . . . . .. . . . . . .. . . .. . . . . . . . .. . . . . .. .. . . .. .. .. .. .. . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . 264 FUSES . .... . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . .. . . . .. . .. . .. .. .. . .. . . . . . . . .. . . . . . .. . .. . . 264 ACCESSORY RELAY (R3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 MULTIFU NCTION GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 VEHIC LE SPEED SENSOR (VSS)... . . .. ... .. . .. .. . ..... . ...... ... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 FUEL LEVEL SENDER . . . . . .. .. . . . . . . . . .. . . . . . . . . . . .. .. .. . . . . . . . . . . . . .. . . . .. . . . . . .. . . . . . . . . .. . . 277 MULTIFUNCTION SWITCH 12-VOLT AUXILIARY POWER OUTLET .. . . .. .. .. .. .. .. .. .. .. . . .. .. .. . . . . . .... .. 12-VOLT POWER OUTLET .... ... ... .. ... ....... ......... ... ... ................ ... ... .... ............... ... ..... . . 277 279 279 HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 TAI LLIGH T........ . .... .... .. . . . . . . . . . . . .. . .. .. . . . . .. .. . . .. . . .. . . . . .. . . . . . .. . .. .. . . .. . . . . . . . . .. . . . . . . . 283 WINCH . ... . ... ...... ... .. . . . . . . . .. . . . .. .. ... .. . ... . .. . .. .. .. . . . .. . . . . ... . . . . . . . . .. . . . .. . . .. ... . . .. ... . . . . 283 WINCH CON TROL SWITCH.......... ..... .... ... ................. ..... ..... .................... ... .. .. .. .. . .. .... 285 D5 AND D6 DIODES (WINCH RELAY)... .. .. . . .. .. . .. . .. .. . . .. . .. . .. . . . .. . . . . .. .. . .. .. .. . .. .. .. .. . .. 286 07 TRANSMISSION 01 - CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ............................................. . ... 289 GENERAL ... .... .. ....... . ...... .. .. .. ............................. . ...................... ... .......... .. ..... 291 PROCEDURES .............. . ....... .. .............. ... ............ ... ................ ... ... ............... .. 291 DRIVE BELT ..... .. ... .... ... ... .. . .. ... ...... ... .... ... .... . ....... .. .... .. . .... ...... ........... . .... . ... . ... ... . DRIVE PULLEY ..... ... .. ...... ... .... ..... . .... ................ ... .. . .... .. . ... .. ... . .. .. ..... .. ........ .. . ... .. . . DR IVEN PULLEY . . .... . ....... .. .. ... . ... ...... ..... .. ...... .. ... .. ......... ...... .. .... ..... ....... ... .. .. .. . CVT AIR GUIDE ....... ...... .... .. ... ..... ... ......... .... . ... ....... .... ... .. .. .. ... .. .. .... ... .. ... ... .. ..... . . . . 08 DRIVETRAIN 291 292 300 305 01 - FRONT DRIVE ... .. ........................................ .. ....... ... .................. .... ................. 307 GENERAL ............................. .. .. ............................... . .................. . ............ ..... 309 PROCEDURES ............... ... ....... .. ...... ... ........... ............ .. .. ..... ......... .. .... ... ... ..... . 309 TI RES AND WHEELS .. .. ...... .... ... . .. ..... .. ... ...... .. ... ... ...... ... ..... . ..... ..... .. ... .. .. .... .. .. .. ... . . 309 WHEEL HUB. . .... ..... ... .......... ...... ... .. . . ..... ... .. .. ...... ......... .... . ... ... .. .. ..... .. ... ..... . ...... .. . 309 FRONT DR IVE SHAFT .. .. . .... ..... .. ... ... ......... .. .......... ... ...... ... ....... .... ...... ... ... .... . ... .... ... 310 DR IVE SHAFT BOOT ............. .. ... .. .... ... . ....... ... .. ..... .. .......... ......... .. . ... ... ........ ............ 312 FRONT DIFFER ENTIAL.. .. ..... .... ... ... .. ..... .... .. . ... ... .......... ... ........ ... ... . .. . . . .. . . . . . .. . . . . . . . 312 FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 PROPELLER SHAFT U-JOINT .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . .. . . . . . . . . .. .. . . . . . 3 17 02 - REAR DRIVE ................ . .................. . ........... ... .............................................. . 319 GENERAL . ........ ...... ... ......... . .... . .................... . .................. ... . .... ........ ... ... . ...... 321 PROCEDURES ......... . ...................... . .............................................................. 321 TIRES AND WHEELS ...... ... . ......... ....... .... ......... ... .. ........... .. ... .. . ..... . ..... .. WHEEL HUB ..... ... ..... ..... . ... . ...... ...... ............ ...... .... . ...... ....... . .. . .... ............ .... ... ... . DIFFERENTIAL PROTECTOR ... .. . ..... ... . .... ..... ..... ..... ........ . ....... . .... .. .... .. ..... ...... ...... . DRIVE SHAFT .... . . 321 32 1 322 322 v

TABLE OF CONTENTS DRIVE SHAFT BOOT.............................. ... . ...... ..... ... .. .. .. .. .. .. . ... .......... .... .. .... .......... 323 REAR PROPELLER SHAFT ... ........... ... ............... .. .............. ..... ............. ..... ... ...... ........ 323 REAR PROPE LLER SHAFT U-JOINT . .. . . . .. . .... .......... .. .. . .... .. . . . . . .. . .. . ..... .. ....... .. . . . .. . .. .. . . . . . . 325 REAR DIFFERENTIAL ... . .... ... ... .. .... ... .. ... .. ... .......... ... ... ......... ........ .. .. .. .... ..... ...... .. .. . 326 09 STEERING SYSTEM 01 - STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 GENERAL ...... .. ......... . ..... . ............... .. .... . .............................. . .... .. ... .............. . 333 PROCEDURES .......... . .. . ..... . ........ . ...... . ............ . ...... . .......... .. ....... ....... .. ..... ...... 333 HANDLEBAR GR IP.. .... .. ... ......... ..... ....... .. .. . ... . ... ..... ... ........... ............ .. . .... ... ...... . .. . 333 HANDLEBAR COVE R ............ .... ................. .. ............. ...... .. ... .. ... ..... ....... ............... ... 333 HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 STEERI NG COLUMN . . . . . .. . . . . . . . . . . . .. . . . .. . . .. . .. . . . . . . . . . . . . . . .. . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . .. . . . 334 STE E RING COLUMN BE AR ING .... . ... . .... .............. .. .. .... ... ..... . ... ........... ... . ....... ........ .... . 335 TIE-ROD ...... ... ...... ..... ...... .. ... .... ..... ... . .... . ... .... ... . ... ..... ... . .. .. ... .... .. ... . ... . ..... .. ... ...... 335 KNUCKLE ... ..... ................................... ... ........ ... ..... . ... .. .... .. . ... . ... ......... .... ... 336 WH EEL BEARIN G.... ... .... . ... ... ..... . ..... .................. ........ ........... ....... ... ..... . . . . .. . . . . . 338 MULTIFUNCTION SWITCH......... ... .. .... . .... ..... ... ..... .... .. .... ....... .... . ... .. .. . .. .......... 339 THROTILE HANDLE..... .. ... ...... ... ................................................ ... ............... ... . . .. .. . 339 HANDLE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 ADJUSTMENT .................. . ............... . ....... . ........... .. ..... . ........... ...... ... ............. 340 S TEERI NG ALIGN M ENT .. ........ .. ... . .. .... .... .... ... ....... .. .... ..... ... ..... ... ...... .. . ........ . . . 340 10 SUSPENSION 01 - FRONT SUSPENSION...................... . ......... .. ...... . ............. . ............................... 343 GENERAL ... .. .... ....... .. ...... ... ...... ........ . .... ........... . ... ... .. .. ......... .. ...... ........... . .. .. 347 PROCEDURES .... ........ . .... ... .... . ............... .... ................ .. .... .. ... .. .... ........ . ... .. .... 347 TIRES AND WHEELS ....... ........... ........... ....... . .... ... ... ....... .. .... .... ... ..... ...... ........ .. ..... . 347 SHOC K ABSORBER AND SPR ING .. . . . . . . .. . . .. . . . .. . .. . . . . . . . . . . .. . . . . . . . . .. . . . . . .. . . . . . . . . . . .. . . . .. . . . . . . . . . . . 347 LOWER SUSPENSION ARM PR OTECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 LOWER SUSPENSION ARM . . . . .. . . . . . . . . . . .. . . . . .. . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . .. . . . . . . . 349 LOWE R BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 UPPER SUSPENSION ARM . ......... .......... .... . .... .......... ... .. ...... .... ........... ...... ..... ..... ...... 352 UPPER SUSPENSI ON ARM BRACKET ..... .... ...... ........... .... ....... .. .. ... ......... ... ....... ... ......... 353 UPPER BALL JOINT ... ... ....... .. . ........ .... . ..... .... ... .. .... ....... .... .... ... ... .. .... . .. . . . . . . .. . .. .. . . .. 354 02 - REAR SUSPENSION . . . . . .. . . .. . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . .. . . . . . . . . . 357 GENERAL ........... . ... .... ........... . .... . ... . .... . ............ . ...... . ..... .... ...... . .... .... ... . ........ 359 PROCEDURES .... .. ... .... .. .......... .... . .. . .. . ............ . ........... . ... .. .. ... . ............. ... .. .... . 359 TIRES AND WHEELS ... ... ................. .. .. .. .. ... . .. .. ... . .............. .... ... ...... ......... ..... .. ..... . 359 REAR SHOCK ..... .. ... ... ...... .. .. . . . .. . . . .. . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 359 TOR SION BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 TRA ILI NG ARM.. . ... . .. ... ..... ... ... ...... .... ........ ... ..... ...... .... .. . . .. . .. . . . . . . . .. . . . .. . .. .. .. . . . .. . . . . . . 361 TRAILI NG ARM BEAR INGS . . . .. . . . . . . . . .. . .. . . . . . . . .. . . . . . .. . . . .. . . . . . .. . .. . . . . . . . . . . . .. . . . . . .. . . .. . . . . .. . . . . . . 362 11 BRAKES VI 01 - FRONT AND REAR BRAKES.......... . .... . ........ . .... . ............................ . .................... 365 GENERAL ...... .. .... ..... .. .. ............. ... .. ... ... .......... . ....... ..... ................ .. . .............. 369 MAINTENANCE ....... . .. ... .......................................................... . ............. .. ...... 369 BRAKE FLUID .. ....... . .. . . . . . .. .. .. .. .. .. . . .. .. .. .. .. .. . .. . ... ... .. .. .. .. . ... .. . . . .. . ... .... ..... .... ... ... 369 PROCEDURES .. .. ......... .. ..... ...... .. .. ........ . ... .... ............. .... .. ... .. ............ ... ..... .. ... 371 REAR BRAKE LIG HT SWITCH . . . . . .. . .. . . . . . . . .. . . . . . . . . . . . .. . . . . . . . .. . . .. . . . . . . . . . . . . .. . . .. . . . . .. . . . . . . . . . . .. . . . 371 FRONT BRAKE LI GHT SWITCH ...... ....... . ..... . ... .. .... . .... .................. ..... ...... ................. ... 372 P AR KING BRAKE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372 BRAKE LEVER .... .. .. .. . ....... ...... ........ ... .... ........ ..... . .. ... . .... . ... .... ... ..... . ........ ... ... . . . FR ONT MAS TER CYLI NDER . .. . ... .. ... . ... ........ ... .. ... . ....... .. ... .. .............. . .. . ... .... .... ... . .... . RE AR MASTER CY LINDER ... ... .... ..... .......... ... .. .. ......... . .... . ....... ....... ....... .. .... .... .. .... . 373 373 3 74

I TABLE OF CONTENTS CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377 BRAKE DISC.. ... .. . .. .. ... .. ... .. .. . ... .... ... ..... ....... . .... ............ ..... . ..... .. .. .. . . ...... .......... ... .. 379 BRAKE PEDAL ..... .... .. ......... .... ... . .... ... ..... .. .. . .... ...... . ... ........ . ....... . . . .. . . . . . . . . . . . . . . . . . . . . . 380 BRAKE HOSES ....... .. ....... .... ......... ... ..... ... . .. .. . .. .... .... . ......... .. .. . ..... ... ... .... ........ ... .. . 380 12 BODY/FRAME 01 - BODY............. . ...................... . ............ . ......... . ............................... . ......... . . . . . 383 GENERAL .. .............................. .. .......... . ....... .. .............................. .. ............ ... 393 PROCEDURES . ... ......... .... . ..... .. .... ................ . .. . .... ... ........... . ........... .. .... ... ....... 393 DECALS .. . .......... ..... ......... . ..... .. .............. .. ........ .. .. .... ... .. ..... ..... ... .. .. . .. .. ..... . ... ...... 393 SEAT ...... ... ... ... . ...... .. ... .... ... . ... .. ... .... ....... .... ... ..... .. ... . .... .... ... .. ... ... ... .... ....... ... . . . . CENTRAL PANEL .... ... . .. .. ... ..... ... .. ... ... ..... ... .............. . ..... ... ... ..... ..... . .. .. ..... .. ....... ... . DAS H BOARD ...... .......... ... ..... .... ... .... . ..... ......... .... ............... ..... .... .. . .... ... .... ... ... . . . SIDE PANEL . . ... ............... ........ ......... ... . ......... . ... . ..... ... .. .... ...... ... ....... .... .. .. . .. . .. .. . FOOTREST ...... . ............. ... ..... ... ....... ........ ...... .... . ..... ... .. .. .... .. ..... ...... .. ... .. ... .. . 393 395 396 396 397 INNER FENDER .. .. .. .. . .. .. .. .. .. .. . . . .. .. .. .. . .. .. .. . .. . .. .. .. . .. . .. .. .. .. .. .. .. . .. .. . .. . . . .. .. .. .. .. .. .. .. ... .. . 397 HEAVY DUTY BUMPER ....... . ... .. .. ... .. . . .. . . . .. .. . .. . . .. .. . .. . . .. . .. .. .. .. .. .. . . .. .. .. . .. .. .. . .. ... .. .. .. . . 397 FRONT BUM PER/FRONT SKID PLATE/FRONT FASCIA .... .. .. . .... . ... .. ... .. ........ . . . . . . . .. . .. . .. .. . .. .. . 398 LU GGAGE RACK............ .. .......... . ......................... .... ... .. ....... .. .. .. .. .......... ...... . ..... ... 399 FENDER ....... ... .. ...... . .. .. ........... .......... . .... .. ................ ............ ... .... ... .. ......... . .... . 399 FENDER SUPPORT .. .. .. . .. . .. .. .. . .. . .. .. . .. .. .. . . . .. .. .. . . . .. . . .. . .. .. . .. .. . . .. .. .. . . .. . .. .. .. .. .. .. . .. .. .. .. .. 402 02 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 GENERAL . ... . ................................. . ......... .. .... . .. . ........... . ..... .. .... .. ...... . ........... 405 PROCEDURES ............... ... ..... . ............. ... .................................... .. .. . ......... ... .. 405 FOOTR EST SUPPORT ... . ... . .... ..... ....... ..................... .... ....... .... .. . ..... ..... ... . ... .... . ... . .... 405 BATIE RY SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 HITCH . ... ... ... .. ... ................................ ....... .... .... ..... ... . ... . ... ... .. .... ... .... .. ... ... ......... 406 RECOVERY HOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406 FRAME ..... .... .. . .. ... . ..... .. .... ........ ..... .. ... .... ........ .. ... . .. . ... . ..... . .... .... ..... .. ... ... ...... ..... 407 13 TECHNICAL SPECIFICATIONS 01 - OUTLANDER SERIES .................. . ....... . .......... . ................................................. 409 02 - RENEGADE MODELS . . .......... ... ........... . ...................................... .. ......... . .......... 419 14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS 01 - ELECTRICAL CONNECTORS . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429 DEUTS CH CONN ECTORS. ...... ..... ... .... ..... ........ ...... ... . ....... .. . ..... . ... ..... ..... .. .. .. . ... ... ..... 429 ECM CONN ECTORS .. ... .... .... ... ............ ... ........ ... .... ........ ...... ... ... ........ ..... ... .... . ...... . . 430 MULTIFUNCTION SPEEDOMETER CONNECTOR.. ... .. ...... .... .. ... ... .. .. ... .. ......... ....... ... ........ . 433 BATIE RY AND STARTER CABLE TERMINALS .... .. ............. ...... . .. . .. . .. .. .. .. . .. . . .. . .. . . . .. .. .. .. . . 434 02 - WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 WIRING CONNECTORS CODING . .. .. .. . . .. . . . . . . . .. . .. .. . . . .. . .. . . .. . . . .. . . . .. . .. . . . .. . . . . . . . .. . .. . . . . . .. . .. .. . 437 VII

SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 2008 Can-Am ATVs as describe in the model list in the INTRODUCTION. This edition was primarily published to be used by mechanical technicians who are already famil iar with all service procedures relating to BRP products. Mechanical technicians should attend tra in ing courses given by B.R.P.T.I. Please note that the instructions will apply only if proper hand tools and special service tools are used. It is understood that this manual may be translated into another language. In the event of any discrepan- cy, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser- vice and Warranty Bulletins may be published to update the content of this manua l. Make sure to read and understand these. It does not include dealer modifications, whether authorized or not by BRP, after manufacturing the product. In addition, the sole purpose of the illustrations throughout the manual, is to assist id entification of the gener al configuration of the parts. They are not to be interpreted as technical draw in gs or exact replicas of the parts. The use of BRP parts is most strongly recommended 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 for which it was designed. & WARNING Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair procedures. This manual emphasizes particular information denoted by the wording and symbols: & WARNING Identifies an instruction which, if not followed, could cause serious personal injury including pos- sibility of death. CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo- nents. NOTE: Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the haza rd , your understanding of the information will promote its correct use. Always use common shop safety pra ctice . BRP discl ai ms liability for all damages and/or injuries result ing from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional mechanic. It is understood that certain modifications may render use of the vehicle il legal under existing federal, provincial and state regulations. VIII vmr2008-040