2011

Shop Manual

CommanderTM 800R/1000
Series

can-am
 Legal deposit:
National Library of Quebec
National Library of Canada 2010

All rights reserved. No parts of this manual may

be reproduced in any form
without the prior written permission of Bombardie
r Recreational Products Inc. (BRP)
© Bombardier Recreational Products Inc. (BRP
) 2010
Printed in Canada

Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt QC Canada

® TM Trademarks of Bombardier Recreational Produ

cts Inc. (BRP) or its affiliates.
* Trademarks. of Bombardier Inc., used under licens
e.
Can-AmTM iTCTM
D.E.S.S.TM Rotax®
XPSTM

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 GNK Viscodrive GmbH
 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
AIR FILTER REPLACEMENT 9
MUFFLER SPARK ARRESTER CLEANING AND INSPECTION 10
ENGINE OIL LEVEL VERIFICATION 11
ENGINE OIL CHANGE 12
ENGINE OIL FILTER REPLACEMENT 12
RECOMMENDED ENGINE COOLANT 13
ENGINE COOLANT LEVEL VERIFICATION 13
ENGINE COOLANT SPECIFIC GRAVITY CHECK 14
ENGINE COOLANT REPLACEMENT 14
COOLING SYSTEM INSPECTION 17
COOLING SYSTEM LEAK TEST 18
PRESSURE CAP TEST 19
ENGINE VALVE CLEARANCE ADJUSTMENT 19
CVT AIR FILTER CLEANING 19
DRIVE BELT INSPECTION 20
DRIVE PULLEY, DRIVEN PULLEY AND ONE-WAY BEARING MAINTENANCE 20
CVT AIR INLET/OUTLET CLEANING 20
GEARBOX OIL LEVEL VERIFICATION 21
GEARBOX OIL REPLACEMENT 21
THROTTLE BODY INSPECTION 22
FUEL TANK VENT BREATHER FILTER REPLACEMENT 22
FUEL SYSTEM INSPECTION 22
FUEL PUMP PRESSURE TEST 22
FUEL PUMP PREFILTER CLEANING 22
BATTERY INSPECTION 22
SPARK PLUG REPLACEMENT 22
VEHICLE SPEED SENSOR (VSS) CLEANING 23
FRONT DIFFERENTIAL OIL LEVEL VERIFICATION 23
FRONT DIFFERENTIAL OIL REPLACEMENT 23
REAR FINAL DRIVE OIL LEVEL VERIFICATION 24
REAR FINAL DRIVE OIL REPLACEMENT 24
DRIVE SHAFT BOOT AND PROTECTOR (VISUAL INSPECTION) 24
DRIVE SHAFT JOINT INSPECTION 25
PROPELLER SHAFT U-JOINT CONDITION 25
PROPELLER SHAFT U-JOINT LUBRICATION 25
WHEEL LUG NUT TORQUE CHECK 25
WHEEL BEARING INSPECTION 25
STEERING SYSTEM INSPECTION 25
SHOCK ABSORBER INSPECTION 25
SHOCK ABSORBER SPHERICAL BEARING LUBRICATION 25
FRONT SUSPENSION ARM LUBRICATION 26
TABLE OF CONTENTS

01 MAINTENANCE (cont'd)
03 - PERIODIC MAINTENANCE PROCEDURES (cont'd)
PROCEDURES (cont'd)
FRONT SUSPENSION ARM INSPECTION 26
BRAKE SYSTEM INSPECTION AND CLEANING 27
BRAKE FLUID REPLACEMENT 27
PASSENGER HANDHOLD CONDITION 29
TOW HITCH INSPECTION 29
04 - PRESEASON PREPARATION 31
05 - STORAGE PROCEDURE 33
GENERAL 33
PROCEDURES 33
FUEL SYSTEM 33
ENGINE 33
ELECTRICAL SYSTEM 34
DRIVE SYSTEM 34
CHASSIS 34
06 - SPECIAL PROCEDURES 35
GENERAL 35
ROLLED OVER VEHICLE 35
. SUBMERGED VEHICLE 35

02 ENGINE, CVT AND GEARBOX

01 - ENGINE REMOVAL AND INSTALLATION 37
GENERAL 38
PROCEDURES 38
ENGINE REMOVAL 38
ENGINE INSTALLATION 40
ENGINE MOUNTS 40
02 - AIR INTAKE SYSTEM 41
GENERAL 43
PROCEDURES 43
AIR FILTER 43
AIR FILTER HOUSING 43
03 - EXHAUST SYSTEM 45
GENERAL 46
PROCEDURES 46
SPARK ARRESTER 46
MUFFLER 46
"Y" EXHAUST PIPE 47
HEAD PIPE (FRONT CYLINDER) 47
HEAD PIPE (REAR CYLINDER) 48
04 - LUBRICATION SYSTEM 49
GENERAL 52
INSPECTION 52
ENGINE OIL PRESSURE 52
TROUBLESHOOTING 52
PROCEDURES
53
OIL COOLER
53
OIL PRESSURE SWITCH (OPS)
54
ENGINE OIL PRESSURE REGULATOR
54
OIL PUMP
55
ENGINE OIL STRAINER
57
REED VALVE
58
 TABLE OF CONTENTS

02 ENGINE, CVT AND GEARBOX (cont'd)

05 - COOLING SYSTEM 59
GENERAL 64
PROCEDURES 64
THERMOSTAT 64
RADIATOR 66
COOLANT TEMPERATURE SENSOR (CTS) 67
RADIATOR COOLING FAN RELAY (R1) 67
RADIATOR COOLING FAN 68
WATER PUMP HOUSING 70
WATER PUMP IMPELLER 71
WATER PUMP SHAFT AND SEALS 71
06 - MAGNETO SYSTEM 81
GENERAL 83
PROCEDURES 83
MAGNETO COVER 83
STATOR 84
ROTOR 85
SPRAG CLUTCH 87
SPRAG CLUTCH GEAR 88
STARTER DRIVE GEARS 89
07 - TOP END 91
GENERAL 96
INSPECTION 96
LEAK TEST 96
PROCEDURES 98
INTAKE MANIFOLD 98
VALVE COVER 99
ROCKER ARM 100
CYLINDER HEAD 102
CAMSHAFT 104
VALVE SPRINGS 106
VALVES 108
VALVE GUIDES 110
CYLINDER 111
PISTON 113
PISTON RINGS 116
08 - TIMING CHAIN 119
GENERAL 121
TROUBLESHOOTING 121
PROCEDURES 121
TIMING CHAIN TENSIONERS 121
CAMSHAFT TIMING GEARS 123
TIMING CHAIN 128
TIMING CHAIN GUIDE (TENSIONER SIDE) 130
09 - BOTTOM END 131
GENERAL 135
PROCEDURES 135
ENGINE DRIVE SHAFT 135
PTO COVER OIL SEAL 137
PTO COVER 138
DRIVE GEARS 140
CRANKCASE 141
CRANKSHAFT 145
 TABLE OF CONTENTS

02 ENGINE, CVT AND GEARBOX (cont'd)

10 - CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 153
GENERAL 156
PROCEDURES 156
CVT COVER 156
DRIVE BELT 157
DRIVE PULLEY 158
DRIVEN PULLEY 166
CVT AIR GUIDE 172
11 - GEARBOX AND 4X4 COUPLING UNIT 173
GENERAL 175
GEARBOX OVERVIEW 175
TROUBLESHOOTING 175
PROCEDURES 176
VSS (VEHICLE SPEED SENSOR) 176
GBPS (GEARBOX POSITION SENSOR) 177
4WD INDICATOR SWITCH 179
ACTUATOR 180
GEARBOX OIL SEALS 181
GEARBOX 183
12 - SHIFTER 199
GENERAL 200
PROCEDURES 200
SHIFT LEVER 200
SHIFTER CABLE 201
SHIFT PLATE 202

03 ELECTRONIC MANAGEMENT SYSTEM

01 - ENGINE MANAGEMENT SYSTEM (EMS) 205
GENERAL 206
SYSTEM DESCRIPTION 206
02 - COMMUNICATION TOOLS AND B.U.D.S 209
GENERAL 209
TROUBLESHOOTING 209
DIAGNOSTIC TIPS 209
PROCEDURES 211
MPI-2 211
B.U.D.S. SOFTWARE 212
03 - DIAGNOSTIC SYSTEM AND FAULT CODES 215
GENERAL 215
DIAGNOSTIC SYSTEM 215
FAULT CODES 216
SPECIFIC FAULTS 219

04 FUEL SYSTEM
01 - INTELLIGENT THROTTLE CONTROL (iTC) 221
GENERAL 221
SYSTEM DESCRIPTION 221
SYSTEM MAIN FEATURES 221
SYSTEM OTHER FEATURES 221
PROCEDURES 222
SPORT/NORMAL SWITCH 222
SEAT BELT SWITCH 222
OVERRIDE SWITCH 222
THROTTLE ACCELERATOR SENSOR (TAS) 222

IV
 TABLE OF CONTENTS

04 FUEL SYSTEM (cont'd)

02 - ELECTRONIC FUEL INJECTION (EFI) 225
GENERAL 225
SYSTEM DESCRIPTION 225
ADJUSTMENT 226
IDLE SPEED 226
TROUBLESHOOTING 227
DIAGNOSTIC TIPS 227
PROCEDURES 227
ENGINE CONTROL MODULE (ECM) 227
FUEL INJECTOR 233
FUEL RAIL 237
THROTTLE BODY 238
THROTTLE POSITION SENSOR (TPS) 240
CRANKSHAFT POSITION SENSOR (CPS) 242
MANIFOLD AIR PRESSURE AND TEMPERATURE SENSOR (MAPTS) 243
CTS (COOLANT TEMPERATURE SENSOR) 246
03 - FUEL TANK AND FUEL PUMP 249
GENERAL 251
SYSTEM DESCRIPTION 251
INSPECTION 252
FUEL TANK LEAK TEST 252
FUEL PUMP PRESSURE TEST 252
TROUBLESHOOTING 255
FUEL SYSTEM DIAGNOSTIC FLOW CHART 255
PROCEDURES 256
FUEL HOSE AND OETIKER CLAMPS 256
FUEL TANK 256
FUEL PUMP 258
FUEL LEVEL SENDER 262
FUEL TANK VENT VALVE 263

05 ELECTRICAL SYSTEM
01 - POWER DISTRIBUTION 265
GENERAL 265
POWER DISTRIBUTION DIAGRAM 265
FUSE BOX 1 266
FUSE BOX 2 266
02 - CONTROLLER AREA NETWORK (CAN) 267
GENERAL 267
SYSTEM DESCRIPTION 267
03 - IGNITION SYSTEM 269
GENERAL 269
SYSTEM DESCRIPTION 269
TROUBLESHOOTING 269
DIAGNOSTIC GUIDELINES 269
PROCEDURES 270
IGNITION SWITCH 270
IGNITION COIL 270
SPARK PLUG 271
04 - CHARGING SYSTEM 273
GENERAL 273
SYSTEM DESCRIPTION 273
INSPECTION 273
CHARGING SYSTEM OUTPUT 273

v
 TABLE OF CONTENTS

05 ELECTRICAL SYSTEM (cont'd)

04 - CHARGING SYSTEM (cont'd)
TROUBLESHOOTING 274
PROCEDURES 274
VOLTAGE REGULATOR/RECTIFIER 274
BATTERY 274
05 - STARTING SYSTEM 277
GENERAL 277
SYSTEM DESCRIPTION 277
TROUBLESHOOTING 277
DIAGNOSTIC GUIDELINES 277
PROCEDURES 278
D2 DIODE (STARTER SOLENOID) 278
START BUTTON 278
STARTER SOLENOID 279
ELECTRIC STARTER 280
06 - DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) 283
GENERAL 283
SYSTEM DESCRIPTION 283
TROUBLESHOOTING 283
DIAGNOSTIC TIPS 283
PROCEDURES 283
KEY PROGRAMMING 283
07 - LIGHTS, GAUGE AND ACCESSORIES 285
GENERAL 285
TROUBLESHOOTING 285
DIAGNOSTIC TIPS 285
PROCEDURES 285
CONSOLE SWITCHES 285
MULTIFUNCTION GAUGE (LCD AND ANALOG/DIGITAL) 286
12 VOLT POWER OUTLET 288
HEADLIGHTS 289
TAILLIGHTS/BRAKE LIGHTS 291
WINCH 292
TURN SIGNALS/HAZARD(EC MODELS ONLY) 293
HORN (EC MODELS ONLY) 294

06 DRIVE SYSTEM
01 - FRONT DRIVE 295
GENERAL 298
SYSTEM DESCRIPTION 298
PROCEDURES 298
WHEEL HUB 298
FRONT DRIVE SHAFT 299
DRIVE SHAFT BOOT 299
FRONT DIFFERENTIAL 300
FRONT PROPELLER SHAFT 303
PROPELLER SHAFT U-JOINTS 303
02 - REAR DRIVE 305
GENERAL 308
PROCEDURES 308
WHEEL HUB 308
DRIVE SHAFT 309
DRIVE SHAFT BOOT 309
PROPELLER SHAFT 310

VI
 TABLE OF CONTENTS

06 DRIVE SYSTEM (cont'd)

02 - REAR DRIVE (cont'd)
PROCEDURES (cont'd)
PROPELLER SHAFT U-JOINTS 310
REAR FINAL DRIVE 311

07 CHASSIS
01 - WHEELS AND TIRES 315
GENERAL 315
PROCEDURES 315
TIRES 315
WHEELS 317
02 - STEERING SYSTEM 319
GENERAL 321
ADJUSTMENT 321
STEERING ALIGNMENT 321
TROUBLESHOOTING 323
DIAGNOSTIC TIPS 323
PROCEDURES 323
STEERING WHEEL 323
STEERING COLUMN 323
RACK AND PINION 325
TIE-ROD ENDS 325
KNUCKLES 326
WHEEL BEARINGS 326
03 - FRONT SUSPENSION 329
GENERAL 330
PROCEDURES 330
SHOCK ABSORBER 330
SHOCK ABSORBER BUSHINGS 331
SPRINGS 331
LOWER SUSPENSION ARM 331
UPPER SUSPENSION ARM 332
SUSPENSION ARM BUSHINGS 333
BALL JOINTS 333
04 - REAR SUSPENSION 335
GENERAL 336
PROCEDURES 336
SHOCK ABSORBERS 336
SHOCK ABSORBER BUSHINGS 337
SPRINGS 337
ANTI-SWAY BAR 338
TRAILING ARM 338
05 - BRAKES 341
GENERAL 343
INSPECTION 343
BRAKE SYSTEM PRESSURE VALIDATION 343
PROCEDURES 344
BRAKE LIGHT SWITCH 344
MASTER CYLINDER 345
CALIPER 347
BRAKE PADS 347
BRAKE DISC 348

VII
 TABLE OF CONTENTS

07 CHASSIS (cont'd)
06 - BODY 349
GENERAL 359
PROCEDURES 359
PLASTIC RIVET 359
DECALS 359
UPPER CONSOLE 359
LOWER CONSOLE 359
LATERAL CONSOLE PANELS 360
GLOVE BOX REMOVAL AND INSTALLATION 361
07 - CARGO BOX 363
GENERAL 369
ADJUSTMENT 369
CARGO BOX ADJUSTMENTS 369
PROCEDURES 371
CARGO BOX GAS SHOCK 371
CARGO BOX 371
08 - FRAME 373
GENERAL 376
PROCEDURES 376
CAGE 376
FRAME 377

08 TECHNICAL SPECIFICATIONS
01 - COMMANDER 800R AND 1000 379

09 WIRING DIAGRAM
01 - WIRING DIAGRAM INFORMATION 389
GENERAL 389
WIRING DIAGRAM LOCATION 389
WIRING DIAGRAM CODES 389
02 - CONNECTOR INFORMATION 391
GENERAL 391
DEUTSCH CONNECTORS 391
PACKARD CONNECTORS 393
PACKARD CONNECTOR (MULTIFUNCTION GAUGE) 394
MOLEX CONNECTOR 395
FURUKAWA CONNECTOR 398
BATTERY AND STARTER CABLE TERMINALS 398

VIII
 SAFETY NOTICE

SAFETY NOTICE
This manual has been prepared as a guide to cor- Although the mere reading of such information
rectly service and repair the 2011 Can-Am' Com- does not eliminate the hazard, your understand-
mander SSV as described in the model list in the ing of the information provided will promote its
INTRODUCTION. correct use. Always use common shop safety
This edition was primarily published to be used by practices.
mechanical technicians who are already familiar It is understood that this manual may be trans-
with all service procedures relating to BRP prod- lated into another language. In the event of any
ucts. Mechanical technicians should attend train- discrepancy, the English version shall prevail.
ing courses given by BRPTI. BRP disclaims liability for all damages and/or in-
Please note that the instructions will apply only juries resulting from the improper use of the con-
if proper hand tools and special service tools are tents of this publication. We strongly recommend
used. that any services be carried out and/or verified by
The contents of this manual depicts parts and/or a highly skilled professional mechanic. It is under-
procedures applicable to a particular product at stood that certain modifications may render use of
the time of writing. Service and warranty bulletins the vehicle illegal under existing federal, provincial
may be published to update the content of this and state regulations.
manual. Dealer modifications that were carried
out after manufacturing of the product, whether
or not authorized by BRP, are not included.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or ex-
act replicas of the parts.
The use of BRP parts is most strongly recom-
mended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.
The engines and the corresponding components
identified in this document should not be utilized
on product(s) other than those mentioned in this
document.
This manual emphasizes particular information
which, is denoted by the following wording and
symbols:

A WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.

A CAUTION Indicates a hazardous situation

which, if not avoided, could result in minor or
moderate injury.
NOTICE Indicates an instruction which, if not
followed, could result in severe damage to ve-
hicle components or other property.
NOTE: Indicates supplementary information re-
quired to fully complete an instruction.

tmr2011-002 IX
INTRODUCTION

INTRODUCTION
This shop manual covers the following BRP made VIN Decal Description
2011 Can-Am side by side vehicles.

MODEL
ENGINE
MODEL NUMBER
3 2
TYPE
MANUFACTURED BY: BOMB RECREATIONAL PRODUCTS INC
6CBA, 6CBC, FORME PAR: BOMBARDIE . 41 R R -TIFS INC.
Commander 800R 810
6DBA, 6DBD MEl. DATE FAB: XX tXXXXMODELMX
6ABA, 6ABC, IN i NW: 2BPS1234X2V000123

Commander 1000 1010

6BBA, 6BBB,
6BBC, 6BBD,
11111111i1111111111 111111111111111
INS VENUE CONFORMS TO ALL APPLICABLE STANDARDS
6BBE, 6BBF, 6EBA, PRESCRIBED UNDER THE FEDERAL AND CANADIAN MOTOR
SAFETY REGULATKNIS 14 AFFECT ON THE DATE OF MANUFACTURF-
6EBC, 6CBA, 6CBC
CE VENICIAE EST CON FORME ATOOTER LES NORMES WI
SONT API:MAKES EN VERTU DU REGLEmewr SUR LA =Mit
DES YEHICULES AUTOMMES DU CANADA EN VIGUEUR ALA
The information and component/system descrip- DATE DE SA FABRICATION.
tions contained in this manual are correct at time MADE IN/FABRIQUE AU: MEXICVMEXIQUE roa 002 aoe
of writing. BRP however, maintains a policy of tmr2011-002-005_a

continuous improvement of its products without TYPICAL — VEHICLE IDENTIFICATION NUMBER LABEL
imposing upon itself any obligation to install them 1. VIN (Vehicle Identification Number)
2. Model number
on products previously manufactured. 3. Manufacturing date

Due to late changes, there may be some differ-

ences between the manufactured product and the ENGINE IDENTIFICATION
description and/or specifications in this document. NUMBER (EIN)
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.

VEHICLE INFORMATION
VEHICLE IDENTIFICATION
NUMBER (VIN)

TYPICAL - RH SIDE OF ENGINE

1. Engine Identification Number (EIN)

LIFTING AND SUPPORTING THE

VEHICLE
Front of Vehicle
1. Place vehicle on a flat non slippery ground.
TYPICAL 2. Ensure vehicle shift lever is set to PARK.
1. VIN (Vehicle Identification Number) location
3. Install an hydraulic jack under front skid plate.
The VIN (Vehicle Identification Number) decal is lo- 4. Lift front of vehicle and install a jack stand on
cated under the glove box on the passenger side. each side under frame section in front of the lip
for center skid plate.

x tmr2011-002
 INTRODUCTION

1. Rear of vehicle
1. Front of vehicle
2. Jack stand
2. Hydraulic jack
3. Frame section
3. Jack stand
4. Lip for center skid plate
5. Center skid plate 6. Lower hydraulic lift and ensure vehicle is sup-
ported safely onto both jack stands.
5. Lower hydraulic lift and ensure vehicle is sup-
ported safely onto both jack stands.
HOISTING THE VEHICLE
Rear of Vehicle The vehicle may be lifted off the ground by the
1. Place vehicle on a flat non slippery ground. cage using a hoist and a lifting strap.
2. Activate 4WD mode. NOTICE The lifting strap must be wrapped
3. Ensure vehicle shift lever is set to PARK. around the horizontal side tubes at the top of
the cage, NOT fore and aft. Lifting vehicle by
4. Install a hydraulic jack under the trailer hitch.
the fore and aft tubes of the cage can cause
damage.

1. Hydraulic jack 1. Lifting strap around horizontal side tubes (top)

2. Trailer hitch 2. Hoist hook

5. Lift rear of vehicle and install a jack stand on

each side under frame section in front of rear
wheel.

tmr2011-002 XI
INTRODUCTION

A WARNING 7. Firmly attach the rear wheels tie-down straps to

both sides of the rear of the trailer with ratch-
— Ensure hoist and lifting strap are rated for ets.
lifting the total vehicle weight. Refer to ap-
8. Ensure that both the front and rear wheels are
plicable manufactures instructions.
firmly secured to the trailer.
— Ensure lifting strap is in good condition be-
fore lifting vehicle.
ENGINE EMISSIONS
— Do not allow anyone in the vehicle or under
any portion of the vehicle while it is sus- INFORMATION
pended by a hoist.
— Do not perform any work on the vehicle MANUFACTURER'S
while it is suspended by a hoist. RESPONSIBILITY
Manufacturers of engines must determine the
TRANSPORTING THE VEHICLE exhaust emission levels for each engine horse-
power family and certify these engines with
If the vehicle needs to be transported, it should be
the United States of America Environmental
carried inside a full size pick-up box or on a flatbed
Protection Agency (EPA). An emissions control
trailer of the appropriate size and capacity.
information label, showing emission levels and
NOTICE Do not tow this vehicle - towing can engine specifications, must be placed on each
seriously damage the vehicle's drive system. vehicle at the time of manufacture.

When contacting a towing or transporting service,

be sure to ask for tie-down straps, a flatbed trailer,
DEALER RESPONSIBILITY
loading ramp or power ramp to safely lift and se- When servicing any vehicle that carry an emis-
cure the vehicle. Ensure the vehicle is properly sions control information label, adjustments must
transported as specified in this section. be kept within published factory specifications.
NOTICE Avoid using chains to tie down the Replacement or repair of any emission related
vehicle - they may damage the surface finish component must be executed in a manner that
or plastic components. maintains emission levels within the prescribed
certification standards.
To load the vehicle for transport, proceed as fol-
Dealers are not to modify the engine in any man-
lows: ner that would alter the horsepower or allow emis-
1. Set gear shift lever to NEUTRAL (N). sion levels to exceed their predetermined factory
2. Remove the key from the ignition switch. specifications.
3. If the vehicle is equipped with a winch, use the Exceptions include manufacturer's prescribed
winch to roll the vehicle onto the transport ve- changes, such as altitude adjustments.
hicle.
4. If the vehicle is not equipped with a winch, pro- OWNER RESPONSIBILITY
ceed as follows: The owner/operator is required to have engine
4.1 Put a strap around the lower arm of each maintenance performed to maintain emission
front suspension. levels within prescribed certification standards.
4.2 Attach the straps to the winch cable of the The owner/operator is not to, and should not al-
towing vehicle. low anyone else to modify the engine in any man-
4.3 Pull the vehicle on the flatbed trailer with ner that would alter the horsepower or allow emis-
the winch. sions levels to exceed their predetermined factory
specifications.

NOTE: Be sure to leave the gear shift lever in

NEUTRAL (N).
EPA EMISSION REGULATIONS
5. Tie down the front wheels to the front of the Vehicles manufactured by BRP are certified to the
trailer using tire towing straps. EPA standards as conforming to the requirements
of the regulations for the control of air pollution
6. Pass a tie-down strap inside each rear wheel.
emitted from new vehicle engines. This certifica-
XII tmr2011-002
 INTRODUCTION

tion is contingent on certain adjustments being

set to factory standards. For this reason, the
factory procedure for servicing the product must
be strictly followed and, whenever practicable,
returned to the original intent of the design.
The responsibilities listed above are general and
in no way a complete listing of the rules and regu-
lations pertaining to the EPA requirements on ex-
haust emissions. For more detailed information
on this subject, you may contact the following lo-
cations:
FOR ALL COURIER SERVICES:
U.S. Environmental Protection Agency
Office of Transportation and Air Quality
1310 L Street NW TYPICAL
1. Left
Washington D.C. 20005 2. Right
REGULAR US POSTAL MAIL:
1200 Pennsylvania Ave. NW This manual uses technical terms which may be
Mail Code 6403J different from the ones of the PARTS CATALOGS.
Washington D.C. 20460 When ordering parts always refer to the specific
INTERNET: http://www. e pa .gov/otaq/ model PARTS CATALOGS.
E-MAIL: [email protected] NOTICE Most fasteners are metric, and most
components are built with parts dimensioned
MANUAL INFORMATION using the metric system. Consult the appropri-
ate PARTS CATALOGto obtain and use the cor-
rect parts and fasteners. Mismatched or incor-
MANUAL PROCEDURES rect fasteners could cause damage to the vehi-
Many of the procedures in this manual are inter- cle.
related. Before undertaking any task, you should
read and thoroughly understand the entire section MANUAL LAYOUT
or subsection in which the procedure is contained
This manual is divided into many major sections as
A WARNING can be seen in the main table of contents at the
beginning of the manual.
Unless otherwise specified, the engine
should be turned OFF and cold for all main- Each section is divided into various subsections,
tenance and repair procedures. and again, each subsection has one or more divi-
sions.
A number of procedures throughout the book re- Illustrations and photos show the typical construc-
quire the use of special tools. Before starting any tion of various assemblies and, in all cases, may
procedure, be sure that you have on hand all re- not reproduce the full detail or exact shape of the
quired tools, or their approved equivalents. parts used in a particular model vehicle. However,
they represent parts which have the same or a
The use of RIGHT and LEFT indications in the text
similar function.
are always referenced to the driving position (sit-
ting on the vehicle).

trnr2011-002 XIII
 INTRODUCTION

TYPICAL PAGE

Section 06 ENGINE I Page heading

Subsection 01 (MAGNETO) indicates section
and subsection.

Subsection title > MAGNETO

Indicates applicable Models
models.

Drop represents a
service product
Exploded view assists to be applied.
you in identifying parts
and their related Dotted box contains
positions. parts applicable to a
specific model.

Bold face number

is used to identify
a part referred to
the text.
NEW indicates that the
part must be replaced
with a new one.

Illustration number
for publishing process.

Document number for %-it Page number

publishing process. ----)1""
r

Specific torque applicable to this installation.

CAUTION: Pay attention to torque specifications.

Some of these are in lbf•in instead of lbf•ft.
Use appropriate torque wrench.

Tygcaliso_2008_en

XIV tmr2011-002
 INTRODUCTION

TYPICAL PAGE

Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)

Tittle in bold
indicates category ___). GENERAL
of information to be
carried out. NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Reference to a Clean threads before applying a threadlocker Re
specific section . )11.SELLOCA7NG FASTENERS and LOC-
or subsection. TITE APPLICATION sections at the beginning of
this manual for complete procedure. "TYPICAL"
WARNING
indicates a general
view which may
Torque wrench tightening specifications
must be strictly adhered to. not represent exact
Locking devices (e.g.: locking tabs, elastic details.
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones. TYP1CA
41(

PROCEDURES NOTE: To remove starting pulley bolts, hold mag Call-outs pertaining
Indicates component
veto flywheel with a socket as shown. to above illustration.
procedures apply to. ----)MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
Indicates specific
a clean cloth. Illustration always
procedure to be ---).Magneto Flywheel Removal follows text to which
carried out. it applies.
Remove muffler, refer to the EXHAUST SYSTEM
section.
Remove acoustic panel.
Remove rewind starter.
Remove starting pulley no. 2. TYPICAL Italic bold face type-
A Models
setting indicates a
the
procedure applicable
Remove the connecting flange retaining
• rewind starter to the engine housing. to a specific
model(s).

mmr2008.001 57

Bold face number following part

name refers to exploded view
at beginning of subsection.

typical_txt_2008_en

XV
tmr2011 -002
 INTRODUCTION

TIGHTENING TORQUE
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, refer to the following table.

A WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices when removed (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter
pins, etc.) must be replaced.

In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce-
dure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.
NOTICE Be sure to use the recommended tightening torque for the specified fastener used.

NOTE: When possible, always apply torque on the nut.

NOTE: Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are
used to secure a part (eg. a cylinder head). Some parts must be torqued according to a specific sequence
and torque pattern as detailed in the installation procedure.

4.8 8.8 9.8 10.9 12.9

- - - - -
Property
class and 0
head 4.8 8.8 9.8 10. 2.9
markings
14.81 II 8.81 II 9.8. IMII iggli 129
WI- OPT UPI MI! IIIPI Mil
5 8 10 12
Property - - - -
class and - MI - - an
nut
markings
0 I° 0 0 :
■I
0
_ 0 • 0 0
_ am
. 0
-

A00A813S

FASTENER FASTENER GRADE/TORQUE

SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5 - 2 Nom 2.5 - 3 Nom 3.5 - 4 N•m 4 - 5 Nom
M4
(13 - 18 lbfoin) (22 - 27 lbf•in) (31 - 35 lbf•ft) (35 - 441bf•ft)
3 - 3.5 Nom 4.5 - 5.5 Nom 7 - 8.5 Nom 8- 10 Nom
M5
(27 - 31 lbf•ft) (40 - 47 lbf•ft) (62 - 75 lbf•ft) (71 - 89 lbf•ft)
6.5 - 8.5 Nom 8 - 12 Nom 10.5 - 15 Nom
M6 16 Nom (142 lbf•in)
(58 - 75 lbf•ft) (71 - 106 lbfoft) (93 - 133 lbfoin)
M8 15 Nom (1331bfoin) 25 N•m (181bf•ft) 32 Nom (24 Ibf•ft) 40 Nom (30 Ibf•ft)
M10 29 Nom (21 lbf•ft) 48 Nom (35 lbf•ft) 61 Nom (45 Ibf•ft) 73 Nom (54 lbfoft)
M12 52 Nom (38 lbfoft) 85 Nom (63 lbfoft) 105 Nom (77 Ibf•ft) 128 Nom (94 lbfoft)
M14 85 Nom (631bf•ft) 135 Nom (1001bf•ft) 170 Nom (1251bf•ft) 200 Nom (1481bf•ft)

xvi tmr2011-002
 INTRODUCTION

FASTENER INFORMATION Threadlocker Application for

Uncovered Holes (Bolts and Nuts)
NOTICE Most components in the vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners
could cause damage to the vehicle or possible
personal injury.

SELF-LOCKING FASTENERS
PROCEDURE

1. Apply here
2. Do not apply

1. Clean threads (bolt and nut) with solvent.

2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
threads and allow to dry.
TYPICAL — SELF-LOCKING FASTENER 3. Choose proper strength Loctite threadlocker.
The following describes common procedures 4. Fit bolt in the hole.
used when working with self-locking fasteners. 5. Apply a few drops of threadlocker at proposed
Use a metal brush or a tap to properly clean a tightened nut engagement area.
threaded hole, then use a solvent. Allow the sol- 6. Position nut and tighten as required.
vent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper Threadlocker Application for Blind
adhesion of the product used for locking the fas- Holes
tener.

LOCTITE® APPLICATION
PROCEDURE
The following describes common procedures
used when working with Loctite products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this shop manual. A

■■■
Imr200/ 04C-001 a

1. On fastener threads
2. On threads and at the bottom of hole

1. Clean threads (bolt and hole) with solvent.

2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.

tmr2011-002 XVII
 INTRODUCTION

4. Apply several drops along the threaded hole Threadlocker Application for
and at the bottom of the hole. Pre-Assembled Parts
5. Apply several drops on bolt threads.
6. Tighten as required.

Threadlocker Application for Stud

Installation in Blind Holes

1. Apply here
2. Do not apply
1. On stud threads
2. On threads and in the hole 1. Clean bolts and nuts with solvent.
3. On retaining nut threads
2. Assemble components.
1. Clean threads (stud and hole) with solvent.
3. Tighten nuts.
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
4. Apply a few drops of proper strength Loctite on
threads and allow to dry.
bolt/nut contact surfaces.
3. Put 2 or 3 drops of proper strength Loctite
5. Avoid touching metal with tip of flask.
threadlocker on female threads and in hole.
NOTE: For preventive maintenance on exist-
NOTE: To avoid a hydro lock situation, do not ap-
ing equipment, retighten nuts and apply proper
ply too much Loctite.
strength Loctite on bolt/nut contact surfaces.
4. Apply several drops of proper strength Loctite
on stud threads. Threadlocker Application for an
5. Install stud. Adjustment Screw
6. Install cover, part, etc.
7. Apply a few drops of proper strength Loctite on
uncovered stud threads.
8. Install and tighten retaining nut(s) as required.

11*
AO0A3PA

1. Apply here
2. Plunger

1. Adjust screw to proper setting.

2. Apply a few drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.

XVIII tmr2011-002
 INTRODUCTION

NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

a soldering iron (232°C (450°F)).

Application for Stripped Thread Repair

1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tapes
5. Cleaned bolt 1. Proper strength Loctite
6. Plate 2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
7. New threads (P/N 293 800 038) on both sides of gasket
8. Threadlocker 3. Loctite Primer N only

Standard Thread Repair 1. Remove old gasket and other contaminants us-
Follow instructions on Loctite FORM-A-THREAD ing LOCTITE CHISEL (GASKET REMOVER) (P/N 413
81668 package. 708 500). Use a mechanical means only if nec-
essary.
If a plate is used to align bolt:
NOTE: Avoid grinding.
1. Apply release agent on mating surfaces.
2. Clean both mating surfaces with solvent.
2. Put waxed paper or similar film on the surfaces.
3. Spray Loctite Primer N on both mating surfaces
3. Twist bolt when inserting it to improve thread and on both sides of gasket and allow to dry 1
conformation. or 2 minutes.
NOTE: NOT intended for engine stud repairs. 4. Apply LOCTITE 518 (P/N 293 800 038) on both
Repair of Small Holes/Fine Threads sides of gasket, using a clean applicator.
Option 1: Enlarge damaged hole, then follow 5. Place gasket on mating surfaces and assemble
STANDARD THREAD REPAIR procedure. parts immediately.
Option 2: Apply FORM-A-THREAD on the screw NOTE: If the cover is bolted to blind holes, apply
and insert in damaged hole. proper strength Loctite in the hole and on threads.
Permanent Stud Installation (Light Duty) Tighten fastener.
1. Use a stud of the desired thread length. If holes are sunken, apply proper strength Loctite
on bolt threads.
2. DO NOT apply release agent on stud.
6. Tighten as usual.
3. Follow Standard Thread Repair procedure.
4. Allow 30 minutes for Loctite FORM-A-THREAD Threadlocker Application for Mounting
to cure. on a Shaft
5. Complete part assembly. Mounting with a Press

tmr201 1-002 XIX

INTRODUCTION

3. Apply a strip of proper strength Loctite on lead-

ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
Th 1 strength and gap are required.
ow
mm l 4. Install according to standard procedure.
ts.4.w....______
-4 la y 2
.*4- 5. Wipe off excess product.
3 6. Allow 30 minutes for product to cure.
AO0A3UA NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
1. Bearing
2. Proper strength Loctite It is generally not necessary to remove gasket
3. Shaft
compound applied on outer gasket diameter.
1. Clean shaft external contact surface.
2. Clean internal contact surface of part to be in-
stalled on shaft.
3. Apply a strip of proper strength Loctite on cir-
cumference of shaft contact surface at inser-
tion or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
4. DO NOT use antiseize Loctite or any similar
product.
5. No curing period is required.
Mounting in Tandem
1. Apply retaining compound on internal contact
surface (bore) of parts to be installed.
2. Continue parts assembly as per previous illus-
tration.

Threadlocker Application for Case-In

Components (Metallic Gaskets)

1. Proper strength Loctite

1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with LOCTITE PRIMER
N (P/N 293 800 041).

XX trnr2011-002
 eSL abed
-- ----- -
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(OOP 900 6M N/d) 9L abed
(1AD) 93010H A31111d ]AlEla
ZS ab ed
(no sco 6Z9 N/d)
90103101dd 1JVHS)INVEID FRG U
(PLL 9E0 6Z9 N/d)
1001 103NNODSICI
(LW 9E0 6M N/d)
1109 9N1)1001 1JVHSNNVHD (9S0 9E0 6ZS N/d)
9ZZ :abed
_IN 4:1371nd 310H GNI18
a
C2MCIrl
OCIOCI
- mos ---wz..-11111
(00S 17 LO 6ZS N/d)
Ee13AJOHDVIN011311GNI 1V11910
60E '66Z :abed
(Ll I 9E0 6Z9 N/d)
(LEO 9E0 6Z9 N/d) 13S 931111d DNIEIV38 310H aNI19
(S00 9E0 6ZS N/d) Old/DVW ibioddns 3SVDNNVHD
• 801DVEL1X3 1N10r AD
6SL abed
(917 L SE0 6Z9 N/d)
(OEL 9E0 6Z9 N/d) 1:1311nd Hoin -o (599 9E0 6Z9 N/d)
(39IM 1001 1N31A13911SV3lAl HSVDIDV9
3onvo AAV3H) 1001 DNIdV\111:10
zs :abed
(00Z 9E0 6Z9 N/d) (LOZ 9E0 6Z9 N/d) (Z99 9E0 6zs N/d)
1001 NO111S0d DalldVHSNNVED 1001 DNIV\111 _l_dVHSVWD 3SOH 931dVCIV
X3CINI S1001 331A83S
 Esz :abed
(9LL 9E0 6Z9 N/d)
9Z . Z H3AOVN3)1 1VNIA81311A133
965 'VVE '8LZ 'LLZ
(198 000 OIL N/d)
"69Z '917Z-EVZ '1VZ '6ZZ '8L1. :e 6 ed
318VO 31.1SONDV1G Z- 1d1A1
smiatt tolettion t e ‘,..11:teenee0A
(EZO 9E0 6Z9 N/d)
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6LZ LLZ '89Z '917Z -1717Z
'1,17Z '9EZ '6ZZ '081 '9L1 '89 :e 5 ed
991 :abed
(ILL 9E0 6Z9 N/d)
(898 9E0 6z9 N/d) H]aioH Foinio N3AIHC1
H]i]vviintAi 911
(661 9E0 6Z9 N/d)
SSANHVH 311SONDVIG 013N9VV\J
99-179 :e 6 ed
(ZZO 9E0 6Z9 N/d)
1001 DNIldll 3NIDN3 (6Z0 9E0 6Z9 N/d)
H01D310Hd 1V ]S 110 IdVHS 3A1EIG
(009 ZEO 6Z9 N/d)
L111-13N1d 3SOH 308\z/1
(17L1 9E0 6Z9 N/d) (KO 9E0 6Z9 N/d)
9E . E H3/\OLAJ34:1 1VNIVN1H31 V\13A H311V1SN1 1V3S 110 1JVHS 3A1HG
X3CINI S7001 331A1:13S
 (0£ I 9E0 6Z9 N/d)
31Vld El3HSfld 1V3S Al=r9'101:1
(ZEO 9E0 6Z9 N/d)
LI311V1SN1/1:13A01A13/:1
91\11HV38 NIVld (89L 9E0 6Z9 N/d)
(XOEILIV3D) E1311V1SN1 1V3S 110
(EE0 9E0 6Z9 N/d)
d311V1SNI 1V3S 110 E13/\00 Old
(616 9E0 6z9 N/d)
10SS31:1d1A100 91\111:1 NO1SId
(Egl. 9E0 669 N/d)
E1311V1SNI d1101:110 NO1S1d
(1Z6 SE0 6zs N/d)
1:1311VISN1 d1101:110 NO1S1d
(L16 9E0 6Z9 N/d)
1:1111V1SN1/1:13A01A111:1 (8L0 9E0 6Z9 N/d)
DNILIV3E1 NIV1d ClIdVD 33Vd1:131N1 Z-IdlAl
 (V9L 9E0 6zs N/d)
dno EIOSS38dIA103 DNI8dS 3A1VA
01. I. : 96 ed
LEE abed
(VZ6 9E0 6zs N/d) a
WW 9 H3ACHA3LI ]ainD 3/VIVA
(690 9E0 6Z9 N/d)
1001 INTAINDITV DNIH331S
(0t7L 9E0 6zg N/d)
3A1VA
(008 LZO 6Z9 N/d)
dIAInd 31:InssaidivvrinDeA
(19U. 9E0 6Z9 N/d)
HOSS38dV\100 9NIEldS 3/V1VA
X3CINI S1001 331AE3S
 Section 01 MAINTENANCE
Subsection 01 (BREAK-IN INSPECTION)

BREAK-IN INSPECTION
This vehicle should be serviced after the first 10 hours or 300 km (200 mil of operation, whichever comes
first, by an authorized Can-Am dealer. The break-in inspection is very important and must not be ne-
glected.
The following message will appear in the cluster as a reminder of when the break-in inspection is due:
MAINTENANCE SOON. The message can be cancelled by alternately pressing the override button and
the brake pedal 3 times, or by using B.U.D.S. software.
Replace
Adjust
lighten
BREAK-IN INSPECTION CHART
Lubricate
Clean
Inspect I
ENGINE
Engine oil and filter X
Valve clearance X X
Cylinder head screws
Air filter X
Engine seals X
Engine mounting fasteners X
Exhaust system X
COOLING SYSTEM
Radiator/cooling system leak (leak test) IX1 1111
FUEL SYSTEM
Throttle body X
Fuel lines, fuel rails, connections, check valves and fuel tank leak test
ELECTRICAL SYSTEM
Spark plugs X
Battery connections X
CVT TRANSMISSION
CVT air inlet/outlet X
CVT air filter X
GEARBOX
Gearbox oil X
Vehicle speed sensor X
DRIVE SYSTEM
Front differential/rear final drive oil X
Front differential/rear final drive (seals and vents)
Front and rear propeller shaft joints X X
WHEEL
Wheel nuts/studs X X
Wheel beadlock (X model) X

trm2011-046 5
 Section 01 MAINTENANCE
Subsection 01 (BREAK-IN INSPECTION)

Replace
Adjust
Tighten
BREAK-IN INSPECTION CHART
Lubricate
Clean
Inspect I
STEERING SYSTEM
Steering system (column, bearing, etc.)
X
Front wheel alignment
BRAKES
Brake fluid
OCCUPANT RESTRAINT SYSTEM
Seat belts
X
Side nets
_ X
BODY/CHASSIS
Cage fasteners
X
Upper and lower tailgates latches
X
Seats latch

6
 Section 01 MAINTENANCE
Subsection 02 (PERIODIC MAINTENANCE SCHEDULE)

PERIODIC MAINTENANCE SCHEDULE

Maintenance is very important for keeping the ve- EVERY 3 000 KM (2,000 MI) OR
hicle in a safe operating condition. Proper main- 100 HOURS OF OPERATION
tenance is the owner's responsibility. The vehicle OR 1 YEAR (whichever comes first)
should be serviced as per the maintenance sched- Inspect seat belts (check for any damages and
ule proper operation)
The following message will appear in the cluster Inspect side nets (check for any damages and
after the first 10 hours of operation and then at ev- ensure they buckle properly)
ery 50 hours that follow as a reminder of when an
inspection is due: MAINTENANCE SOON. The Replace the engine oil and filter
message can be cancelled by alternately pressing Inspect and adjust the valve clearance
the override button and the brake pedal 3 times,
or by using B.U.D.S. software. Inspect and clean the muffler spark arrester
Check engine coolant strength
A WARNING Inspect throttle body
Failure to properly maintain the vehicle ac-
cording to the maintenance schedule and Clean the fuel pump pre-filter
procedures can make it unsafe to operate. Inspect the fuel pump pressure
Replace fuel vent breather filter
EVERY 750 KM (500 MI) OR 25 HOURS OF
OPERATION (whichever comes first) Inspect the drive belt

Clean the CVT air inlet/outlet Inspect, clean and lubricate the drive and driven
pulleys (including the one-way bearing)
Inspect and clean the CVT air filter Inspect the gearbox oil level and condition
Inspect the brake pads Inspect wheel bearings
Tighten the wheel lug nuts Inspect the steering system (column, bearing, etc.)
Inspect the drive shaft boots and protectors Inspect and clean the brake system
Inspect passenger grab handles condition Inspect frame for any damage
Inspect hitch condition Replace rear final drive oil
Inspect driver and passenger seat latch operation
EVERY 6 000KM (4,000 MI) OR
Inspect tailgates latch operation 200 HOURS OF OPERATION
OR 2 YEARS (whichever comes first)
EVERY 1 500 KM (1,000 MI) OR 50 HOURS OF
OPERATION (whichever comes first) Replace the engine coolant

Replace the air filter Verify the cooling system and perform a pressure
test on pressure cap and cooling system
Verify battery condition
Verify the fuel system and perform a fuel system
Inspect the front differential/rear final drive oil level leak test
Inspect the drive shaft joints condition Replace spark plugs
Inspect the front/rear propeller shaft joint condition Replace the front differential oil
Grease the front/rear propeller shaft joints Replace gearbox oil
Inspect the tie rod ends Clean the vehicle speed sensor
Inspect shock absorbers for any leaks Replace the brake fluid
Lubricate shock absorber spherical bearings
(X model)
Inspect and lubricate front suspension arms

tmr2011-003 7
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

PERIODIC MAINTENANCE
PROCEDURES
SERVICE TOOLS
Description Part Number Page
TEST CAP 529 035 991 18
VACUUM/PRESSURE PUMP 529 021 800 18, 28

SERVICE PRODUCTS
Description Part Number Page
BRAKE FLUID 293 600 131 28
BRP PREMIXED COOLANT 219 700 362 13
COSMO RUBBER GREASE 293 550 055 27
SUSPENSION GREASE 293 550 033 26
XPS PARTS AND BRAKES CLEANER 219 701 705 22, 27
XPS SYNTHETIC BLEND OIL (SUMMER GRADE) 293 600 121 12
XPS SYNTHETIC GEAR OIL (75W 140) 293 600 140 21, 24
XPS SYNTHETIC GEAR OIL (75W 90) 293 600 043 24
XPS SYNTHETIC GREASE 293 550 010 27
XPS SYNTHETIC OIL (WINTER GRADE) 293 600 112 12

GENERAL NOTE: Riding in a group in these conditions

would increase even more the air filter replace-
This subsection provides:
ment requirement.
— Fluid level verifications
— Maintenance procedures. Air Filter Removal
The following systems should be serviced accord- Remove service cover.
ing to the PERIODIC MAINTENANCE SCHED-
ULE.

PROCEDURES
AIR FILTER REPLACEMENT
NOTICE Never modify the air intake system.
Otherwise, engine performance degradation
or damage can occur. The engine is calibrated
to operate specifically with these components.

Air Filter Replacement Guideline

Air filter replacement should be adjusted accord-
ing to riding conditions as it is critical to ensure
proper engine performance and life span.
1. Service cover
Air filter replacement frequency must be in-
creased for the following dusty conditions: Release clamps and remove air filter housing
cover.
— Riding on dry sand
— Riding on dry dirt covered surfaces
— Riding on dry gravel roads or similar conditions.

tmr2011-044 9
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

MUFFLER SPARK ARRESTER

CLEANING AND INSPECTION
A CAUTION Never perform this operation
immediately after the engine has been running
as exhaust system is very hot.
Remove the muffler cover.

1. Release clamps

Remove air filter.

1. Muffler cover
2. Exhaust tail pipe

Remove and discard the tail pipe retaining screws.

1. Air filter

Replace air filter if clogged. Always use the rec-

ommended air filter or an equivalent.

Air Filter Installation

Inspect air filter housing for cleanliness.
NOTICE If any sands or other particles are
1. Retaining screws
found in air filter housing, clean it using a
vacuum cleaner. Remove exhaust tail pipe, gasket (discard) and
spark arrester.
Install air filter.
Install air filter housing cover and latch all clamps.
Install service cover.

10 tmr201 1-044
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

ENGINE OIL LEVEL

VERIFICATION
NOTICE Operating the engine with an im-
proper level may severely damage engine.
With vehicle on a level surface and engine cold,
check the oil level as follows:
1. Remove passenger seat.
2. Unscrew dipstick then remove it and wipe
clean.

7. Spark arrester
2. Gasket
3. Exhaust tail pipe

Remove carbon deposits from the spark arrester

using a brush.
NOTICE Use a soft brush and be careful to
avoid damaging spark arrester mesh.

1. Dipstick

3. Reinstall dipstick, screw in it completely.

4. Remove dipstick and check oil level. It should
be near or equal to the upper mark.

7. Clean spark arrester

TYPICAL
Inspect mesh of spark arrester for any damage. 1. MIN.
Replace as required. 2. MAX.
3. Operating range
For installation, reverse the removal procedure.
However pay attention to the following. To add oil, remove the dipstick. Place a funnel into
the dipstick tube.
Install new gasket and retaining screws.
Add a small amount of recommended oil and
PART TORQUE recheck oil level.
11 N•m ± 1 N•m Repeat the above procedures until oil level
Tail pipe retaining screws
(97 lbf•in ± 9 lbf•in) reaches the dipstick's upper mark.
NOTE: Do not overfill. Wipe off any spillage.
Properly tighten dipstick.
Install passenger seat.

tmr201 1-044 11
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

ENGINE OIL CHANGE NOTICE Never use the gasket ring a second
time. Always replace by a new one.
Place vehicle on a level surface.
Oil change and oil filter replacement should be Install and tighten drain plug to the recommended
done with a warm engine. torque.
DRAIN PLUG TIGHTENING TORQUE
A CAUTION The engine oil can be very hot.
30 N•rn ± 2 N•m (22 lbf•ft ± 1 lbf•ft)
Wait until engine oil is warm.
Ensure vehicle is on a level surface. Replace oil filter. Refer to ENGINE OIL FILTER RE-
Remove dipstick. PLACEMENT in this subsection.
Place a drain pan under the engine drain plug area. Refill engine with recommended engine oil.

Clean the drain plug area. ENGINE OIL CAPACITY

Unscrew drain plug and discard the gasket ring. 2.2 L (23.25qt (U.S. fig.))

RECOMMENDED ENGINE OIL

SEASON TYPE
XPS SYNTHETIC BLEND
Summer OIL (SUMMER GRADE)
(P/N 293 600 121)
XPS SYNTHETIC OIL (WINTER
Winter
GRADE) (P/N 293 600 112)

If recommended XPS oil is not available, use a

4-stroke SAE 5W 40 engine oil that meets or ex-
ceeds the requirements for API service classifica-
tion SM, SL or SJ. Always check the API service
label certification on the oil container, it must con-
tain at least one of the above standards.
DRAIN PLUG ACCESS
1. Oil drain plug After filling, check the oil level, refer to ENGINE
2. Skid plate
OIL LEVEL VERIFICATION in this subsection.
Start engine and let it idle for a few minutes.
Ensure oil filter and drain plug areas are not leak-
ing.
Stop engine.
Wait a while to allow oil to flow down to
crankcase, then check oil level again.
Dispose oil and filter as per your local environmen-
tal regulations.

ENGINE OIL FILTER

REPLACEMENT
1. Gasket ring Oil Filter Removal
2. Drain plug
Clean oil filter area.
Allow oil to drain completely from the crankcase. Remove oil filter cover screws.
Clean the magnetic drain plug from metal shav- Remove oil filter cover.
ings and residue. Presence of debris gives an in-
Remove oil filter.
dication of internal engine damage.
Install a NEW gasket ring on the drain plug.

12 tmr2011-044
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

1. Oil filter screw

2. Oil filter cover
3. 0-ring I. Slightly oil
4. Oil filter 2. Slightly oil

Oil Filter Installation Install the cover on the engine.

Check and clean the oil filter inlet and outlet area Tighten oil filter cover screws to recommended
for dirt and other contaminations. torque.
OIL FILTER COVER SCREWS TIGHTENING
TORQUE
10 N•m ± 1 N•rn (891bf•in ± 9 lbf•in)

RECOMMENDED ENGINE
COOLANT
COOLANT
BRP
BRP PREMIXED COOLANT
RECOMMENDED
(P/N 219 700 362)
PRODUCT
Distilled water and
ALTERNATIVE,
antifreeze solution
OR IF NOT
1. Outlet bore to the engine oil providing system (50% demineralized water,
2. Inlet bore from the oil pump to the oil filter AVAILABLE
50% antifreeze)
Install a NEW 0-ring on oil filter cover.
NOTICE Always use ethylene-glycol an-
Install the filter into the cover.
tifreeze containing corrosion inhibitors specif-
Apply engine oil on 0-ring and grease on the end ically formulated for internal combustion
of filter. aluminum engines.

ENGINE COOLANT LEVEL

VERIFICATION
A WARNING
Check coolant level with engine cold.

1. Place vehicle on a level surface.

2. Open service cover.
3. Remove the pressure cap.

tmr201 1-044 13
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

A WARNING
In order to avoid potential burns, do not re-
move the pressure cap if the engine is hot.

tTno201 , -001 CBE a.

COOLANT EXPANSION TANK

1. MAX. level
2. MIN. level
3. Operating range

1. Air filter housing cover

8. Add coolant if level is below MIN. mark. Use a
2. Coolant expansion tank cap funnel to avoid spillage. Do not overfill.
3. Pressure cap
9. Properly reinstall coolant expansion tank cap.
4. Ensure cooling system is full up to the pressure 10. Reinstall service cover.
cap seat.
NOTE: A cooling system that frequently requires
addition of coolant is an indication of leaks or en-
gine problems.

ENGINE COOLANT SPECIFIC

GRAVITY CHECK
Remove pressure cap.
Use an antifreeze tester to test coolant strength.
MINIMUM RECOMMENDED COOLANT
STRENGTH
-30°C (-22°F)

ENGINE COOLANT
1. Cooling system refill adapter
2. Expansion tank hose REPLACEMENT
3. Coolant system full level (pressure cap seat)
Cooling System Draining
5. Add coolant in system as necessary.
6. Properly reinstall pressure cap on refill adapter. A WARNING
7. Check coolant level in expansion tank. In order to avoid potential burns, do not re-
move the pressure cap or loosen the coolant
NOTE: Coolant level can be checked by looking at drain plug if the engine is hot.
the side of the coolant expansion tank under the
RH front fender.
1. Remove service cover.
2. Remove the cooling system pressure cap.

14 tmr2011-044
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

1. Pressure cap

3. Unscrew coolant drain plug and drain the

1. Oil filter cover
coolant into a suitable container. 2. Water pump cover
3. Coolant drain plug
NOTE: The drain plug is accessible from under-
neath the vehicle. 4. Disconnect the lower radiator hose and drain
the remaining coolant into a suitable container.
NOTE: Take note of the position of the hose
clamp on the lower radiator hose at the radiator.

1. Cooling system drain plug access

NOTE: Do not unscrew the coolant drain plug

completely.

1. Hose clamp position to note

2. Lower radiator hose to remove

5. Drain cooling system completely.

6. Reinstall cooling system drain plug.
COOLING SYSTEM DRAIN PLUG TORQUE
9 Nam to 11 Nam (80 lbf•in to 97 lbfain)

7. Reinstall radiator hose as noted prior to re-

moval.
RADIATOR HOSE CLAMP
2.5 N•m to 3.5 N•m (22 lbf•in to 31 lbf•in)

8. Siphon the cooling system expansion tank.

trnr2011-044 15
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

9. Fill cooling system with coolant, refer to COOL-

ING SYSTEM BLEEDING procedure.

Cooling System Bleeding

80013 Models
1. Unscrew bleed screw on thermostat housing
cover of front cylinder.

1. Rear cylinder bleed screw

All Models
3. Remove the pressure cap.
4. Fill the cooling system until coolant comes out
of the bleed screw(s).
5. Install the bleed screw(s) using NEW gasket
ring(s) and torque as per following chart.
TYPICAL BLEED SCREW INSTALLATION
1. Bleed screw
GASKET RING TORQUE
1000 Models
4.4 N•m to 5.6 N•m
2. Unscrew bleed screws on thermostat housing New
(39 lbf•in to 50 lbfein)
covers of both front and rear cylinders.
6. Continue adding coolant until system is full up
to the pressure cap seat in the refill adapter.

1. Front cylinder bleed screw

1. Cooling system refill adapter
2. Expansion tank hose
3. Coolant system full level (pressure cap seat)

7. Install pressure cap.

NOTICE The following steps must be carried
out as specified to ensure proper cooling sys-
tem bleeding in addition to the previous steps.

16 tmr2011-044
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

8. Lift the entire front end of the vehicle so the

front tires are 60 cm (2 ft) above the ground for
at least 1 minute.

1. Cooling system refill adapter

2. Expansion tank hose
3. Coolant system full level (pressure cap seat)
ENTIRE FRONT END LIFTED
1. Ground level 15. Install the pressure cap.
A. 60 cm (24 in)
16. Check coolant level in the coolant expansion
9. Lower vehicle to the ground. tank and fill to the MIN. level (as required).
10. Remove pressure cap and add coolant as re- 17. Run engine at idle with the pressure cap ON
quired. until the cooling fan cycles on for a second
time.
11. Install pressure cap.
18. Stop the engine and let it cool down.
12. Lift driver's side of vehicle 60 cm (2 ft) above
it's horizontal position for at least 1 minute. A WARNING
In order to avoid potential burns, do not re-
move the pressure cap if the engine is hot.

19. When the engine is cool, remove pressure cap

and add coolant if required.
20. Install pressure cap.
21. Check coolant level in the expansion tank.
Add coolant as required. Refer to ENGINE
COOLANT LEVEL VERIFICATION in this sub-
section.

COOLING SYSTEM INSPECTION

1. Check general condition of hoses and clamps
for tightness.
2. Check the leak indicator hose for oil or coolant.
NOTE: Leaking coolant indicates a defective ro-
DRIVER'S SIDE LIFTED tary seal. Leaking oil indicates a defective oil seal.
1. Ground level
A. 60cm (24 in) If either seal is leaking, both seals must be re-
placed at the same time. Refer to WATER PUMP
13. Lower vehicle to the ground. SHAFT AND SEALS in this subsection.
14. Remove pressure cap and add coolant as re-
quired up to the pressure cap seat in the refill
adapter.

tmr2011-044 17
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

COOLANT EXPANSION TANK VENTS

1. Slots atop neck
2. Flat threadless portion on tank neck
1. Water pump
2. Leak indicator hose
4. Carry out an ENGINE COOLANT SPECIFIC
NOTE: Another leak indicator hole is visible on the GRAVITY CHECKas detailed in this subsection.
PTO side. It provides an indication of the PTO gas- 5. Carry out a PRESSURE CAP TESTas detailed in
ket condition. If a liquid leaks from this hole, PTO this subsection.
gasket replacement is necessary.
6. Replace engine coolant if contaminated.
NOTE: Engine coolant should be replaced every 2
years or if contaminated.

COOLING SYSTEM LEAK TEST

A WARNING
To avoid potential burns, do not remove the
pressure cap or loosen the cooling system
drain plug if the engine is hot.

1. Open service cover.

2. Remove cooling system pressure cap.
3. Install TEST CAP (P/N 529 035 991) on filler neck.

1. Leak indicator hole

2. Oil cooler

3. Ensure vents on coolant expansion tank neck

are not obstructed (see following illustration).

4. Using the VACUUM/PRESSURE PUMP (P/N 529

021 800), pressurize cooling system.

18 tmr2011-044
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

NOTE: Use mean value of exhaust/intake to en-

sure a proper valve adjustment.
Hold the adjustment screw at the proper position
and torque the locking nut.

COOLING SYSTEM LEAK TEST

103 kPa (15 PSI)

If there is no pressure drop after 10 minutes, there

is no leak in the cooling system.
If the pressure drops, check all hoses, radiator,
cylinders and engine base for coolant leaks or air
bubbles.

PRESSURE CAP TEST

1. Adjustment screw
Test the pressure cap using a cooling system 2. Locking nut
tester. 3. Feeler gauge

Replace the cap if it does not hold the pressure, Repeat the procedure for each valve.
or if it opens at a relief pressure that is too low or
too high. Before installing valve covers, recheck valve clear-
ance.
PRESSURE CAP RELIEF PRESSURE
Approximately 110 kPa (16 PSI) CVT AIR FILTER CLEANING
CVT Ai r Filter
ENGINE VALVE CLEARANCE CVT Air Filter Removal
ADJUSTMENT 1. Remove the CVT air filter plastic cover located
NOTE: Check and adjust valve clearance only on LH side of hood near driver.
when engine is cold.
Remove valve covers, refer to TOP END subsec-
tion.
Before checking or adjusting the valve clearance,
turn crankshaft to TDC ignition of the respective
cylinder, refer to CAMSHAFT TIMING GEARin the
TIMING CHAIN subsection.
Using feeler gauge, check the valve clearance.
VALVE CLEARANCE
0.11 mm to 0.19 mm
EXHAUST
(.0043 in to .0075 in)
0.06 mm to 0.14 mm
INTAKE
(.0024 in to .0055 in)
1. CVT air filter plastic cover
If the valve clearance is out of specification, adjust
valves as follows. 2. Slide the cover rearward.

tmr201 1-044 19
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

4. Dry filter completely.

5. Clean inside the CVT air inlet end.
CVT Air Filter Installation
1. Install air filter on CVT inlet using retaining tabs.
2. Install CVT air filter cover by sliding in place to-
ward front of vehicle.

DRIVE BELT INSPECTION

Inspect belt for cracks, fraying or abnormal wear.
Replace if necessary.
Step 1: Slide cover rearward
Check drive belt width at cord level. Replace if it
is out of specification (see table below).
3. Pull CVT air filter out.
DRIVE BELT WIDTH
SERVICE LIMIT I 30 mm (1.181 in)

1. CVT air filter 1. Drive belt

2. Cord in drive belt
CVT Air Filter Cleaning
1. Remove CVT air filter. DRIVE PULLEY, DRIVEN PULLEY
AND ONE-WAY BEARING
MAINTENANCE
Refer to CONTINUOUSLY VARIABLE TRANSMIS-
SION (CVT) subsection.

CVT AIR INLET/OUTLET

CLEANING
1. Remove CVT cover, refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT) subsection.
2. Inspect and clean the air inlet and outlet open-
ings from inside the inner CVT cover.
3. Inspect and clean the aft end of air outlet duct
at rear of the vehicle.
1. CVT air filter
NOTE: If a lot of debris or grime are found in the
2. Inspect filter and replace if damaged. CVT system, it may be necessary to remove the
ducts and thoroughly clean them.
3. Gently clean using a solution of soft soap and
water, then rinse filter. 4. Reinstall CVT cover.

20 tmr2011 -044
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

GEARBOX OIL LEVEL

VERIFICATION
Remove the RH lateral console panel and the fuel
tank cover.
Check the gearbox oil level by removing the gear-
box oil level plug.

7. Magnetic drain plug

2. Seaiing ring
3. Oil filler screw
4. 0-ring

Dispose gearbox oil as per your local environmen-

tal regulations.

Inspection
Oil condition gives information about the teeth
7. Engine oil dipstick condition inside the gearbox. See TROU-
2. Gearbox oil level plug BLESHOOTING in this subsection.
The oil should be level with the bottom of the oil Clean the magnetic drain plug from metal shav-
level hole. ings and dirt. Presence of debris gives an indica-
tion of failure inside the gearbox. Check gearbox
NOTICE Operating the gearbox with an im- to correct the problem.
proper oil level may severely damage gearbox.
Replace 0-ring of oil filler screw if brittle, hard or
otherwise damaged.
GEARBOX OIL REPLACEMENT
Draining Procedure Filling Procedure
Make sure that magnetic drain plug is reinstalled
Prior to change the oil, ensure vehicle is on a level
surface. and tight.
Always install a NEW sealing ring.
Oil change should be done with a warm engine.

a WARNING . PART TORQUE

20 N•m ± 2 N•m
The gearbox oil can be very hot. Magnetic drain plug
(15 lbf•ft ± 1 lbf•ft)

Place a drain pan under the gearbox drain plug With the vehicle on a level surface, fill the gear-
area. box through the oil filler hole with XPS SYNTHE-
TIC GEAR OIL (75W 140) (P/N 293 600 140) until the
Clean drain plug area and remove magnetic drain
oil reaches the lower threads of the oil filler hole
plug with its sealing ring to drain gearbox oil.
(around 450 ml (15.22 U.S. oz)).
Discard sealing ring. Always install a NEW one.
However, if the XPS synthetic gear oil is not
Remove oil filler screw including its 0-ring. available use a gearbox oil that meets the require-
NOTICE Pay attention not to loose ments of 75W 140 API GL-5 synthetic gear oil.
ring on
oil filler screw. Install the oil filler screw with its 0-ring. Tighten
oil filler screw to recommended torque.
Wait a while to allow oil flow out of gearbox.

tmr2011-044 21
Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

PART TORQUE A WARNING

5 N•m ± 0.6 I\l•rn All fuel system leaks must be repaired. Dam-
Oil filler screw
(44 lbfein ± 5 lbf•in) aged, worn or leaking fuel system com-
ponents should be replaced to ensure fuel
system tightness.
THROTTLE BODY INSPECTION
1. Refer to AIR INTAKE SYSTEM subsection and FUEL PUMP PRESSURE TEST
remove the following:
Refer to FUEL TANK AND FUEL PUMP subsec-
— Air filter housing
tion for procedure.
— Adapter hose between air filter housing and
throttle body.
FUEL PUMP PREFILTER
2. Visually inspect throttle plate and throttle body
venturi for cleanliness. CLEANING
3. Clean inside throttle body using a common 1. Remove fuel pump from fuel tank, refer to
throttle body cleaner if necessary. FUEL PUMP REMOVAL in FUEL TANK AND
FUEL PUMP subsection.
FUEL TANK VENT BREATHER 2. Clean the fuel pump prefilter (strainer) using
FILTER REPLACEMENT XPS PARTS AND BRAKES CLEANER (P/N 219 701
7051 and low pressure air.
Ensure breather filter is installed with the flow ar-
3. If the fuel pump prefilter is heavily soiled,
row pointing towards the vent hose.
clogged or damaged:
Secure the vent hose using a locking tie as illus- — Replace it with a new one. Refer to FUEL
trated. PUMP STRAINER REPLACEMENT in the
FUEL TANK AND FUEL PUMPsubsection.
— Inspect inside of fuel tank for contaminants.
— Clean fuel tank as required.
— Inspect fuel tank vent breather filter. Re-
place as necessary. Refer to FUEL TANK
VENT BREATHER FILTER in FUEL TANK
AND FUEL PUMP subsection.

BATTERY INSPECTION
Visually inspect battery casing for cracks or other
damage. If casing is damaged, replace battery
and thoroughly clean battery rack with water and
baking soda.
Inspect battery posts condition, battery rack
FUEL TANK VENT BREATHER FILTER
mounting, straps and strap attachment points.
7. Direction arrow on breather filter pointing towards vent hose For battery testing, refer to CHARGING SYSTEM
2. Vent hose secured with a locking tie
subsection.

FUEL SYSTEM INSPECTION SPARK PLUG REPLACEMENT

1. Visually inspect fuel tank for cracks, wear
marks, signs of leakage or any other damages. Spark Plug Removal
2. Visually inspect fuel system hoses for proper Unplug the spark plug cable.
rooting, cracking, wear marks, signs of leakage Clean the spark plug area with pressurized air.
or any other damages. Unscrew spark plug.
3. Carry out a FUEL TANK LEAK TEST, refer to
FUEL TANK AND FUEL PUMP subsection.

22 tmr2011-044
 MAINTENANCE
Section 01
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

Spark Plug Installation TORQUE

Prior to installation make sure that contact sur- 22.5 Nom ± 2.5 Nom
faces of the cylinder head and spark plug are free FILLER PLUG
(17 lbfoft ± 2 lbfoft)
of grime.
1. Using a wire feeler gauge, set electrode gap as
specified in TECHNICAL SPECIFICATIONS. FRONT DIFFERENTIAL OIL
2. Apply antiseize lubricant over the spark plug
REPLACEMENT
threads to prevent possible seizure. Place vehicle on a level surface. Set transmission
3. Hand screw spark plug into cylinder head, then in park position.
tighten with a torque wrench and an appropri- From underneath of vehicle, clean drain plug area.
ate socket.
SPARK PLUG TORQUE
20 Nom ± 2 Nom (15 lbf•ft ± 1 lbf•ft)

VEHICLE SPEED SENSOR (VSS)

CLEANING
Remove the VSS. Refer to VSS REMOVAL in
GEARBOX AND 4X4 COUPLING UNIT subsec-
tion.
Remove all metal particles and oil from the VSS
magnet. 1. Drain plug access hole
NOTE: A dirty VSS will cause erratic speedometer
readings. Place a drain pan under the front differential.
Remove drain plug.
FRONT DIFFERENTIAL OIL LEVEL Unscrew filler plug.
VERIFICATION
Clean filler plug prior to checking oil level.

FRONT RIGHT SIDE OF VEHICLE

1. Filler plug

Install drain plug.

FRONT RIGHT SIDE OF VEHICLE
1. Filler plug
TORQUE
With vehicle on a level surface, check oil level 7.5 Nom ± 0.5 Nom
by removing filler plug. Oil level must reach the DRAIN PLUG
(66 lbfoin ± 41bf•in)
lower edge.
Reinstall filler plug with a NEW sealing ring. Refill front differential with recommended oil.

tmr201 1-044 23
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

CAPACITY RECOMMENDED OIL Place a drain pan under rear final drive.

XPS SYNTHETIC GEAR OIL Unscrew filler plug.

500 ml
(75W 90) (P/N 293 600 043) or Remove drain plug.
(17 U.S. oz)
a 75W 90 (API GL-5) gear oil

Reinstall filler plug with a NEW sealing ring.

TORQUE
22.5 Nom ± 2.5 N•m
FILLER PLUG
(17 lbfoft ± 2 lbfoft)

REAR FINAL DRIVE OIL LEVEL

VERIFICATION
Ensure vehicle is on a level surface.
Clean filler plug area.
LH REAR SIDE OF VEHICLE
Remove filler plug. 1. Drain plug
2. Filler plug

Install drain plug.

TORQUE
7.5 Nom ± 0.5 Nom
DRAIN PLUG
(66 lbfoin ± 4 lbfoin)

Refill the rear final drive.

RECOMMENDED OIL QUANTITY
XPS SYNTHETIC
GEAR OIL (75W 140)
350 ml
(P/N 293 600 140)
(12 U.S oz)
LH REAR SIDE OF VEHICLE or a 75W 140
1. Filler plug (API GL-5) gear oil

It is possible to verify the oil level by inserting a Reinstall filler plug with a NEW sealing ring.
wire with a 90° bend through the oil filler hole.
TORQUE
Oil level is within the following distance from the
bottom of oil filler plug threads when the vehicle 22.5 N•m ± 2.5 Nom
FILLER PLUG
is level on ground. (17 lbfoft ± 2 lbf•ft)

OIL LEVEL
20 mm ± 5 mm (9/16 in ± 3/16 in)
DRIVE SHAFT BOOT AND
PROTECTOR (VISUAL
Reinstall filler plug with a NEW sealing ring. INSPECTION)
TORQUE Visually inspect each drive shaft boot for grease
22.5 Nom ± 2.5 Nom leak, cracks or opening.
FILLER PLUG
(17 lbfoft ± 2 lbf•ft) Check if the drive shaft boot protector are fixed
firmly, not torn or otherwise damaged.
REAR FINAL DRIVE OIL Replace if necessary.
REPLACEMENT
Ensure vehicle is on a level surface.
Remove the rear skid plate.
Clean filler and drain plug areas.
24 tmr2011-044
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

DRIVE SHAFT JOINT 2. Hold wheel by the top and the bottom and
INSPECTION move it. Check for any play.
3. If there is any loose, replace wheel bearing, re-
Turn and move drive shaft to detect excessive
fer to STEERING SYSTEM subsection.
play.
NOTE: To properly locate play during this inspec-
tion, be sure to check other components for wear
PROPELLER SHAFT U-JOINT or loose (ball joints, suspension pivots, etc). If
CONDITION necessary repair or replace all defective parts
Check yoke U-joints for wear, backlash or axial before checking the wheel bearing condition. Be
play, replace if necessary. careful not to misjudge loose in the ball joint and
loose in the wheel bearing.
PROPELLER SHAFT U-JOINT
LUBRICATION STEERING SYSTEM INSPECTION
Steering Column
PROPELLER SHAFT U-JOINT LUBRICATION
Turn and move steering column to detect any play.
Use Hi-temp bearing grease NLGI-2 or an equivalent
Rack and Pinion
WHEEL LUG NUT TORQUE Check rack and pinion boots for:
CHECK — Damage
— Cracks.
Tighten wheel lug nuts to the specified torque us-
ing the illustrated sequence. Replace if necessary.

WHEEL LUG NUTS Tie-Rod End

100 N•rn ± 10 N•rn Check tie-rod end ball joint for:
TORQUE
(74 lbf•ft ± 7 lbf•ft) — Damage
— Pitting
— Play.
Replace if necessary.

SHOCK ABSORBER INSPECTION

Check shock absorber for any leaks, replace if nec-
essary.

SHOCK ABSORBER SPHERICAL

BEARING LUBRICATION
HPG Shock Absorber with Remote Reservoir
1. Remove shock absorber from vehicle.
2. Remove shock sleeves then 0-rings from
shock absorber.

TIGHTENING SEQUENCE

WHEEL BEARING INSPECTION

1. Safely lift and support the front of vehicle. Re-
fer to INTRODUCTION subsection.

tmr201 1-044 25
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

LOWER SUSPENSION ARM

1. Sleeve 1. Grease fittings
2. 0-ring

3. Clean spherical bearing using a shop rag to re-

move any dirt and debris.
4. Lubricate spherical bearing as illustrated.
SPHERICAL BEARING LUBRICATION
SUSPENSION GREASE (P/N 293 550 033)

UPPER SUSPENSION ARM

1. Grease fitting

FRONT SUSPENSION ARM

INSPECTION
Check suspension arm for:
1. Apply grease here
— Cracks
— Pitting
5. Install 0-rings then shock sleeves. — Bending
6. Install shock absorber. — Distortion.
Check suspension arm for abnormal play:
FRONT SUSPENSION ARM — Side to side
LUBRICATION — Up and down.
Lubricate suspension arm at grease fittings. If any play is detected, inspect:
SUSPENSION ARM LUBRICATION — Bushings
— Cushions
SUSPENSION GREASE (P/N 293 550 033)
— Wear plates.
Check ball joint for:
— Damage
— Pitting
— Play.

26 tmr2011-044
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

Check ball joint bellows for: 3. Lubricate caliper sliders and pins using an
— Damage appropriate BRAKE CALIPER SYNTHETIC
— Cracks. GREASE.

Brake Disc
BRAKE SYSTEM INSPECTION
1. Check brake disc as follows:
AND CLEANING
— Check disc thickness
NOTICE Do not clean brake components in — Check disc surfaces
petroleum based solvent. Use brake system — Check disc warpage.
cleaner only. Soiled brake pads must be re- NOTE: Refer to BRAKE DISC INSPECTION in
placed with new ones. BRAKES subsection for details.
2. Clean brake disc using XPS PARTS AND BRAKES
Brake Pads CLEANER (P/N 219 701 705).
1. Measure brake pad lining thickness.
Master Cylinder
BRAKE PAD MINIMUM THICKNESS
1. Check master cylinder as follows:
1 mm (1/32 in)
— Check cleanliness of master cylinder rod and
NOTE: The brake pad grooves are wear indica- boot.
tors. — Check master cylinder boot for cracks or
damage.
2. If required, clean then lubricate master cylinder
rod and boot using COSMO RUBBER GREASE
(P/N 293 550 055).

Brake Pedal
1. Check brake pedal as follows:
— Brake pedal pivot movement
BRAKE PAD GROOVE — Brake pedal pivot cleanliness.
WARNING 2. If required, clean then lubricate brake pedal
pivot using XPS SYNTHETIC GREASE (P/N 293
Brake pads must always be replaced in pairs.
550 010).

Brake Caliper Brake Hoses

1. Remove calipers then check the following com- 1. Check hoses for leaks, crushed, deformations,
ponents: cracking or scrapes.
— Check brake pad pins NOTE: Any deformation can restrict the proper
— Check caliper boot for cracks flow of fluid and cause braking problems.
— Check caliper movement on its support
— Check pistons movement BRAKE FLUID REPLACEMENT
— Check pistons for scratches, rust or other
damages.
Brake Fluid Draining
1. Clean and remove reservoir cover with its di-
2. Clean the following components using XPS
aphragm.
PARTS AND BRAKES CLEANER (P/N 219 701 705):
— Brake pads 2. Connect a clear hose into caliper bleeder.
— Caliper support and slider
— Caliper pistons, spring and pins.
NOTE: Do not remove pistons from caliper for
cleaning them.

tmr201 1-044 27
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

Brake Fluid Bleeding

Bleeding Procedure Using a Vacuum Pump
NOTE: Brake fluid reservoir must be kept full to
prevent air from being pumped into the system.
1. On each caliper, unscrew bleeder until brake
fluid comes out then close it.
2. Install the VACUUM/PRESSURE PUMP (P/N 529
021 800) onto caliper bleeder.

1. Caliper bleeder

3. Loosen caliper bleeder.

4. Pump brake pedal until no more fluid flows out.
5. Repeat draining procedure for the other caliper
bleeders.

Brake Fluid Filling

1. Add recommended brake fluid to MAX. mark.
Do not overfill. 3. Place pump to vacuum position.
4. Pump vacuum pump a few times.
5. Loosen bleeder.
6. Continue to pump until no more air bubbles ap-
pear in clear hose.
7. Close then tighten bleeder.
BLEEDER TORQUE
5.5 Nom ± 1.5 Nom (49 lbfoin ± 13 lbfoin)

8. Add recommended brake fluid to MAX. mark.

Do not overfill.
9. Perform bleeding procedure for the other
caliper bleeders.
10. Check brake pedal operation:
TYPICAL — If brake pedal feels spongy, bleed system
1. MIN. again then carry out the BRAKE SYSTEM
2. MAX.
PRESSURE VALIDATION as detailed in
RECOMMENDED BRAKE FLUID BRAKES subsection.
DOT 4 BRAKE FLUID (P/N 293 600 131) Manual Bleeding Procedure
NOTE: Brake fluid reservoir must be kept full to
a WARNING prevent air from being pumped into the system.
— Use only DOT 4 brake fluid from a sealed 1. Connect a clear hose onto caliper bleeder.
container. 2. Pump up system pressure with brake pedal un-
— Do not use brake fluid from an old or al- til pedal resistance is felt.
ready opened container.
3. Depress and hold brake pedal.
4. Open bleeder and then close it.
5. Release brake pedal slowly.

28 tmr2011-044
 Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

NOTE: Do not release brake pedal until bleeder

has been closed.
6. Repeat procedure until fluid flows out without
any air bubbles.
7. Tighten bleeder.
BLEEDER TORQUE
5.5 N•rn ± 1.5 N•m (491bf•in ± 13 lbf•in)

8. Perform bleeding procedure for the other

caliper bleeders.
9. Check brake pedal operation:
— If brake pedal feels spongy, bleed system
again then carry out the BRAKE SYSTEM
PRESSURE VALIDATION as detailed in
BRAKES subsection.

PASSENGER HANDHOLD
CONDITION
Check if the passenger handholds are fixed firmly,
not bent or otherwise damaged.
Replace if necessary.

TOW HITCH INSPECTION

Ensure tow hitch receptacle module is solidly
mounted.
Inspect hitch for cracks and other damages.
Repair or replace as necessary.

tmr2011-044 29
 Section 01 MAINTENANCE
Subsection 04 (PRESEASON PREPARATION)

PRESEASON PREPARATION
Prior to using vehicle, proper vehicle preparation
is required after a storage period.
If any worn, broken or damaged parts are found,
replace them.
Remove rags that were installed for storage: CVT
outlet hose and muffler.
Disconnect air inlet hose from the air filter housing
and inspect for animal nests etc. Reinstall hose.
Drain fuel tank and fill with fresh fuel if a fuel sta-
bilizer was not used for the storage.
Reinstall battery. Refer to CHARGING SYSTEM.
Using the maintenance chart, perform the items
titled EVERY 3 000 km (2,000 mi) OR 100 HOURS
OF OPERATION OR 1 YEAR.

MAATEKalvf.1,SC■4EDIJIF

1 --*-EVERY 3 000AM 12.000 MI} OR 100 HOURS OF OPERATION OR 1

YEAR WHICHEVER COMES FIRST)
oket belts SC1eCk 101 ooe deirwges and pa0 50' 311011,

/aspen! sic* netS (check tot any damages and tiley must buckle properly}

Replete the eng•ne ok and tiller

trnr2011-004-001 a

1. Use this chart

NOTE: If the "every 6 000 km (4,000 mi) or 200

hours of operation or 2 years" maintenance ser-
vice is due, also perform the related items as per
the maintenance chart.
Test drive vehicle to confirm proper operation.

tmr2011-004 31
_
 Section 01 MAINTENANCE
Subsection 05 (STORAGE PROCEDURE)

STORAGE PROCEDURE
SERVICE PRODUCTS
Description Part Number Page
BRP FUEL STABILIZER 413 408 600 33
BRP HEAVY DUTY CLEANER 293 110 001 34
XPS LUBE 293 600 016 34
XPS MULTI-PURPOSE CLEANER 219 701 709 34
XPS STORAGE OIL (EXCEPT U.S. COUNTRY) 413 711 600 33
XPS STORAGE OIL (U.S. COUNTRY ONLY) 413 711 900 33

GENERAL 3. Spray storage oil into each cylinder.

If the SSV is not used or is to be stored for an NOTE: Use the storage oil as per country availabil-
extended period of time, more than 4 months, be ity.
sure to perform the storage procedures described STORAGE OIL
below.
XPS STORAGE OIL (EXCEPT U.S. COUNTRY)
Where applicable, refer to the appropriate subsec- (P/N 413 711 600)
tions in this manual for the required tasks outlined
in these procedures. XPS STORAGE OIL (U.S. COUNTRY ONLY)
(P/N 413 711 900)
PROCEDURES 4. Press start button, 1 or 2 seconds maximum, to
NOTE: To facilitate the inspection and ensure lubricate cylinders.
adequate lubrication of components, it is rec- 5. Reinstall the spark plugs.
ommended to clean the entire vehicle. Refer to
NOTE: Do not run engine during storage period.
VEHICLE CLEANING in this subsection.
6. Block muffler outlet with a rag.
FUEL SYSTEM
Fuel System Protection
With the new fuel additives, it is critical to use the
BRP FUEL STABILIZER (P/N 413 408 600) or an equiv-
alent to prevent fuel deterioration and fuel system
gumming. Follow the manufacturer's instructions
for proper use.
NOTICE Fuel stabilizer should be added
prior to engine lubrication to ensure fuel sys-
tem components protection against varnish
deposits.

Pour fuel stabilizer in fuel tank. Fill up fuel tank.

ENGINE 1. Muffler outlet

Engine Internal Lubrication CVT Protection

Engine internal parts must be lubricated to protect Remove drive belt. Refer to ENGINE, CVT AND
them from rust formation during the storage pe- GEARBOX.
riod.
Close CVT cover.
Proceed as follows: Block CVT outlet with a rag.
1. Remove lateral console panels. NOTE: To reach the CVT outlet, tilt the cargo box.
2. Remove spark plugs.

tmr2011-005 33
Section 01 MAINTENANCE
Subsection 05 (STORAGE PROCEDURE)

Vehicle Cleaning
Wash and dry the vehicle.
NOTICE Never use a high pressure washer
to clean the vehicle. USE LOW PRESSURE
ONLY (like a garden hose). The high pressure
can cause electrical or mechanical damages.
Remove any dirt or rust.
To clean the vinyl or plastic parts, use only flan-
nel clothes with XPS MULTI-PURPOSE CLEANER
(P/N 219 701 709).
NOTICE It is necessary to use flannel cloths
on plastic parts to avoid damaging surfaces.
1. Tilted cargo box
Never clean plastic parts with strong deter-
gent, degreasing agent, paint thinner, acetone,
products containing chlorine, etc.

To clean the entire vehicle, including metallic parts

use BRP HEAVY DUTY CLEANER (P/N 293 110 001).
Inspect the vehicle and repair any damage. Touch
up all metal spots where paint has been scratched
off. Spray all metal parts with XPS LUBE (P/N 293
600 016).

Vehicle Protection
Protect the vehicle with a cover to prevent dust
accumulation during storage.
NOTICE The vehicle has to be stored in
a cool and dry place and covered with an
1 CVT outlet
opaque tarpaulin. This will prevent sun rays
and grime from affecting plastic components
and vehicle finish.
ELECTRICAL SYSTEM
Battery Removal
Remove the battery.
Charge and store battery.

DRIVE SYSTEM
Lubricate front and rear propeller joints.
Lubricate the engine output shaft with XPS LUBE
(P/N 293 600 016).

CHASSIS
Lubrication
Lubricate front suspension (no lube on rear).

Tire Pressure
Inflate tires to the recommended pressure.

34 tmr201 1-005
 Section 01 MAINTENANCE
Subsection 06 (SPECIAL PROCEDURES)

SPECIAL PROCEDURES
SERVICE PRODUCTS
Description Part Number Page
XPS LUBE 293 600 016 35

GENERAL Drain, inspect and clean the CVT.

NOTE: Component failures resulting from these Empty muffler (removal required).
events are not warrantable. Unplug ECM connectors and open fuse boxes.
Refer to the appropriate subsections in this man- Check for presence of water. Dry as necessary.
ual for the required tasks outlined in these proce- Replace the engine oil (without starting the en-
dures. gine).
Remove spark plugs. Crank engine in drowned
ROLLED OVER VEHICLE mode to expel any water.
In the event the vehicle was rolled over, check the
following. A CAUTION Keep away from spark plug
holes to avoid to be splashed when cranking
Inspect suspension components and steering sys-
engine.
tem components.
Add a small quantity of engine oil in cylinders (ap-
Inspect body and chassis for damage (welded
proximately 2 teaspoonfuls).
joints, bent or cracked parts).
Install spark plugs (replace if required).
Pay particular attention to the cage, shoulder
protector, side nets, seat belts and their mecha- Replace gearbox oil.
nisms. Look for water in fuel tank, in doubt, flush fuel
tank and refill with new gas.
A WARNING Look for water in brake system. Replace brake
Do not use vehicle if any of the safety devices fluid as required.
are damaged or inoperative.
A WARNING
Check all fluids level before restarting engine.
Before starting engine, use B.U.D.S. and
NOTICE Check for oil accumulation in the air check vehicle for fault codes.
intake system. Check air filter.
Start the engine and allow it to run at idle speed
After restarting engine, check multifunction gauge until the engine reaches its operating tempera-
if any malfunction is detected. ture.
Troubleshoot and repair as required before using Stop the engine.
vehicle.
Change engine oil and filter.
NOTE: Change oil as many times as necessary,
SUBMERGED VEHICLE until there is no whitish appearance in engine oil.
In the event the vehicle was submerged, proceed Check gearbox oil. Replace oil if contaminated
with the following. with water.
NOTICE A submerged vehicle may cause Replace oil of front differential.
several damages (short and long term) if not Replace oil of rear final drive.
erviced adequately or soon enough. Do not
crank or s a t engine. Lubricate front and rear suspensions and pro-
peller shaft joints. Refer to FRONT AND REAR
Drain the entire air intake sys em. Inspect the SUSPENSIONS.
throttle body. Remove parts as required. Spray all metal parts with XPS LUBE (P/N 293 600 016).
Replace the air filter. Test drive to confirm proper operation.

tmr2011-006 35
-
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

ENGINE REMOVAL AND INSTALLATION

SERVICE TOOLS
Description Part Number Page

ENGINE LIFTING TOOL 529 036 022 39

4.9 ± 0.4 N•rn

(43 ± 4 lbf•in)
62.5 ± 7.5 N•rn 4 ± 1 N•rn
(46 ± 6 lbf•ft) (35 ± 9 lbf•n)

62.5 ± 7.5 N•rn

(46 ± 6 I•)

imr2011-007-001 a

37
mmr2011-007
Section 02 ENGINE, CVT AND GEARBOX
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

GENERAL NOTE: Drain engine oil only if engine overhaul is

necessary.
A WARNING 8. Drain the engine coolant. Refer to COOLING
To avoid potential burns, let engine and ex- SYSTEM subsection.
haust system cool down before servicing.
9. Remove fuel tank. Refer to FUEL TANK AND
FUEL PUMP subsection.
During assembly/installation, use the torque val-
ues and service products as in the exploded view. 10. Remove the LH passenger handhold bar.

Clean threads before applying a threadlocker. Re-

fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATIONat the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
cotter pin, etc.) must be replaced.

Hoses, cables or locking ties removed during a

procedure must be reinstalled as per factory stan- 11. Remove the panel reinforcement support.
dards.

PROCEDURES
ENGINE REMOVAL
Vehicle and Engine Preparation
1. Place vehicle on a workstation that will have ac-
cess to an engine-lifting hoist.
2. Safely lift and support the vehicle. Refer to IN-
TRODUCTIONsubsection.
1. Panel reinforcement support
3. Unplug the BLACK (-) cable from battery, then
the RED (+) cable. 12. Disconnect both engine coolant hoses at cylin-
NOTICE Always unplug battery cables ex- der heads.
actly in the specified order, the BLACK (-) cable 13. Remove the plenumand the air intake mani-
first. fold.
4. Remove the front section of the cage. 13.1 Loosen clamp securing throttle body to
plenum.
5. Remove seats.
13.2 Detach the plenum support from the
6. Refer to BODYsubsection and remove the fol- front cylinder head.
lowing plastic parts:
13.3 Unscrew air intake manifold from cylin-
— Upper and lower consoles
der heads.
— LH and RH lateral console panels
13.4 Remove plenum and air intake manifold
— Under seat storage compartment
as an assembly.
— Fuel tank cowl
— Glove box
— RH inner panel.
7. Drain engine oil. Refer to LUBRICATION SYS-
TEM subsection.

38 mrnr2011-007
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

7. Engine coolant hoses

2. Plenum
3. Air intake manifold
23. Remove the upper engine support with its rub-
14. Remove the shift plate. ber isolator.
15. Remove the shifter cable bracket.

7. Shift plate
2. Shifter cable bracket
7. Rubber isolator is located between frame and engine support
16. Remove the front and rear head pipes. Refer
to EXHAUST SYSTEM subsection. 24. Disconnect the CVT inlet duct from the CVT
cover.
17. Disconnect the coolant hose at water pump.
25. Disconnect the crankcase vent hose.
18. Disconnect the gearbox vent hose.
26. Unplug all remaining connectors and remove
19. Remove the CVT outlet duct.
required cables from engine. Cut all necessary
20. Unplug and remove the CTS (coolant temper- locking ties.
ature sensor). — Spark plug cables
21. Remove the coolant plastic housing from the — Starter cable (retaining nut on starter body)
rear cylinder head. — GBPS (Gear Box Position Sensor)
— Vehicle speed sensor
— Actuator connector
— Neutral switch
— OPS (Oil Pressure Sensor)
— CPS (Crankshaft Position Sensor)
— Engine ground cable (screwed on LH side of
the engine)
— Magneto.

Lifting Engine
1. Install the ENGINE LIFTING TOOL (P/N 529 036
1. CTS 022).
2. Coolant plastic housing

22. Detach the shifter cable from its bracket and

remove it.
mmr2011-007 39
Section 02 ENGINE, CVT AND GEARBOX
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

Install the rear propeller shaft onto engine output

shaft.
Connect the front propeller shaft to engine output
shaft while lowering engine.
Install rear and front engine mounting bolts then
torque all mounting bolts.
NOTE: Do not install plastic parts, seats and cage
front portion prior to FINAL ASSEMBLY.

Final Assembly Procedure

1. Fill engine with the recommended oil and quan-
tity. Refer to LUBRICATION SYSTEM subsec-
2. Remove retaining screws on front and rear pro- tion
peller shafts. 2. Fill and bleed cooling system. Refer to COOL-
3. Remove the front and rear engine support ING SYSTEM subsection.
bolts. 3. Check for any leaks.
4. Carefully lower the rear of the engine enough 4. Reinstall plastic parts, seats and the front por-
to reinstall temporally the engine support bolt. tion of the cage.
5. Insert a spacer (± 9.5 mm (3/8 in) of thickness) 5. Test drive vehicle to confirm proper operation.
between the engine support and the bolt.
NOTE: The spacer used in the following illustra- ENGINE MOUNTS
tion is a monkey wrench of 25 cm (10 in).
NOTE: Use the same procedure for the front and
rear engine mounts.

Engine Mount Removal

Insert a punch into engine mount bushing and
push the opposite engine mount out.

6. Raise the front of engine to separate front pro-

peller shaft from engine.
NOTE: If the propeller shaft cannot be removed
easily, remove bolts retaining the front differen-
tial to create more space. Refer to FRONT DRIVE
subsection.
7. Lower the front of engine to remove the rear Engine Mount Installation
engine support bolt and the spacer. The installation is the reverse of the removal pro-
8. Remove engine from vehicle. cedure.

ENGINE INSTALLATION
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Prior to install engine, inspect condition of engine
mounts.

40 mmr2011-007
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 02 (AIR INTAKE SYSTEM)

AIR INTAKE SYSTEM

SERVICE PRODUCTS
Part Number Page
Description
LOCTITE 5910 293 800 081 44

41
tmr2011-008
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 02 (AIR INTAKE SYSTEM)

AIR FILTER HOUSING

6 + 1 N•rn
ky;---L-(53 ± 9 lbf•in)

2.5 ± 0.5 1\l•rn

(22 ± 4 lbf•in)
To
Throttle
Body

To PTO
cover
tm r2011 -008-001 _a

42 tmr2011-008
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 02 (AIR INTAKE SYSTEM)

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATIONat the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e.g.: locking FROM INSIDE OF COCKPIT - PASSENGER SIDE
1. RH inner panel
tabs, elastic stop nuts, cotter pin, etc.) must
be replaced. 2. Remove retaining bolts of air filter housing.

Hoses, cables or locking ties removed during a

procedure must be reinstalled as per factory stan-
dards.
NOTICE Never modify the air intake system.
Otherwise, engine performance degradation
or damage can occur. The engine is calibrated
to operate specifically with these components.

PROCEDURES
AIR FILTER 1. Air filter housing retaining bolts

For air filter servicing, refer to PERIODIC MAIN- 3. Disconnect air inlet hose from the LH side of air
TENANCE PROCEDURES subsection. filter housing.

AIR FILTER HOUSING

Air Filter Housing Removal
1. Remove the following parts:
1.1 Service cover

1. Air inlet hose

4. Disconnect intake adapter from throttle body.

1. Service cover

1.2 RH inner panel.

tmr201 1-008
43
Section 02 ENGINE, CVT AND GEARBOX
Subsection 02 (AIR INTAKE SYSTEM)

FROM INSIDE OF COCKPIT - PASSENGER SIDE 1. Intake adapter recess into air filter housing notch
1. Intake adapter
2. Throttle body TORQUE

5. Disconnect vent hose from the rear of air filter 2.5 N•rn ± 0.5 N•m
Gear clamps
housing. (22 lbfein ± 41bf•in)
6 Nom ± 1 N•m
Air filter housing nuts
(53 lbf•in ± 9 lbf•in)

1. Vent hose

Air Filter Housing Installation

For installation, reverse the removal procedure
but pay attention to the following.
If the intake adapter is removed, reseal it with
LOCTITE 5910 (P/N 293 800 081) and align its recess
with the notch on air filter housing.

7. Apply Loctite 5910 between intake adapter lips and housing wall

44 tmr2011-008
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 03 (EXHAUST SYSTEM)

EXHAUST SYSTEM

)14' 13 1 N•rn
(155 ± 9 lbf•in)

13 ± 1 N•rn
(155 ± 9 lbf•in)

11 ± 1 N•m
(97 ± 9 lbf•in)

(1=7:0
L

ME(

®= Component must be replaced when removed

tmr2011-009
45
Section 02 ENGINE, CVT AND GEARBOX
Subsection 03 (EXHAUST SYSTEM)

GENERAL
A WARNING
To avoid potential burns, never touch exhaust
system components immediately after the
engine has been run because these compo-
nents are very hot. Let engine and exhaust
system cool down before performing any
servicing.

During assembly/installation, use the torque val- 1. Muffler cover bolts

ues and service products as in the exploded
2. Open cargo box and detach springs from the "Y"
views.
exhaust pipe.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATIONat the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
cotter pin, etc.) must be replaced.

Hoses, cables or locking ties removed during a

procedure must be reinstalled as per factory stan-
dards. 3. Remove muffler retaining bolts.

PROCEDURES
SPARK ARRESTER
For spark arrester servicing, refer to PERIODIC
MAINTENANCE PROCEDURES subsection.

MUFFLER

4. Remove the muffler.

5. Discard the gasket at the end of "Y" exhaust
pipe.

Muffler Inspection
1. Muffler Check muffler for cracks or other damages. Re-
place if necessary.
Muffler Removal
Muffler Installation
1. Remove the muffler cover.
For the installation, reverse the removal proce-
dure.

46 tmr2011-009
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 03 (EXHAUST SYSTEM)

"Y" EXHAUST PIPE — Rubber support

— Head pipe nuts.
3. Remove front head pipe from vehicle according
to following sub-steps:
NOTE: The space to remove the front head
pipe is limited. When the head pipe is posi-
tioned correctly as shown, it can be removed
easily without force.
3.1 Position the rubber support rod near the
front of the seat bracket.

1. "Y" exhaust pipe

"Y" Exhaust Pipe Removal

1. Open the cargo box.
2. Remove the following parts:
— Springs from head pipes
— Muffler
— "Y" exhaust pipe from vehicle.

"Y" Exhaust Pipe Inspection

Check "Y" exhaust pipe for cracks, bending or 1. Rubber support rod
other damages. Replace if need. 2. Seat bracket

Check if the rubber support is brittle, hard or oth- 3.2 Turn and lift the rear end of the head pipe.
erwise damage. Replace if need.

"Y" Exhaust Pipe Installation

The installation is the reverse of the removal pro-
cedure.

HEAD PIPE (FRONT CYLINDER)

Step 1: Turn outward

Step 2: Lift

3.3 Remove head pipe from vehicle.

1. Front head pipe Front Head Pipe Inspection

Check head pipe for cracks, bending or other dam-
Front Head Pipe Removal ages. Replace if need.
1. Refer to BODYsubsection and remove the fol- Check if the rubber support is brittle, hard or oth-
lowing plastic parts: erwise damage. Replace if need.
— LH lateral console panel
— Under seat storage compartment. Front Head Pipe Installation
2. Remove the following parts: The installation is the reverse of the removal pro-
— Springs from "Y" exhaust pipe cedure. However, pay attention to the following.
Install NEW exhaust gaskets.

Imr2011-009 47
Section 02 ENGINE, CVT AND GEARBOX
Subsection 03 (EXHAUST SYSTEM)

TORQUE
13 N•rn ± 1 N•rn
Head pipe nuts
(115 lbf•in ± 9lbf•in)

HEAD PIPE (REAR CYLINDER)

1. Rear heap pipe

Rear Head Pipe Removal

1. Remove the following parts:
— Springs from "Y" exhaust pipe
— LH lateral console panel, refer to BODYsub-
section
— Head pipe nuts.
2. Remove head pipe from the vehicle.
3. Remove and discard exhaust gaskets.

Rear Head Pipe Inspection

Check head pipe for cracks, bending or other dam-
ages. Replace if need.
Check if the rubber support is brittle, hard or oth-
erwise damage. Replace if need.

Rear Head Pipe Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install NEW exhaust gaskets.
TORQUE
13 N•m ± 1 N•m
Head pipe nuts
(115 lbf•in ± 9lbf•in)

48 tmr2011-009
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

LUBRICATION SYSTEM
SERVICE TOOLS
Description Part Number Page
ADAPTER HOSE 529 035 652 52
DISCONNECT TOOL 529 035 714 52
PRESSURE GAUGE 529 035 709 52

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE) 293 800 060 54

tmr2011-010 49
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

COMPONENTS

50 ± 6 N•m
20 ± 2 N•rn (37 ± 4 lbf•ft)
(15 ± 1 lbf•ft)

044010,zo
12 ± 1 N•m
(106 ± 9 lbf•in)

Engine oil

Loctite (1
243

10 ± 1 N•m
(89 ± 9 Ibf•in)

Engine
oil

i'
,.,, 4.... 30 ± 2 N•rn
122 ± 1 lbf•ft)
Loctite
24 3 ,....,,

Engine
6 ± 0.7 N•rn
oil
(53 ± 6 lbf•iin)

- 10 ± 1 N•rn
(89 ± 9 lbf•in)

Engine
4ite
8 ± 1 N•m
(71 ± 9 lbf•in) Loctite
oil 0
243 Loctite
243
gpyi = Component must be replaced when removed 7 -± 0.5 N•rn
(62 ± 4 lbf•in)
TnIr201 GM d

50 tmr2011-010
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

ENGINE LUBRICATION CIRCUIT

1. Camshaft bearings
2. Oil pressure switch
3. Oil filter
. Oil pressure regulator valve
5. Oil strainer
6. Oil pump
7. Crankshaft main bearings
8. Crankshaft support bearing
9. Connecting rod bearings

tmr2011-010 51
Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

GENERAL OIL
1250 RPM 6000 RPM
PRESSURE
During assembly/installation, use the torque val-
ues and service products as in the exploded view. 300 kPa
MINIMAL 70 kPa (10 PSI)
(44 PSI)
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE 150 kPa 350 kPa
NOMINAL
APPLICATION at the beginning of this manual for (22 PSI) (51 PSI)
complete procedure. 250 kPa 450 kPa
MAXIMAL
(36 PSI) (65 PSI)
A WARNING
Torque wrench tightening specifications If the engine oil pressure is out of specifications,
must strictly be adhered to. check the points described in TROUBLESHOOT-
Locking devices when removed (e.g.: locking ING section.
tabs, elastic stop nuts, self-locking fasteners, Remove oil pressure gauge and adapter hose.
etc.) must be replaced.
NOTE: To remove adapter hose from oil pressure
gauge, use the DISCONNECT TOOL (P/N 529 035
INSPECTION 714).
Reinstall the oil pressure switch.
ENGINE OIL PRESSURE
NOTE: The engine oil pressure test should be TROUBLESHOOTING
done with a warm engine 100°C (212°F) and the
recommended oil.
LOW OR NO OIL PRESSURE
Remove the oil pressure switch. Refer to OIL 1. Oil level is too low.
PRESSURE SWITCH in this subsection. - Refill engine with recommended engine oil. Re-
fer to OIL LEVEL VERIFICATION in the PERIODIC
Install PRESSURE GAUGE (P/N 529 035 709) and MAINTENANCE PROCEDURES subsection.
ADAPTER HOSE (P/N 529 035 652).
- Check for high oil consumption, refer to HIGH
OIL CONSUMPTION in the TROUBLESHOOT-
ING subsection.
- Check for engine oil leaks. For leak indicator
holes, refer to COOLING SYSTEM subsection.
Repair if necessary

2. Use of unsuitable engine oil type.

- Replace engine oil by the recommended engine
oil.

3. Clogged oil filter.

- Replace oil and oil filter at the same time.

4. Defective oil pressure switch.

- Test oil pressure switch, see procedure in this
subsection.
5. Defective or worn oil pump.
- Check oil pump, see procedure in this subsection.

6. Defective engine oil pressure regulator.

- Check engine oil pressure regulator, see proce-
dure in this subsection.

7. Worn plain bearings in crankcase.

- Check plain bearings clearance, refer to BOTTOM
END subsection.
The engine oil pressure should be within the fol-
8. Clogged engine oil strainer.
lowing values.
- Clean engine oil strainer, see procedure in this
subsection.

52 tmr2011-010
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

OIL CONTAMINATION Place rags or towels under oil cooler to catch re-
maining oil and coolant.
1. Defective water pump seal ring or rotary seal.
- Check for oil or coolant leak from indicator hole
Remove oil cooler and discard gasket.
near water pump, refer to COOLING SYSTEM
subsection. Replace seal if necessary
2. Cylinder head or cylinder base gasket leak.
- Retighten cylinder head to specified torque, refer
to TOP END subsection. Replace gasket if tight-
ening does not solve the problem.

3. Engine internal damage.

- Repair engine.

4. Oil cooler gasket leak.

- Replace oil cooler gasket and change engine oil.

HIGH OIL CONSUMPTION

1. Leaking breather oil seal. 1. Oil cooler
- Check if the oil seal of the breather is brittle, hard 2. Gasket
or damaged. Refer to BOTTOM END subsection.
Oil Cooler Inspection
2. Valve stem seals worn or damaged.
Check oil cooler for cracks or other damage.
- Replace valve stem seals.
Replace if necessary.
3. Worn piston rings (blue exhaust smoke).
- Replace piston rings. Oil Cooler Installation
For installation, reverse the removal procedure.
PROCEDURES Pay attention to the following details.
Wipe off any oil and coolant spillage.
OIL COOLER Install a NEW gasket.
Oil Cooler Removal Refill engine oil with recommended oil and at the
Drain engine oil. Refer to ENGINE OIL CHANGE proper oil lever. Refer to ENGINE OIL CHANGE
in the PERIODIC MAINTENANCE PROCEDURES in the PERIODIC MAINTENANCE PROCEDURES
subsection. subsection.
Drain coolant. Refer to COOLING SYSTEM sub- Refill and bleed cooling system. Refer to COOL-
section. ING SYSTEM subsection.
Remove oil cooler retaining screws.

11,0011 0 , 0-00(3

1. Retaining screws
2. Oil cooler

tmr2011-010 53
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

OIL PRESSURE SWITCH (OPS)

If resistance values are incorrect, replace the oil

1. Oil pressure switch pressure switch.
If the values are correct, check wiring.
Oil Pressure Switch Activation
Oil pressure switch works when engine oil pres- Oil Pressure Switch Removal
sure is 20 kPa to 40 kPa (2.9 PSI to 5.8 PSI). Unplug the oil pressure switch connector.
To check the function of the oil pressure switch, Unscrew and remove oil pressure switch.
an oil pressure test has to be performed. Refer to
ENGINE OIL PRESSURE in this subsection. Oil Pressure Switch Installation
If the engine oil pressure is good, check the resis- Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
tance of the oil pressure switch while engine is off threads of oil pressure switch.
and while engine is running. Tighten oil pressure switch to specified torque.
Oil Pressure Switch Resistance Test OIL PRESSURE SWITCH TIGHTENING TORQUE
Disconnect the connector from the oil pressure 12 N•m ± 1 N•m (106 lbfein ± 91bf•in)
switch.
Use a multimeter to check the resistance be- ENGINE OIL PRESSURE
tween as shown.
REGULATOR
OPS ENGINE NOT ENGINE
CONNECTOR RUNNING RUNNING The oil pressure regulator is located on the engine
magneto side (inside magneto cover).
PIN RESISTANCE (S2)
Infinite (open)
Close to 0 52 when pressure
Engine
4 (normally reaches
ground
closed switch) 20 kPa to 40 kPa
(2.9 PSI to 5.8 PSI)

1. Engine oil pressure regulator

54 tmr2011-010
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

NOTE: The oil pressure regulator system works

when the oil pressure exceeds 400 kPa (58 PSI).

Oil Pressure Regulator Removal

Remove plug screw and pull oil pressure regulator
out.

7. Oil pump

Oil Pump Removal

Remove the PTO cover. Refer to PTO COVER in
the BOTTOM END subsection.
1. Plug screw 1. Remove:
2. Gasket ring
3. Pressure regulator housing — Retaining ring
4. Spring
5. Pressure regulator valve — Oil pump gear
— Needle pin
Oil Pressure Regulator Inspection — Thrust washer.
Inspect pressure regulator housing and valve for
scoring or other damages.
Check spring for free length.
SPRING FREE LENGTH
NEW NOMINAL 39 mm (1.535 in)
SERVICE LIMIT 37 mm (1.457 in)

NOTE: Replace worn or damaged components.

Clean bore and thread in the magneto housing
from metal shavings and other contaminations.

Oil Pressure Regulator Installation

For installation, reverse the removal procedure.
Pay attention to the following details. 1. Thrust washer
2. Needle pin
NOTE: At installation always replace the gasket 3. Oil pump gear
4. Retaining ring
ring of the plug screw by a new one.
2. Remove oil pump cover screws and pull oil
OIL PUMP pump cover out.

The oil pump is located on the engine PTO side

(behind PTO cove r)

tmr2011-010 55
Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

1. Retaining screws
2. Oil pump cover
1. Oil pump bore
3. Remove oil pump shaft with needle pin and in- 2. Outer rotor
3. Oil pump shaft
ner rotor. 4. Needle pin
5. Inner rotor
4. Remove outer rotor.
Check inner rotor for corrosion pin holes or other
damages. If so, replace oil pump shaft assembly.

1. Pittings on the teeth

1. Outer rotor Using a feeler gauge, measure the clearance of

2. Needle pin
3. Oil pump shaft inner and outer rotors as shown.
4. Inner rotor

Oil Pump Inspection

Inspect oil pump and oil pump cover bore for
marks, scratches or other damages. Check for
scratches in crankcase between outer rotor and
oil pump bore. If so, replace damaged parts.
Check oil pump cover for damages and for surface
straightness with a straightedge.

1. Outer rotor
2. Inner rotor
A. 0.25mm (.0098 in)

56 tmr2011-010
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

If clearance of inner and outer rotors exceeds the Oil Pump Installation
tolerance, replace oil pump shaft assembly. En- For installation, reverse the removal procedure.
sure to also check oil pump cover. If damaged, re-
place the complete oil pump assembly. Pay attention to the following details.
If clearance between outer rotor and its bore NOTE: The outer rotor and inner rotor are marked.
in crankcase exceeds the tolerance, replace When installing, make sure both markings are on
the complete oil pump assembly and/or the the outer side.
crankcase.
Using a depth gauge, measure the axial clearance
of the oil pump as shown.

TYPICAL
1. Markings

After reinstallation of the remaining parts, check

for smooth operation of the oil pump assembly.

Oil Pump Final Test

After engine is completely reassembled, start en-
gine and make sure oil pressure is within speci-
OIL PUMP — MEASUREMENT "A" fications (refer to ENGINE OIL PRESSUREin this
section).

ENGINE OIL STRAINER

The engine oil strainer is located between both
crankcase halves.

Oil Strainer Removal

Separate crankcase halves. Refer to BOTTOM
END subsection.
Remove screws and retaining plate.
Pull out engine oil strainer.

OIL PUMP COVER — MEASUREMENT "B"

Difference between measurements A and B

should not exceed specification. If so, replace
the complete oil pump assembly.
OIL PUMP AXIAL CLEARANCE
SERVICE LIMIT I 0.2 mm (.008 in)

NOTE: When the axial clearance of the oil pump

shaft assembly increases, the oil pressure de- 1. Engine oil strainer
2. Retaining plate
creases. 3. Screws

tmr2011-010 57
Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

Oil Strainer Cleaning and Inspection Reed Valve Installation

Clean engine oil strainer with a part cleaner then The installation is the reverse of the removal pro-
use an air gun to dry it. cedure.

A WARNING
Always wear eye protector. Chemicals can
cause a rash break out and injure your eyes.

Check engine oil strainer for cracks or other dam-

age. Replace if damaged.

Oil Strainer Installation

The installation is the reverse of the removal pro-
cedure.

REED VALVE
The engine is equipped with a reed valve which
prevents accumulation of larger oil quantities in
the crankcase. The reed valve is fitted into the
crankcase.

1. Reed valve
2. Stopper
3. Screws

Reed Valve Removal

Remove:
— PTO cover (refer to PTO COVER in the BOT-
TOM END subsection)
— Reed valve retaining screws
— Stopper plate
— Reed valve.

Reed Valve Inspection

Check reed valve for cracks or other damage.
Replace reed valve if damaged.

58 tmr2011-010
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

COOLING SYSTEM
SERVICE TOOLS
Description Part Number Page
BLIND HOLE PULLER KIT 529 036 056 76
FLUKE 115 MULTIMETER 529 035 868 68
HANDLE 420 877 650 78
LARGE HOSE PINCHER 529 032 500 64-66
OIL SEAL PUSHER 529 035 757 78
ROTARY SEAL PUSHER PLATE 529 036 130 74
SEAL PUSHER 529 035 766 74, 78

SERVICE PRODUCTS
Description Part Number Page
DOW CORNING 111 413 707 000 78
LOCTITE 243 (BLUE) 293 800 060 66

tmr2011-011 59
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

RADIATOR
8008 Engine

10 ± 2 N•m
(88 ± 18 lbf•in)

7 ± 1 N•m
(62 ± 9 lbf•in)

2
10 ± 2 N•m
(88 ± 18 lbf•in)

3 ± 0.5 N•rn
(27 ± 4 lbf•in)

Engine

3 ± 0.5 N•rn
(27 ± 4 lbf•in)

IZE3 = Component must be replaced when removed.

trn12011-011-1CO_a

60 tmr2011-011
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

RADIATOR
1000 Engine

Early Models

Radiator

IME1-7-A

10 ± 2 N•rn
(88 ± 18 lbf•ini

3 ± 0.5 N•rn
(27 ± 4 lbf•in)
Engine

3 ± 0.5 Wm
(27 ± 4 lbf•in)
10 ± 2 N•m
;10 I 8 ± 18 lbf•in)
4 =8
.....j 1 ---------_
\,,..._
tr,

3 ± 0.5 N•rn
(27 ± 4 lbf•in)
Engine

Imm = Component must be replaced when removed.

I.,2011011-101_a

61
tmr2011-011
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

WATER PUMP
800R Engine

5 _t 0.6 N•rn 6 ± 0.7 NI•rn

(53 ± 6 lbf•in) 5 ± 0.6 N•rn
(44 ± 5 lbf•in) (44 ± 5 lbf•in)

' Loctite
411111* 243 6 ± 0.7 N•rn

0 (53 ± 6 lbf•in)

Loctite
V
*4111ik 243

CTS See (EFI)

111-- 16 ± 2 N•rn
/ (142 ± 18 lbfqn)

20 ± 2 NI•rn
(15 ±. 1 lbf•ft)

10 ± 1 NJ•n-1
(89 ± 9 lbf•in)

2.5 ± 0.3 (\i•m

(22 ± 3 lbf•in)

Molycote
111

imr2011.011002a

62
tmr2011-011
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

WATER PUMP
1000 Engine

5 ± 0.6 N•m
(44 ± 5 lbf•in)

0
6 ± 0.7 N•m
(53 ± 6 lbf•in)

Loctite
243
•
5 ±- 0.6 Nem
(44 ± 5 lbf•in)
0 CTS See (EFI)

16 ± 2 N•m
20 ±- 2 Nem (142 ± 18 lbf•in)
(15 ± 1 lbf•ft) 6 ± 0.7 N•m
(53 ± 6 lbf•in)

Loctite
243
CZ)
10 ± 1 N•m
(89 ± 9 lbf•in)

Engine
oil

2.5 ± 0.3 N•m

(22 ± 3 lbf•in)

Molycote
111

Engine oil

tmr2011 011 001_0

tmr2011-011 63
Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

GENERAL There are two possible locations (see illustra-

tions).
A WARNING
Never start engine without coolant. Some
engine parts such as the rotary seal on the
water pump shaft can be damaged.

During assembly/installation, use the torque val-

ues and service products as specified in the ex-
ploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICAT/ONat the beginning of this manual for
complete procedure.

A WARNING THERMOSTAT LOCATION - LH FRONT WHEEL WELL ACCESS

Torque wrench tightening specifications 7. In-line thermostat
2. Radiator
must strictly be adhered to.
Locking devices when removed must be re-
placed (e.g.: locking tabs, elastic stop nuts,
self-locking fasteners, etc.).

PROCEDURES
THERMOSTAT
The thermostat is a single action type.

Thermostat Location
8008 Models
The thermostat is located in the thermostat hous- THERMOSTAT LOCATION - RH FRONT WHEEL WELL ACCESS
ing at the top of the front cylinder (RH side). 1. In-line thermostat

Thermostat Removal
8008 Models
1. Install a LARGE HOSE PINCHER (P/N 529 032 500)
on both radiator hoses.
2. Drain remainder of cooling system, refer to
PERIODIC MAINTENANCE PROCEDURES
subsection.
3. Remove thermostat housing screws and re-
move thermostat cover.

TYPICAL - THERMOSTAT LOCATION 800R MODELS

1. Front cylinder
2. Thermostat housing

1000 Models
The thermostat is mounted in-line in the cooling
system circuit.

64 tmr2011-011
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

THERMOSTAT LOCATION - FRONT CYLINDER HEAD

1. Thermostat cover 1. Radiator - LH side
2. Thermostat housing 2. Large hose clamp on upper hose (lower hose RH side similar)
3. Cover screws
4. Bleed screw
2. Drain remainder of cooling system, refer to
4. Pull thermostat and gasket from thermostat PERIODIC MAINTENANCE PROCEDURES
housing. subsection.
1000 Models with Thermostat Access
thru LH Front Wheel Well
3. Remove service cover, refer to BODY subsec-
tion.
4. Remove air filter housing, refer to AIR INTAKE
SYSTEM subsection.
5. Remove Oetiker clamps that secure hoses to
thermostat.
6. Remove clamp that secures thermostat hous-
ing to frame.

TYPICAL
1. Thermostat with gasket

1000 Models
1. Install a LARGE HOSE PINCHER (P/N 529 032 500)
on both radiator hoses.

THERMOSTAT EARLY 1000 PRODUCTION MODELS - AIR

529032500
FILTER HOUSING REMOVED
1. Thermostat
2. Oetiker clamps (3)
3. Support clamp

7. Pull hoses from thermostat housing to remove

thermostat.

tmr2011-011 65
Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

1000 Models with Thermostat Access Radiator Removal

thru RH Front Wheel Well 1. Install a LARGE HOSE PINCHER (P/N 529 032 500)
8. Remove Oetiker clamps that secure hoses to on both radiator hoses.
thermostat.
9. Pull hoses from thermostat housing to remove
thermostat.

Thermostat Test
To check thermostat, put it in water and heat the
water.
THERMOSTAT OPENING TEMPERATURE
MODELS STARTS TO OPEN FULLY OPEN
800R 65°C (149°F) 75°C (167°F)
1000 65°C (149°F) 88°C (190°F)

Replace thermostat if it does not begin to open at

specified temperature.
Check if gasket is brittle, hard or damaged. If so,
replace gasket.

Thermostat Installation
800R Models
For installation, reverse the removal procedure.
Pay attention to the following.
THERMOSTAT COVER INSTALLATION
1. Radiator - LH side
GASKET PRODUCT TORQUE 2. Large hose clamp on upper hose (lower hose RH side similar)

LOCTITE 2. Lift front of vehicle to extend suspension.

243 (BLUE) 6 N•rn ± 0.6 N•rn
New 3. Remove the following parts from the radiator:
(P/N 293 800 060) (531bf•in ± 5Ibf•in)
on screws — Radiator inlet hose (LH upper)
— Radiator outlet hose (RH lower)
1000 Models — Radiator mounting screws (2 at top of radia-
Reverse removal procedures. tor).
All Models 4. Disconnect cooling fan electrical connector.
Refill cooling system. 5. Remove cooling fan vent hose from frame.
Bleed cooling system, refer to PERIODIC MAIN- NOTE: Take note of the rooting of the vent hose
TENANCE PROCEDURES subsection. on the cooling fan motor. See following illustra-
tion.
NOTICE The cooling system must be bled as
specified.

Check for coolant leaks.

RADIATOR
Radiator Inspection
Check radiating fins for clogging or damage.
Remove insects, mud or other obstructions with
compressed air or low pressure water.

66 tmr2011-011
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

2. Install the rubber bushings between bottom of

radiator and radiator support.
3. Ensure the vent hose on the cooling fan motor
is properly rooted as prior to removal.
NOTE: Cooling fan vent hose must pass over the
top RH frame member, then be inserted down
into the RH vertical bumper tube.
NOTICE If the vent hose on the cooling fan
motor is not properly rooted, the fan motor
may be damaged due to improper venting.

RADIATOR - REAR VIEW

1. Radiator mounting screws
2. Lower mounting bushings
3. Radiator fan electrical connector
4. Fan motor vent hose

6. Remove the 2 forward air filter housing mount-

ing screws.
NOTE: This will make room for lifting the radiator
off its lower mounting bushings.

1. Cooling fan vent hose

2. RH top frame member
3. RH vertical bumper tube

4. Fill radiator with the recommended coolant.

Refer to PERIODIC MAINTENANCE PROCE-
DURES subsection.
5. Bleed the cooling system, refer to PERIODIC
MAINTENANCE PROCEDURES subsection.
NOTICE The cooling system must be bled as
specified.
1. Forward air filter housing mounting screws to remove
6. Check for coolant leaks from radiator and
Models Equipped with a Winch hoses.
7. Remove the winch, refer to LIGHTS, GAUGE
AND ACCESSORIES subsection. COOLANT TEMPERATURE
All Models SENSOR (CTS)
8. Lift radiator t and tilt its lower end towards the Refer to ELECTRONIC FUEL INJECTION (EFI)
front of the vehicle. subsection.
NOTE: Turning steering to LH stop or removing
LH front wheel assembly provides greater access RADIATOR COOLING FAN RELAY
for radiator removal. (R1)
9. Carefully remove radiator through LH wheel
Relay Installation (Radiator Cooling
well.
Fan)
Radiator Installation NOTE: Relay may be inverted by 180° at installa-
1. For installation, reverse the removal procedure tion and it will work correctly. Ensure to align tabs
of relay with terminals of fuse holder at installa-
however, pay attention to the following details.
tion.
tmr2011-011 67
Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

TERMINAL RESISTANCE
Open circuit
30 87
(OL)

1. R1 Radiator cooling fan relay 4. Connect battery as shown and probe relay
again as follows.
Relay Operation Test (Radiator Cooling
TERMINAL RESISTANCE
Fan)
The easiest way to check the relay is to remove it 0.5 C2 max.
30 87
(continuity)
and bypass it using a jumper. If the radiator cool-
ing fan is activated, replace the relay. See illustra-
tion to find where to bypass the relay.

If relay failed any test, replace it.

RADIATOR COOLING FAN

Radiator Cooling Fan Operation
The ECM controls the radiator cooling fan via the
input of the coolant temperature sensor (CTS) and
JUMPER RELAY R1 (RADIATOR FAN) the manifold air pressure and temperature sensor
(MAPTS). Refer to the following table.
Relay Continuity Test (Radiator
Cooling Fan)
1. Remove relay.
2. Use the FLUKE 115 MULTIMETER (P/N 529 035
868), and select the 52 position.
3. Probe relay as follows.

68 tmr2011-011
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

CHECK MESSAGE IN
ENGINE INTAKE COOLING LIMP HOME
ENGINE MULTIFUNCTION
TEMPERATURE TEMPERATURE FAN MODE
LIGHT GAUGE
— 88°C (190°F) Turns ON
— 85°C (185°F) Turns OFF
96°C (205°F) Turns ON
92°C (198°F) — Turn OFF — —
- Check engine
115°C (239°F) — ON Turns ON
- Hi Temp
Engine RPM
118°C (244°F) — ON Flashes Limp Home
limited to 4000

Radiator Cooling Fan Fuse Location Fuel Pump

The fuse is located in the fuse box underneath the

dashboard on the driver's side. • Enabled Disabled

Activate

Fuel Pump

ooling Fan 1

Accesory Relay

1. Cooling Fan activation button

If fan turns on, check CTS, wiring harness and

connectors. If all parts are good, replace the ECM.
If fan does not turn on when the Cooling Fan but-
ton is pressed, refer to the following troubleshoot-
ing chart.

1. Cooling fan fuse

Radiator Cooling Fan Test

1. Connect the vehicle to B.U.D.S., refer to COM-
MUNICATION TOOLS AND B.U. D.S. for proce-
dure and connector location.
2. In B.U.D.S. software, select the following:
— Read Data button
— Activation page tab
— ECM page
— Cooling Fan button.

trnr2011-011 69
Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

COOLING FAN TROUBLESHOOTING CHART WATER PUMP HOUSING

Is fan working? YES —) I Everything is OK It is located on the engine MAG side.
NO 4, Water Pump Housing Removal
Check "Relay driver"
fuse (5A) and
YES —)
Replace fuse A WARNING
fan fuse (30A). Is fan working? To avoid potential burns, do not remove the
Is fuse burnt? radiator cap or loosen the coolant drain plug
NO 4. if the engine is hot.

Bypass fan relay R1 Drain cooling system.

4. Remove radiator outlet hose from water pump
housing.
Replace relay
Fan turns? YES .. ) Remove screws retaining water pump housing.
Is fan working?

NO 4,
Apply 12 Vdc to fan
connector

4.
Replace fan
Fan turns? NO —)
Is fan working?

YES 4,
Check CTS

4,
Replace CTS
CTS works? NO —)
Is fan working?

YES 4. 1. Coolant drain plug

2. Sealing ring
Check wiring harness 3. Screws
and connectors 4. Water pump housing

4, Pull water pump housing to remove it.

Harness and Repair or replace
connectors good?
NO —)
defective part(s)
Water Pump Housing Inspection
Check if gasket is brittle, hard or damaged and re-
YES 4, place as necessary.
Try a new ECM ---) I Is fan working?

Radiator Cooling Fan Removal

1. Disconnect fan motor electrical connector.
2. Remove fan motor vent tube from vehicle
frame.
3. Remove 4 fan retaining screws.
4. Remove the radiator fan.

Radiator Cooling Fan Installation

For the installation, reverse the removal proce- TYPICAL
dure. 1. Gasket

70 tmr2011-011
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

Water Pump Housing Installation WATER PUMP SHAFT AND

The installation is the opposite of the removal pro- SEALS
cedure.
Rotary Seal and Oil Seal Removal
NOTICE To prevent leaking, take care that the (Assembled Engine)
gasket is exactly in groove when you reinstall Remove water pump housing, refer to WATER
the water pump housing. PUMP HOUSING in this subsection.
Tighten screws of water pump housing in a criss 1. Carefully pry out inner part of the rotary seal
cross sequence. using 2 screwdrivers.

WATER PUMP IMPELLER

Water Pump Impeller Removal
Remove water pump housing.
Unscrew impeller.

1. Inner part of rotary seal

1. Turn counterclockwise to unscrew

NOTICE Water pump shaft and impeller have

right-hand threads. Remove by turning coun-
terclockwise and install by turning clockwise.

Water Pump Impeller Inspection

Check impeller for cracks or other damage. Re-
place impeller if damaged.

Water Pump Impeller Installation

The installation is the opposite of the removal pro-
TYPICAL - INNER PART OF ROTARY SEAL REMOVED
cedure.
NOTICE Be careful not to damage impeller 2. Carefully bend down the outer part of rotary
fins during installation. seal lip using a small chisel.

tmr2011-011
71
Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

4. Thoroughly remove carefully sealing residue

and burr of rotary seal using a scraper.
NOTICE Be careful not to damage water
pump shaft.

1. Small chisel
1. Scraper
3. Use 2 screwdrivers and carefully remove the
5. Install 2 wooden screws in the seal.
outer part of the rotary seal.

1. Wooden screws
2. Oil seal

6. Remove oil seal from crankcase by puling

screws with pliers.

7. Screwdrivers

NOTICE Be careful not to damage the

crankcase while removing outer part of the
rotary seal.

72 tmr2011-07 1
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

OIL SEAL INSTALLATION

4. Ensure that the oil seal is properly seated in wa-

ter pump cavity.
1. Pull on screws to remove seal

7. Check water pump shaft axial play. If not ade-

quate, engine must be disassembled to replace
the water pump shaft.
8. Clean oil seal seat.

TYPICAL
1. Oil seal properly seated

Rotary Seal
NOTICE Read and thoroughly understand
the entire procedure of installing the rotary
seal before starting it.

1. Apply engine oil on water pump shaft.

Rotary Seal and Oil Seal Installation
2. Place rotary seal onto water pump shaft and pull
(Engine Assembled) out water pump shaft by hand.
Oil Seal NOTICE Do not install the rotary seal com-
Apply engine oil on water pump shaft. pletely into the crankcase to prevent the water
1. Apply grease to the lips of the oil seal. pump shaft plastic gear from breaking. Push it
partially in, then pull the shaft.
2. Carefully install the oil seal over the water pump
shaft. 3. Place a robust M8 flat washer (P/N 420 227
3. Push the oil seal into the water pump cavity us- 935) onto water pump shaft.
ing a 17 mm (11/16in) deep socket. 4. Install a M8 x 1.25 nut onto water pump shaft
by hand.
5. Then thread nut 1-1/2 turns to pull the shaft into
rotary seal.

73
tmr2011-011
Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

1. Rotary seal
2. M8 robust flat washer (P/N 420 227 935)
3. M8 x 1.25 nut (P/N 233 281 414)

6. Remove M8 nut.
NOTE: The M8 flat washer remains on water 1. 4 x tubes (70mm (2.75in) length)
2. 4 x screws M6 x 85
pump shaft. 3. Plane surface on pusher bolt
7. Use the ROTARY SEAL PUSHER PLATE (P/N 529
036 130) with M6 x 85 screws (P/N 420 440 347) 8. Apply a little grease at the end of tool pusher
and tubes (70 mm (2.75 in) length) to install ro- bolt.
tary seal as follows. 9. Ensure that the pusher bolt of rotary seal
pusher plate is completely unscrewed.
10. Install rotary seal pusher plate on crankcase by
torquing the M6 screws.
NOTICE Do not use pneumatic or electric
tools for screwing the rotary seal pusher plate
screws.

ROTARY SEAL PUSHER PLATE (P/N 529 036 130)

NOTE: Make sure the tool pusher bolt has a plane

surface. If required, grind the pusher bolt.

ROTARY SEAL PUSHER PLATE INSTALLATION

1. Rotary seal pusher plate
2. Tube (70mm (2.75 in) length)
3. M6 x 85 screw
4. Pusher bolt

11. Install SEAL PUSHER (P/N 529 035 766) between

rotary seal pusher plate and water pump shaft.

74 tmr2071-011
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

SEAL PUSHER (P/N 529 035 766)

1. M8 robust flat washer (P/N 420 227 935)

2. M8 x 1.25 nut (P,/N 233 281 414)

Repeat the steps 5 to 15 another 2 times until ro-

tary seal is completely seated in the crankcase.
18. Remove tools from crankcase.

SEAL PUSHER INSTALLATION WITH ROTARY SEAL PUSHER

1. Seal pusher aligned with pusher bolt

12. Tigh ten the pusher bolt by hand until it stops

again st the seal pusher. ROTARY SEAL PROPERLY SEATED ON CRANKCASE
13. Caref ully thread the pusher bolt 1-1/2 turns.
19. Place a robust M8 flat washer onto water
14. Ensure that the rotary seal is going straight pump shaft.
into cra nkcase.
20. Pull water pump shaft in proper position until
15. Remove tools from crankcase. the rotary seal is flush with the end of water
16. Place a r obust M8 flat washer (P/N 420 227 pump shaft threads.
935) onto water pump shaft.
NOTICE Ensure that the water pump shaft is
17. Install M8 x 1.25 nut (P/N 233 281 414) onto properly adjusted with rotary seal.
water pum p shaft.

tmr2011-011 75
Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

WATER PUMP SHAFT PROPERLY ADJUSTED WITH ROTARY 1. Water pump intermediate driven gear (removed)
SEAL 2. Needle pin
3. Thrust washer
NOTICE Ensure that the water pump shaft
moves freely while pushing it toward the 4. Using a soft hammer, push out water pump
crankcase. shaft with inner portion of rotary seal from
inside of crankcase MAG side.
Water Pump Shaft/Seal Removal
(Disassembled Engine)
1. Remove the following parts:
— Water pump housing
— Water pump impeller.
2. Remove the circlip retaining the intermediate
driven gear on water pump shaft.

1. Water pump shaft

2. Crankcase MAG side

5. To remove outer part of rotary seal, use an ex-

pander from BLIND HOLE PULLER KIT (P/N 529
036 056).
6. Install expander snugly against outer part of ro-
tary seal and pull seal out.

1. Circlip
2. Water pump gear

3. Remove the:
— Water pump intermediate driven gear
— Needle pin
— Thrust washer.

76 tmr2011-011
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

OIL SEAL REMOVAL - VIEW FROM INSIDE CRANKCASE MAG

SIDE
TYPICAL 7. Orifices for oil seal removal

NOTICE When removing water pump shaft, Water Pump Shaft/Seal Inspection
always replace rotary seal with water pump (Disassembled Engine)
shaft. Also replace oil seal in crankcase (be-
hind rotary seal). Inspect water pump gear for wear and damage on
the snap mechanism to the needle pin. Replace if
7. Remove oil seal from inside of crankcase MAG damaged.
side using a pusher tool. Check water pump intermediate drive gear for
NOTICE Be careful not to damage the rotary wear or broken teeth. Replace if damaged.
seal surface in crankcase. NOTICE Never use the circlip a second time.
Always install a NEW one.

1. Oil seal
2. Machined surface for rotary sea'
1. Water pump intermediate drive gear
2. Circlip
3. Intermediate shaft
4. Crankcase PTO side

Water Pump Shaft/Seal Installation

(Disassembled Engine)
For installation, reverse the removal procedure.
However, pay attention to the following.
NOTE: For installation use the torque values
specified in the exploded view.

tmr2011-011 77
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

NOTICE Always replace rotary seal and wa-

ter pump shaft together. Also, install a NEW oil
seal (behind rotary seal) at the same time.

NOTE: Never use oil in the press fit area of the oil
seal and rotary seal.
Clean rotary seal surface of any old sealant.
Use the OIL SEAL PUSHER (P/N 529 035 757) and
the HANDLE (P/N 420 877 650) to install oil seal.

1. Sealing lip
2. Oil seal properly installed

1. Handle Apply engine oil on the water pump shaft and in-
2. Pusher
termediate shaft.
When installing the oil seal on the pusher, make Slide water pump shaft with the new rotary seal
sure the sealing lip points outwards. into crankcase.
Push NEW oil seal in place. To properly install water pump shaft with rotary
seal, use the SEAL PUSHER (P/N 529 035 766).

SEAL PUSHER (P/N 529 035 766)

1. Oil seal
2. Installer handle with oil seal pusher

Apply DOW CORNING 111 (P/N 413 707 000) on seal-

ing lip of the oil seal.

1. Surface where rotary seal is pushed by tool

NOTICE Never use a hammer for rotary seal

installation. Only use a press to avoid damag-
ing the ceramic component.

78 tmr2011-011
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

1. Water pump shaft with rotary seal 7. Circlip

2. Water pump seal installer 2. Water pump gear

Install thrust washer and needle pin on water NOTICE After installation, water pump shaft
pump shaft. with rotary seal must rotate freely.
NOTICE A missing thrust washer will cause a Tighten screws of the water pump housing cross-
leaking rotary seal. wise.

1. Water pump intermediate driven gear

2. Needle pin
3. Thrust washer

Ensure water pump intermediate driven gear

snaps properly onto needle pin, then install the
circlip to retain the gear onto the shaft.
NOTICE Never use the circlip a second time.
Always install a NEW one.

tmr2011-011 79
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 06 (MAGNETO SYSTEM)

MAGNETO SYSTEM
SERVICE TOOLS
Description Part Number Page
CRANKSHAFT LOCKING BOLT 529 035 617 85
CRANKSHAFT PROTECTOR 529 036 034 86
MAGNETO DIAGNOSTIC HARNESS 529 036 199 84-85
MAGNETO PULLER 529 035 748 86

SERVICE PRODUCTS
Description Part Number Page
DREI BOND SEALING COMPOUND 420 297 906 83
LOCTITE 648 (GREEN) 413 711 400 88
LOCTITE 767 (ANTISEIZE LUBRICANT) 293 800 070 89
LOCTITE CHISEL (GASKET REMOVER) 413 708 500 83
PULLEY FLANGE CLEANER 413 711 809 87

trnr2011-012 81
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 06 (MAGNETO SYSTEM)

See
6 ± 0.7 N•m ELECTRONIC FUEL
(53 ± 6 lbf•in) INJECTION (EFI)

Drei Bond sealing

compound

Loctite 243
'so 4 ± 0.3 N•m
(35 ± 3 lbf•in)
10 ± 1 N•m
(89 ± 9 lbf•in)
11 ± 1 N•m
(97 ± 9 lbf•in)

150 ± 10 N•m
(111 ± 7 lbf•ft)

Engine 50 ± 6 N•m
oil (37 ± 4 lbf•ft)

Loctite
648 5

30 ± 2 N•m
(22 ± 1 lbf•ft) Loctite 767
(antiseize lubricant)

Engine oil

25 ± 3 N•m
(18 ± 2 lbf•ft)

tmr2011-012-001_a

82
tmr2011-012
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 06 (MAGNETO SYSTEM)

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
cotter pins, etc.) must be replaced. 1. Magneto cover
2. Retaining screws

PROCEDURES Pull out magneto cover.

MAGNETO COVER Magneto Cover Inspection and

Cleaning
Magneto Cover Access in Vehicle
Check magneto cover for cracks or other damage.
Remove fuel tank, refer to FUEL TANK AND FUEL Replace if necessary.
PUMP.
NOTE: Clean all metal components in a non-
Magneto Cover Removal ferrous metal cleaner. Use LOCTITE CHISEL (GAS-
KET REMOVER) (P/N 413 708 500), or suitable
Drain engine oil (refer to LUBRICATION SYSTEM. equivalent.
Remove crankshaft position sensor (CPS) and cut
tie raps. A WARNING
Disconnect magneto connector. Wear safety glasses and work in a well
ventilated area when working with strong
Remove dipstick and oil level tube with 0-rings.
chemical products. Also wear suitable
non-absorbent gloves to protect your hands.

Magneto Cover Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
NOTE: At installation replace magneto cover gas-
ket.
Apply DREI BOND SEALING COMPOUND (P/N 420
297 906) on stator cable grommet as shown in next
illustration.

1. Dipstick
2. Oil level tube
3. Crank position sensor (CPS)
4. 0-rings

Remove magneto cover retaining screws.

tmr2011-012 83
Section 02 ENGINE, CVT AND GEARBOX
Subsection 06 (MAGNETO SYSTEM)

7. Stator cable grommet (apply Drei Bond sealing compound) 1. Magneto connector

Tighten screws using the following sequence. Stator Static Test: Continuity
1. Disconnect the magneto connector.
2. Install the MAGNETO DIAGNOSTIC HARNESS
(P/N 529 036 199) on magneto connector (mag-
neto side).
3. Set multimeter to ft
4. Connect multimeter between YELLOW wires.
5. Read resistance.
RESISTANCE @
TERMINAL
20°C (68°F)
1 and 2
1 and 3 0.15 - 0.30 S2
2 and 3

TIGHTENING SEQUENCE

Refill engine with recommended oil.

STATO R
Stator Connector Access
Refer to BODYand remove upper console.

TYPICAL

6. If any reading is out of specification, replace sta-

tor.
7. Re-plug connectors properly.

84 tmr2011-012
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 06 (MAGNETO SYSTEM)

Stator Static Test: Insulation 7. If voltage is lower than specification, replace

1. Install the MAGNETO DIAGNOSTIC HARNESS stator.
(P/N 529 036 199) on magneto connector (mag- 8. Re-plug connectors properly.
neto side).
2. Set multimeter to Q.
Stator Removal
Remove MAGNETO COVER. See procedure in
3. Connect multimeter between any YELLOW
this subsection.
wire and engine ground.
4. Read resistance. Remove screws securing the wire holding strip.
Remove stator retaining screws then the stator.
RESISTANCE @
TEST PROBES
20°C (68°F) Stator Inspection
Any YELLOW wire and Check stator windings and insulation for cracks or
Infinite (open circuit)
engine ground other damages. If damaged replace it.
Check if stator wires are brittle, hard or otherwise
damaged.

Stator Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
NOTICE When installing the stator take care
to route wires properly and install retaining
strip.
NOTE: There is only one position for the stator
(notch in the magneto housing cover).

00■1111w"
TYPICAL

5. If there is a resistance or continuity, the stator

coils and/or the wiring is shorted to ground and
needs to be repaired or replaced.
6. Re-plug connectors properly.

Stator Dynamic Test: AC Voltage

1. Unplug magneto wiring harness connector.
2. Install theMAGNETO DIAGNOSTIC HARNESS
(P/N 529 036 199) between unplugged connec-
tors.
vrm2006-04'-006_a

NOTE: Both connectors must be plugged. 1. Threads for cable holding strip
2. Notch for stator
3. Set multimeter to Vac.
4. Start engine.
ROTOR
5. Connect multimeter between YELLOW wires.
Rotor Removal
6. Read voltage as per following table.
Remove MAGNETO COVER. See procedure in
TEST ENGINE this subsection.
TERMINAL VOLTAGE
SPEED
Lock crankshaft with CRANKSHAFT LOCKING BOLT
1 and 2 (P/N 529 035 617) (refer to BOTTOM END).
4000 RPM 1 and 3 10 - 25 Vac Heat screw in order to break the Loctite.
2 and 3

tmr2011-012 85
Section 02 ENGINE, CVT AND GEARBOX
Subsection 06 (MAGNETO SYSTEM)

Remove screw and washer securing rotor to

crankshaft.

1. Rotor
2. Magneto puller

1. Screw M16
Screw magneto puller bolt to remove rotor.
2. Washer
3. Rotor Rotor Inspection
Install MAGNETO PULLER (P/N 529 035 748) and Check inner side of rotor for scratches or other
CRANKSHAFT PROTECTOR (P/N 529 036 034) then damage.
remove rotor. Blow pressurized air in the rotor oil bore and make
sure it is not clogged.

MAGNETO PULLER

1. Rotor
2. Oil bore

Check keyway of the rotor for wear or damages.

CRANKSHAFT PROTECTOR
Check if trigger wheel teeth are bent or otherwise
NOTE: Use grease to place protector on crank- damaged.
shaft end prior to screw on the magneto puller.
Check woodruff key and keyway on the crank-
shaft for wear or damages.
Replace parts as necessary.

Rotor Installation
For installation, reverse the removal procedure.
However, pay attention to the following.

86 tmr2011-012
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 06 (MAGNETO SYSTEM)

Clean crankshaft taper and rotor with PULLEY

FLANGE CLEANER (P/N 413 711 809).
NOTICE Taper on crankshaft and rotor must
be free of grease.

Blow pressurized air in the rotor oil bore.

Clean the crankshaft oil passage and threads us-
ing PULLEY FLANGE CLEANER (P/N 413 711 809).

1. Starter double gear

2. Sprag clutch gear
3. Intermediate gear

SPRAG CLUTCH
Sprag Clutch Removal
Remove MAGNETO COVER. See procedure in
this subsection.
1. Crankshaft (MAG side)
2. Oil passage Heat screws in order to break the Loctite.
3. Threads
Loosen sprag clutch housing screws located in-
Oil sprag clutch and install sprag clutch gear. side rotor.

1. Rotor
2. Sprag clutch housing screws
1. Sprag clutch
2. Sprag clutch housing Remove rotor (refer to ROTOR above).
3. Sprag clutch gear
4. Apply engine oil here Remove sprag clutch gear.
Slide rotor onto crankshaft. The woodruff key and Remove sprag clutch housing screws and sprag
the keyway must be aligned. clutch housing.
Rotate starter double gear counterclockwise to
align intermediate gear teeth with sprag clutch
gear.

tmr2011-012 87
Section 02 ENGINE, CVT AND GEARBOX
Subsection 06 (MAGNETO SYSTEM)

Apply engine oil on sprag clutch and inside sprag

clutch gear hole.

1. Sprag clutch housing screws

2. Rotor
3. Sprag clutch
4. Sprag clutch housing

Sprag Clutch Inspection

Inspect sprag clutch and sprag clutch housing for 1. Sprag clutch
2. Sprag clutch housing
wear and damage. 3. Sprag clutch gear
4. Apply engine oil here
Also check the collar of the sprag clutch gear.
Perform a functional test of the sprag clutch. To Install rotor then torque sprag clutch housing
do so, rotate sprag clutch gear in sprag clutch. screws to 30 N•m (22 lbf•ft).
NOTE: Sprag clutch must lock in counterclock-
wise direction. SPRAG CLUTCH GEAR
Sprag Clutch Gear Removal
Remove ROTOR. See procedure in this subsec-
tion.
Pull sprag clutch gear out of the rotor.

SPRAG CLUTCH FUNCTIONAL TEST

1. Lock

NOTE: Sprag clutch, housing and gear must be

replaced at the same time, if damaged.

Sprag Clutch Installation 1. Rotor

2. Sprag clutch gear
For installation, reverse the removal procedure.
Pay attention to the following details. Sprag Clutch Gear Inspection
Apply LOCTITE 648 (GREEN) (P/N 413 711 400) on Inspect gear, especially teeth and sprag clutch col-
threads of sprag clutch housing screws. lar, for wear and other damage.
Install screws but do not torque yet. Check needle bearing condition. Replace sprag
clutch gear if necessary.

88 tmr2011-012
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 06 (MAGNETO SYSTEM)

Starter Drive Gear Inspection

Inspect gears and location pins for wear and dam-
age.
Replace parts as necessary.

Starter Drive Gear Installation

The installation is the reverse of the removal pro-
cedure. Pay attention to the following details.
Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) on starter gear before installing
the starter double gear.
Apply engine oil on location pins.

NSPECT
1. Teeth
2. Collar
3. Needle bearing

Sprag Clutch Gear Installation

The installation is the reverse of the removal pro-
cedure.
NOTE: Apply engine oil on needle bearing and col-
lar of sprag clutch gear.

STARTER DRIVE GEARS

The starter drive gears are located on the engine
MAG side behind the magneto cover.

1. Intermediate gear
2. Starter double gear
3. Starter gear
4. Location ()Ins

Starter Drive Gear Removal

Remove MAGNETO COVER. See procedure in
this subsection.
Remove location pins, starter double gear and in-
termediate gear.

tmr2011-012
89
f
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

TOP END
SERVICE TOOLS
Description Part Number Page
CRANKSHAFT LOCKING BOLT 529 035 617 112
PISTON CIRCLIP INSTALLER 529 035 921 115
PISTON CIRCLIP INSTALLER 529 036 153 115
PISTON RING COMPRESSOR 529 035 919 112
TDC DIAL INDICATOR 414 104 700 97
VALVE GUIDE INSTALLER 529 036 140 110
VALVE GUIDE REMOVER 5 MM 529 035 924 110
VALVE SPRING COMPRESSOR CUP 529 035 764 106
VALVE SPRING COMPRESSOR 529 035 724 106

SERVICE TOOLS - OTHER SUPPLIER

Description Part Number Page
SNAP ON PLIERS
- YA 8230 108

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 767 (ANTISEIZE LUBRICANT) 293 800 070 111

tmr2011-013 91
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

INTAKE MANIFOLD

10 ± 1 N•m
(89 ± 9 lbf•in)

6 -± 0.7 Nom
(53 ± 6 lbf•in)
Loctite 243
Engine i
oil

See Loctite 243 0.7 ± 0.1 N•m

ELECTRONIC (6 ± 1 lbf•in)
FUEL
INJECTION
(EFI)

10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
6 ± 0.7 N•m See
ELECTRONIC
(53 ± 6 lbf•in)
FUEL
INJECTION
Engine oil (EFI)

Engine oil

See
ELECTRONIC
FUEL
10 ± 1 N•rn INJECTION
(89 ± 9 lbf•in) (EFI)

20 ± 2.5 Nem
(15 ± 2 lbf•ft)

ynr2011-013-001a

92
tmr2011-013
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

CYLINDER HEAD NO. 1

7 ± 0.8 N•m
(62 ± 7 lbf•in)

12 ± 1 N•m
(106 ± 9 lbf•in)

See tightening
procedure

20 ± 2 N•m
10 ± 1 N•m
Engine oil (15± 1.5 lbf•ft)
(89 ± 9 lbf•in)

Engine oil

12 ± 1 N•m
(106 ± 9 lbf•in)

= Component must be replaced 6

when removed Engine oil
10 ± 1 N•rn
(89 ± 9 lbf•in) Loctite 648

tmr2011-013-002a

tmr2011-013 93
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

CYLINDER HEAD NO. 2

Engine oil
7 ± 0.8 N•rn
0 12 ± 1 N•m (62 ± 7 lbf•in)

(106 ± 9 Ib•re)

See tightening
procedure

20 ± 2 N•m
(5 ± 1.5 lbf•ft)

See
Ignition System Engine oil 6 0
Engine oil
6

10 ± 1 N•rin
(89 ± 9 lbf•in)

Engine oil
6

6
Loctite 648

6 Engine oil 10 ± 1 N•m

(89 9 lbf•in)

= Component must be replaced when removed

tmr2011-013-003_a

94 tmr2011-013
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

CYLINDERS AND PISTONS

Imr2011-013 95
Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

GENERAL When disassembling parts that are duplicated

in the engine, (e.g.: valves), it is a strongly rec-
Special reference are made in the text for proce- ommended to note their position (PTO/MAG
dures which are different for cylinder no. 1 and side, front/rear cylinder) and to keep them as a
cylinder no. 2. "group". If you find a defective component, it
would be much easier to find the cause of the
failure among its group of parts (e.g.: you found
a worn valve guide. A bent spring could be the
cause and it will be easy to know which one
among the springs is the cause to replace it if
you grouped them at disassembly). Also, since
used parts have matched together during the
engine operation, they will keep their matched fit
when you reassemble them together within their
"group".

INSPECTION
LEAK TEST
Before performing the cylinder leak test, verify the
following:
— Clamp(s) tightness
1. Cylinder 1 (front)
2. Cylinder 2 (rear) — Radiator and hoses.
When diagnosing an engine problem, always per- NOTE: For best accuracy, the leak test should be
form a cylinder leak test. done with the engine at normal operating temper-
ature.
Always place the vehicle on level surface.
NOTE: Even though the following procedures do A WARNING
not require the engine removal, many illustrations Prevent burning yourself on hot engine parts.
show the engine out of the vehicle for more clar-
ity. Preparation
Always disconnect BLACK (-) cable from the bat- Disconnect battery.
tery, then RED (+) cable before working on the en-
gine. A WARNING
Even if the removal of many parts is not neces- Always respect this order for disassembly;
sary to reach another part, it is recommended to disconnect BLACK (-) cable first.
remove these parts in order to check them.
During assembly/installation, use the torque val- Remove radiator cap.
ues and service products as in the exploded
views. A WARNING
Clean threads before applying a threadlocker. Re- To prevent burning yourself only remove
fer to SELF LOCKING FASTENERS and LOCTITE
- the radiator cap by wearing the appropriate
APPLICATION at the beginning of this manual for safety equipment.
complete procedure.
Unplug spark plug cable.
A WARNING Clean spark plug area and remove spark plug from
Torque wrench tightening specifications cylinder head.
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pin, etc.) must
be replaced.

96 tmr2011-013
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

7. Dial gauge

1. Spark plug cable NOTE: If a dial gauge is not available, use a screw-
2. Spark plug
driver or another similarly suitable tool.
Remove valve cover.
NOTICE Do not scratch or damage piston/
cylinder surface.
NOTE: At ignition TDC the marks on the camshaft
timing gear have to be parallel to cylinder head
base as per following illustration.

1. Valve cover screws

2. Valve cover

Rotate crankshaft until piston is at ignition TDC.

To turn crankshaft, there are two possible proce-
dures. 1. Marks on camshaft timing gear
2. Cylinder head base
First Procedure
Leak Test
Turn the drive pulley.
Connect to adequate air supply.
Second Procedure
Set needle of measuring gauge to zero.
1. Remove plug screw with 0-ring from magneto
NOTE: All testers have specific instructions on
cover.
gauge operation and required pressure.
2. Use a 14 mm Allen key and turn crankshaft.
Install gauge adapter into previously cleaned spark
NOTICE Turn only clockwise to avoid loosen- plug hole.
ing of magneto flywheel Allen screw. Supply combustion chamber with air pressure.
Using the TDC DIAL INDICATOR (P/N 414 104 700),
turn the crankshaft and set the piston to precisely
ignition TDC.

tmr2011-013 97
Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

NOTE: For all the checkpoints mentioned above,

see the appropriate engine section to diagnose
and repair the engine.

Reassembly
Reverse the preparation procedure. Ensure to
respect torque values and use of appropriate
products/lubricants. Refer to exploded views in
other sections of this manual as required.

PROCEDURES
INTAKE MANIFOLD
Intake Manifold Access
Refer to BODYand remove the lower console.

TYPICAL Intake Manifold Removal

1. Leak tester
2. Air supply hose 1. Disable fuel pump using B.U.D.S. Select the
ECM and Activation tabs, then click on Dis-
Note the amount or percentage of leakage (de-
abled in the fuel pump area.
pending on tester).
LEAKAGE ENGINE 1,44i1XAN

PERCENTAGE CONDITION
0% to 15% Excellent condition
16% to 25% Good condition
Fair condition; reduced
26% to 40%
engine performance
A.consat1 1c.,
Poor condition, diagnose
41% and higher
and repair engine

NOTE: To make sure there is no false reading due

to a valves not perfectly seated, tap each valve ad-
justment screw (on the rocker) using a soft ham- trnr2011-013 016_3

1. Click "Disabled"
mer.
2. Release fuel pressure by running engine until it
Diagnosis runs out of gas.
Listen for air leaks. 3. Disconnect the fuel hoses at the fuel injectors,
Air escaping in intake port/throttle body means refer to ELECTRONIC FUEL INJECTION (EFI).
leaking intake valve(s)
— Air escaping in exhaust port means leaking ex- A CAUTION The fuel hose may still be un-
haust valve(s) der pressure.
Air bubbles in the coolant (radiator) means leak- 4. Disconnect fuel injectors electrical connectors.
ing cylinder head gasket
5. Remove intake plenum adapter.
Air/coolant escaping from cylinder/head means
damaged gasket(s) and/or loosened screws
— Air escaping into crankcase area means exces-
sively worn cylinder and/or broken piston rings
— Air/oil escaping from crankcase means dam-
aged gasket and/or loosened screws (refer to
BOTTOM END subsection).

98 tmr2011-013
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

1. Plenum adapter elbow

2. Plenum elbow to plenum retaining screws
3. Plenum elbow to intake manifold clamps
1. Valve cover screws
2. Valve cover
6. Remove intake manifold to cylinder head retain-
ing screws, then remove intake manifold. Remove valve cover and gasket.
Intake Manifold Inspection
Check intake manifold for cracks, warping at
flanges or any other damage. Replace if neces-
sary.

Intake Manifold Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Tighten intake manifold retaining screws to spec-
ified torque one cylinder at a time.
INTAKE MANIFOLD RETAINING SCREWS
TIGHTENING TORQUE 1. Valve cover
2. Gasket
20 N•rn ± 2.5 N•m (15 lbfeft ± 2 lbf•ft)
Repeat the procedure for the other valve cover if
Enable fuel pump using B.U.D.S. required.

VALVE COVER Valve Cover Inspection

Check the gasket on the valve cover if it is brittle,
Valve Cover Removal
cracked or hard. If so, replace the gasket.
To remove cylinder 1 valve cover, remove plenum.
Remove valve cover screws of valve cover. Valve Cover Installation
For installation, reverse the removal procedure.
Tighten valve cover retaining screws to specified
torque in a criss-cross sequence.
VALVE COVER RETAINING SCREWS
TIGHTENING TORQUE
7 N•m ± 0.8 Nom (62 lbf•in ± 7 lbf•in)

On cylinder 1, install the plenum bracket using the

appropriate mounting holes.

tmr2011-013
99
Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

1. Mounting holes for the 1000 engine

2. Mounting holes for the 80OR engine

ROCKER ARM
Rocker Arm Removal
1. Rocker arm shaft
Remove valve cover. 2. Rocker arm (exhaust side)
3. Rocker arm (intake side)
Place the cylinder at TDC ignition, refer to TIMING 4. Adjustment screw
5. Lock nut
CHAIN subsection.
Remove timing chain tensioner and camshaft tim- Remove rocker arm assembly (exhaust side and
ing gear, refer to TIMING CHAIN subsection. intake side) with adjustment screws and lock
Remove pan head screw and camshaft retaining nuts.
plate. Remove thrust washers.

1. Camshaft retaining plate

2. Pan head screw 1. Rocker arm (exhaust side)
3. Cylinder head 2. Rocker arm (intake side)
3. Thrust washers
Remove rocker arm shafts.
NOTICE Pay attention not to lose thrust
washers or drop them into the timing chain
compartment.

100 tmr2011-013
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END>

1. 2 thrust washers 1. Free movement of adjustment screw top

2. Rocker arm (exhaust side)
3. Cylinder head (spark plug side) Rocker Arm Shaft
4. Big taper to spark plug side
Check for scored friction surfaces; if so, replace
Rocker Arm Inspection parts.
Inspect each rocker arm for cracks and scored fric- Measure rocker arm shaft diameter.
tion surfaces. If so, replace rocker arm assembly.
Check the rocker arm rollers for free movement,
wear and excessive radial play. Replace rocker
arm assembly if necessary.

A. Measure rocker arm shaft diameter here

ROCKER ARM SHAFT DIAMETER

12.00 mm to 12.018 mm
NEW
(.4724 in to .4731 in)
SERVICE LIMIT 11.990 mm (.472 in)

Any area worn excessively will require parts re-

1. Rocker arm (exhaust side)
placement.
2. Roller
A. Bore for rocker arm shaft Rocker Arm Installation
Measure rocker arm bore diameter. If diameter NOTE: Use the same procedure for exhaust and
is out of specification, change the rocker arm as- intake rocker arm.
sembly. Apply engine oil on rocker arm shaft.
ROCKER ARM BORE DIAMETER Install the rocker arm shafts with the chamfered
edge first and use following procedure.
12.036 mm to 12.050 mm
NEW Insert a rocker arm pin through rocker arm pin
(.4739 in to .4744 in)
bore.
SERVICE LIMIT 12.060 mm (.4748 in)
Install a thrust washer at timing chain side, then
Check adjustment screws for free movement, the proper rocker arm (exhaust side or intake
cracks and/or excessive play. side).
Push in rocker arm shaft until its chamfer reaches
the end of rocker arm bore.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

NOTE: Before removing cylinder head, blow out

remaining coolant by air pressure. During cylin-
der head removal, the remaining coolant in cylin-
der head could overflow into the engine and a little
quantity of coolant could drop into the engine. In
this case, the engine oil will be contaminated.
Disconnect spark plug wire.
Disconnect temperature sensor connector, lo-
cated at rear cylinder head.
Remove the intake manifold (see INTAKE MANI-
FOLD in this subsection).
On cylinder 1, remove plenum.
On cylinder 2, remove the shift cable bracket.
Remove the chain tensioner (see CHAIN TEN-
SIONER in the TIMING CHAINsubsection).
Remove the valve cover and its gasket (see VALVE
1. Rocker arm shaft COVER above).
2. Thrust washer (timing chain side)
3. Thrust washer (spark plug side) Remove the camshaft timing gear (see TIMING
CHAIN GEAR in the TIMING CHAIN subsection).
Place the other thrust washer and push rocker
arm shaft to end position. Unscrew cylinder head M6 and M10 screws re-
taining cylinder head and cylinder to cylinder base.
Install the camshaft retaining plate.
Adjust valve clearance, refer to PERIODIC MAIN-
TENANCE PROCEDURE.

CYLINDER HEAD
Cylinder Head Access
Refer to BODYand remove:
— Lower console
— LH and RH lateral console panels.
Remove LH passenger handhold bar.

1. Cylinder head screws MW

2. Cylinder head screws M6

Pull up cylinder head.

Remove timing chain guide (fixed).
Remove and discard the cylinder head gasket.

LH PASSENGER HANDHOLD BAR

Cylinder Head Removal

The removal procedure is the same for both cylin-
der heads.
Drain coolant (refer to COOLING SYSTEM).

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NOTICE Timing chain guide (fixed) has to be

fixed between cylinder and cylinder head.

7. Cylinder head
2. Timing chain
3. Chain guide (fixed) TYPICAL
4. Cylinder head gasket 1. Timing chain guide (tensioner side) mounted in crankcase
2. Timing chain guide (fixed) between cylinder and cylinder head
Cylinder Head Inspection
Install a NEW cylinder head gasket.
Inspect timing chain guide (fixed) for wear, cracks
or other damages. Replace if necessary. NOTICE Cylinder head screws of 800R en-
gine and 1000 engine have different lengths.
Check for cracks between valve seats, if so, re-
place cylinder head.
Check mating surface between cylinder and cylin-
der head for contamination. If so, clean both sur-
faces.
Clean oil support through the cylinder head from
contamination.

800R
1. M10 x 740
2. M6 x 86
7. Oil port to lubricate camshaft lobes intake/exhaust 1000
2. Oil supply to camshaft bearing journal (timing chain side) 1. M10 x 159
3. Oil supply to camshaft bearing journal (spark plug side) 2. M6 x 105

First, torque M10 cylinder head screws in

Cylinder Head Installation criss-cross sequence to 20 N•rn ± 1 N•m
NOTE: Never invert front and rear cylinder heads. (15 lbf•ft ± 1 lbf•ft) then finish by tightening to
On the 800R, cylinder heads are not identical. 180° +/- 5°.
For installation, reverse the removal procedure.
Pay attention to the following details.
Ensure dowel pins are in place.

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Subsection 07 (TOP END)

CYLINDER HEAD TIGHTENING TORQUE

Preliminary 20 N•m ± 11\lsm
torque (15 lbf•ft ± 1 lbf•ft)
Final torque 180° +1- 5°

Install cylinder head M6 screws.

1. Intake cam
2. Exhaust cam
3. Camshaft of cylinder 1
4. Camshaft of cylinder 2
5. Flat spot

Camshaft Removal
The removal procedure is the same for both
camshafts.
1. Cylinder head screws M10
2. Cylinder head screws M6 Each camshaft is different in design. Thus, it is im-
portant not to mix up any parts of the camshaft as-
Check timing chain guide (tensioner side) for sembly with that of the other cylinder. Keep parts
movement. as a group.
Remove crankshaft locking bolt and reinstall plug Remove valve cover (see VALVE COVER in this
screw with sealing ring. subsection).
On cylinder 1, install the plenum bracket using the Remove the chain tensioner (see CHAIN TEN-
appropriate mounting holes. SIONER in the TIMING CHA/N subsection).
Remove the camshaft timing gear (see
CAMSHAFT TIMING GEAR in the TIMING CHAIN
subsection).
Remove the camshaft retaining plate.

1. Mounting holes for the 1000 engine

2. Mounting holes for the 800R engine

CAMSHAFT
NOTE: The engine is equipped with two different
camshafts.
1. Camshaft retaining plate
2. Pan head screw
3. Cylinder head

Remove rocker arms (see ROCKER ARM above).

Remove the camshaft.

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NOTE: For removal rotate camshaft so that 1000

intake/exhaust lobe shows to upper side of cylin-
CAMSHAFT LOBE (EXHAUST)
der head.
32.860 mm to 33.060 mm
NEW
(1.294 in to 1.302 in)
SERVICE LIMIT 32.840 mm (1.293 in)
CAMSHAFT LOBE (INTAKE)
32.960 mm to 33.160 mm
NEW
(1.298 in to 1.306 in)
SERVICE LIMIT 32.940 mm (1.297 in)

CAMSHAFT JOURNAL
(TIMING CHAIN SIDE)
34.959 mm to 34.975 mm
NEW
(1.3763 in to 1.377 in)
SERVICE LIMIT 34.950 mm (1.376 in)
1. Camshaft retaining plate
2. Area for camshaft lobes CAMSHAFT JOURNAL
3 Camshaft (SPARK PLUG SIDE)
21.959 mm to 21.980 mm
Camshaft Inspection NEW (.8645 in to .8654 in)
Check each lobe and bearing journal of camshaft
SERVICE LIMIT 21.950 mm (.8642 in)
for scoring, scuffing, cracks or other signs of wear.
Measure camshaft journal diameter and lobe Measure clearance between both ends of
height using a micrometer. camshaft and cylinder head.

A. Camshaft lobe (exhaust valves)

B. Camshaft lobe (intake valves)
C. Camshaft journal (timing chain side)
D Camshaft journal (spark plug side)

800R A. Camshaft bearing (timing chain side)

B. Camshaft bearing (spark plug side)
CAMSHAFT LOBE (EXHAUST)
32.950 mm to 33.150 mm
NEW
(1.2972 in to 1.3051 in)
SERVICE LIMIT 32.930 mm (1.2965 in)
CAMSHAFT LOBE (INTAKE)
32.890 mm to 33.090 mm
NEW
(1.2949 in to 1.3028 in)
SERVICE LIMIT 32.870 mm (1.2941 in)

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

CAMSHAFT BEARING Compress valve spring using VALVE SPRING COM-

(TIMING CHAIN SIDE) PRESSOR (P/N 529 035 724) and VALVE SPRING
COMPRESSOR CUP (P/N 529 035 764).
35.000 mm to 35.025 mm
NEW
(1.378 in to 1.3789 in)
SERVICE LIMIT 35.040 mm (1.3795 in)
CAMSHAFT BEARING
(SPARK PLUG SIDE)
22.000 mm to 22.021 mm
NEW
(.8661 in to .867 in)
SERVICE LIMIT 22.040 mm (.8677 in)

Replace parts that are not within specifications.

Camshaft Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTICE The camshafts are not identical in
design. Do not invert the camshafts during
assembly. Any mix-up of the components will
A WARNING
Always wear safety glasses when disassem-
lead to engine damage.
bling valve springs. Be careful when unlock-
Place the camshaft retaining plate in the slot of the ing valves. Components could fly away be-
camshaft. cause of the strong spring preload.

1. Direction of movement
2. Camshaft retaining plate LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF
3. Slot retaining camshaft THE VALVE

For other parts, refer to proper installation proce- Remove valve cotters.
dure.

VALVE SPRINGS
Valve Spring Removal
Remove rocker arms (see ROCKER ARM in this
subsection).
Remove cylinder head (see CYLINDER HEAD in
this subsection).

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A. Valve spring length

VALVE SPRING FREE LENGTH

1. Valve spring compressor clamp

NOMINAL NEW 40.81 mm (1.607 in)
2. Valve spring compressor cup
3. Valve cotter SERVICE LIMIT 39.00 mm (1.535 in)

Remove valve spring compressor and withdraw Replace valves springs if not within specifications.
valve spring retainer and valve spring.
Valve Spring Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Colored area of the valve spring must be placed
on top.
To ease installation of cotters, apply oil or grease
on them so that they remain in place while relea-
sing the spring.
NOTE: Valve cotter must be properly engaged in
valve stem grooves.

1. Valve spring retainer

2. Valve spring

Valve Spring Inspection

Check valve spring for visible damage. If so, re-
place valve spring.
Check valve spring for free length and straight-
ness.

1. Position of the valve spring

2. Valve cotter

After spring is installed, ensure it is properly

locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
times.
NOTICE An improperly locked valve spring
will cause engine damage.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

VALVES Valve Inspection

Valve Removal Valve Stem Seal
Remove valve spring, see VALVE SPRING in this Always install new seals whenever valves are re-
subsection. moved.
Push valve stem, then pull valves (intake and ex- Valve
haust) out of valve guide.
Inspect valve surface, check for abnormal stem
wear and bending. If out of specification, replace
by a new one.

VALVE OUT OF ROUND

1. Intake valves 31 mm (INTAKE AND EXHAUST VALVES)
2. Exhaust valves 27 mm
NEW 0.005 mm (.0002 in)
Remove valve stem seal with SNAP-ON PLIERS
(P/N YA 8230) and discard it. SERVICE LIMIT 0.06 mm (.0024 in)

Valve Stem and Valve Guide Clearance

Measure valve stem and valve guide in three
places using a micrometer and a small bore
gauge.
NOTE: Clean valve guide to remove carbon de-
posits before measuring.
Change valve if valve stem is out of specification
or has other damages such as wear or friction sur-
face.

A. Valve stem diameter

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VALVE STEM DIAMETER VALVE SEAT CONTACT WIDTH

EXHAUST VALVE EXHAUST VALVE
4.956 mm to 4.970 mm 1.25 mm to 1.55 mm
NEW NEW
(.1951 in to .1957 in) (.049 in to .061 in)
SERVICE LIMIT 4.930 mm (.1941 in) SERVICE LIMIT 2.00 mm (.079 in)
INTAKE VALVE INTAKE VALVE
4.966 mm to 4.980 mm 1.05 mm to 1.35 mm
NEW NEW
(.1955 in to .1961 in) (.041 in to .053 in)
SERVICE LIMIT 4.930 mm (.1941 in) SERVICE LIMIT 1.80 mm (.071 in)

Replace valve guide out of cylinder head if valve If valve seat contact width is too wide or has dark
guide is out of specification or has other dam- spots, replace the cylinder head.
ages such as wear or friction surface (see VALVE
GUIDE PROCEDURE in this subsection).
VALVE GUIDE DIAMETER (INTAKE AND
EXHAUST VALVES)
4.998 mm to 5.018 mm
NEW
(.1968 in to .1976 in)
SERVICE LIMIT 5.050 mm (.1988 in)

Valve Face and Seat

A. Valve face contact width

B. Valve seat contact width

Valve Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Install a NEW valve stem seal. Make sure thrust
washer is installed before installing seal.
1. Valve seat
2. Exhaust valve contaminated area Apply engine oil on valve stem and install it.
3. Valve face (contact surface to valve seat)
NOTICE Be careful when valve stem is
Check valve face and seat for burning or pittings passed through sealing lips of valve stem
and replace valve or cylinder head if there are seal.
signs of damage.
Ensure to seat valves properly. Apply some lap-
ping compound to valve face and work valve on its
seat with a lapping tool (see VALVE GUIDE PRO-
CEDURE in this subsection).
Measure valve face contact width.
NOTE: The location of contact area should be in
center of valve seat.
Measure valve seat width using a caliper.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

1. Thrust washer
2. Sealing lips of valve stem seal

To ease installation of cotters, apply oil or grease

1. Valve guide remover
on them so that they remain in place while relea- 2. Valve guide
sing the spring.
After spring is installed, ensure it is properly Valve Guide Inspection
locked by tapping on valve stem end with a soft Always replace valve stem seals whenever valve
hammer so that valve opens and closes a few guides are removed.
times. Clean the valve guide bore before reinstalling the
NOTICE An improperly locked valve spring valve guide into cylinder head.
will cause engine damage.
Valve Guide Installation
VALVE GUIDES For installation, reverse the removal procedure.
Pay attention to the following details.
Valve Guide Removal Use the VALVE GUIDE INSTALLER (P/N 529 036 140)
Remove cylinder head (see CYLINDER HEAD in to install valve guide.
this subsection).
Remove valves (see VALVES in this subsection).
NOTE: Clean valve guide area from contamination
before removal.
Using the VALVE GUIDE REMOVER 5 MM (P/N 529
035 924) and a hammer, drive the valve guide out
of cylinder head.

1. Valve guide installer

2. Valve guide

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NOTE: Apply LOCTITE 767 (ANTISEIZE LUBRICANT) CYLINDER

(P/N 293 800 070) on valve guide prior to install it
into the cylinder head. Cylinder Removal
Remove chain tensioner (see CHAIN TENSIONER
NOTICE Push valve guide in the cold cylinder
in the TIMING CHAIN subsection).
head as per following illustration.
Remove the camshaft timing gear (see
CAMSHAFT TIMING GEAR in the TIMING CHAIN
subsection).
Remove the cylinder head (see CYLINDER HEAD
in this subsection).
Pull cylinder.
Discard cylinder base gaskets.

1. Thrust surface of cylinder head

2. Valve guide
A. Measurement from thrust surface to valve guide top

VALVE GUIDE (MEASUREMENT "A")

14.00 mm to 14.40 mm
NEW
(.5512 in to .5669 in)

Apply some lapping compound to valve face and

work valve on its seat with a lapping tool. 1. Cylinder
2. Piston assembly
3. Cylinder base gasket
4. Camshaft timing chain

Cylinder Inspection
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder. If so, re-
place cylinder.
Cylinder Taper
Measure cylinder bore and if it is out of specifica-
tions, replace cylinder and piston rings.
Measure cylinder bore at 3 recommended posi-
tions. See the following illustration.
1. Valve seat
2. Valve face (contact surface to valve seat)
3. Turn valve while pushing against cylinder head
A. Valve seat angle 45°

NOTE: Ensure to seat valves properly. Apply

marking paste to ease checking contact pattern.
Repeat procedure until valve seat/valve face fits
together.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

Cylinder Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTICE Always replace cylinder base gasket
before installing the cylinder.
First mount cylinder 2. Then remove the CRANK-
SHAFT LOCKING BOLT (P/N 529 035 617). Crank
the engine further and position piston 1 at TDC.
Mount cylinder 1. The cylinder can not be pushed
fully over the piston unless the piston is located
1. First measuring of diameter at TDC.
2. Second measuring of diameter
3. Third measuring of diameter Apply engine oil in the bottom area of the cylin-
800R der bore and also on the band of the PISTON RING
A. 5mm (.197in) from cylinder bottom
B. 63mm (2.48in) COMPRESSOR (P/N 529 035 919).
C. 32mm (1.26in)
1000
A. 5mm (.197 in) from cylinder bottom
B. 58mm (2.283 in)
C. 52 mm (2.047 in)

CYLINDER TAPER IN DIAMETER

NEW (maximum) 0.038 mm (.0015 in)
SERVICE LIMIT 0.090 mm (.0035 in)

Distance between measurements should not ex-

ceed the service limit mentioned above.
Cylinder Out of Round
Measure cylinder diameter in piston axis direction
from top of cylinder. Take another measurement
90° from first one and compare.
NOTE: Take the same measuring points like de-
scribed in CYLINDER TAPER above.

A. Perpendicular to crankshaft axis

1. Piston ring compressor tool
B. Parallel to crankshaft axis
2. Piston
3. Cylinder
CYLINDER OUT OF ROUND
NOTE: Put timing chain through the chain pit then
NEW (maximum) 0.015 mm (.0006 in)
put the cylinder in place.
SERVICE LIMIT 0.020 mm (.0008 in)
NOTICE Chain guide has to be fixed between
cylinder and cylinder head.

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NOTE: After both cylinders are installed, turn

crankshaft until piston of cylinder 2 is at TDC and
lock crankshaft. Refer to CRANKSHAFT in the
BOTTOM END subsection.
Install cylinder head and the other parts in accor-
dance with the proper installation procedures.

PISTON
Piston Removal
Remove cylinder head (see CYLINDER HEAD in
this subsection). 1. Piston
2. Piston pin
Remove the cylinder (see CYLINDER in this sub-
section). Detach piston from connecting rod.
Place a rag under piston and in the area of timing
chain compartment. Piston Inspection
Inspect piston for scoring, cracking or other dam-
A WARNING ages. Replace piston and piston rings if neces-
Piston circlips are spring loaded. sary.
Using a micrometer, measure piston at 8 mm
Remove one piston circlip and discard it. (.315 in) perpendicularly (90°) to piston pin.

1. Measuring perpendicularly (90°) to piston pin

A. 8mm (.315in)

The measured dimension should be as described

in the following tables. If not, replace piston.
1. Piston circlip
PISTON MEASUREMENT
NOTE: The removal of both piston circlips is not
necessary to remove piston pin. 90.950 mm to 90.966 mm
NEW
(3.5807 in to 3.5813 in)
Push piston pin out of piston.
SERVICE LIMIT 90.850 mm (3.577 in)

Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston dimen-
sion.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

Read the measurement on the cylinder bore

gauge. The result is the exact piston/cylinder wall
clearance.
PISTON/CYLINDER CLEARANCE
0.027 mm to 0.057 mm
NEW
(.0011 in to .0022 in)
SERVICE LIMIT 0.100 mm (.0039 in)

NOTE: Make sure used piston is not worn.

If clearance exceeds specified tolerance, replace
piston by a new one and measure piston/cylinder
1. Micrometer set to the piston dimension clearance again.
With the micrometer set to the dimension, adjust NOTE: Make sure the cylinder bore gauge indica-
a cylinder bore gauge to the micrometer dimen- tor is set exactly at the same position as with the
sion and set the indicator to 0 (zero). micrometer, otherwise the reading will be false.
Connecting Rod/Piston Pin Clearance
Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other
damages.
Measure piston pin. See the following illustration
for the proper measurement positions.

1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge

A. Piston pin diameter

PISTON PIN DIAMETER

800R
19.996 mm to 20.000 mm
NEW
(.7872 in to .7874 in)
SERVICE LIMIT 19.980 mm (.7866 in)
1000
21.996 mm to 22.000 mm
NEW
(.866 in to .8661 in)
SERVICE LIMIT 21.980 mm (.8654 in)

Replace piston pin if diameter is out of specifica-

TYPICAL tions.
7 Indicator set to 0 (zero)
Measure inside diameter of connecting rod small
Position the dial bore gauge 20 mm (.787 in) above end bushing.
cylinder base, measuring perpendicularly (90°) to
piston pin axis.
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1. Bore gauge
2. Connecting rod

CONNECTING ROD SMALL END DIAMETER

800R
20.010 mm to 20.020 mm
NEW
(.7878 in to .7882 in)
SERVICE LIMIT 20.060 mm (.7898 in) 1. Piston of cylinder 1
2. Mark on piston must show to intake side of cylinder 1
1000 3. Piston of cylinder 2
4. Mark on piston must show to exhaust side of cylinder 2
20.010 mm to 20.020 mm
NEW Use the piston appropriate circlip installer to as-
(.7878 in to .7882 in)
semble the NEW piston circlip as per following
SERVICE LIMIT 20.050 mm (.7894 in)
procedure:
Replace connecting rod if diameter of connecting ENGINE TYPE TOOL
rod small end is out of specifications. Refer to
PISTON CIRCLIP
BOTTOM END subsection for removal procedure. 800R INSTALLER
Compare measurements to obtain the connecting (P/N 529 035 921)
rod/piston pin clearance. PISTON CIRCLIP
CONNECTING ROD/ 1000 INSTALLER
PISTON PIN CLEARANCE (P/N 529 036 153)

SERVICE LIMIT I 0.080 mm (.0031 in)

Piston Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Apply engine oil on the piston pin.
TYPICAL
Insert piston pin into piston and connecting rod.
NOTICE Always replace disassembled piston
For each cylinder, install piston with the punched
arrow on piston dome is pointing toward the rear circlip(s) by new ones. Place a rag on cylinder
side of the engine. base to avoid dropping the circlip inside the en-
gine.
Front cylinder: Mark on top of piston must show
to intake side. Place circlip in sleeve as per following illustration.
Rear cylinder: Mark on top of piston must show
to exhaust side.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

CORRECT POSITION OF THE PISTON CIRCLIP

1. Circlip
2. Sleeve
3. Assembly jig from piston clip installer
PISTON RINGS
Push taper side of assembly jig until circlip
Ring Removal
reaches middle of sleeve.
Remove the piston (see PISTON in this subsec-
Align sleeve with piston pin axis and push assem- tion).
bly jig until circlip engages in piston.
Ring Inspection
Ring/Piston Groove Clearance
Using a feeler gauge measure each ring/piston
groove clearance. If the clearance is too large, the
piston and the piston rings should be replaced.
RING/PISTON GROOVE CLEARANCE
UPPER COMPRESSION RING
0.03 mm to 0.07 mm
NEW
(.0012 in to .0028 in)
SERVICE LIMIT 0.150 mm (.0059 in)
LOWER COMPRESSION RING
1. Hold piston while pushing circlip in place 0.02 mm to 0.06 mm
2. Sleeve NEW
3. Assembly jig (.0008 in to .0024 in)
4. Direction to push circlip
SERVICE LIMIT 0.150 mm (.0059 in)
NOTE: Take care that the hook of the piston circlip OIL SCRAPER RING
is positioned properly.
0.01 mm to 0.18 mm
NEW
(.0004 in to .0071 in)
SERVICE LIMIT 0.250 mm (.0098 in)

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 07 (TOP END)

1. Piston vmr2007-036-009a
2. Feeler gauge
1. Upper compression ring
2. Lower compression ring
Ring End Gap 3. Oil scraper ring

RING END GAP NOTICE Ensure that top and second rings are
UPPER COMPRESSION RING not interchanged.

0.20 mm to 0.40 mm NOTE: Use a ring expander to prevent breakage

NEW
(.008 in to .016 in) during installation. The oil ring must be installed
SERVICE LIMIT 0.60 mm (.024 in) by hand.
Check that rings rotate smoothly after installation.
LOWER COMPRESSION RING
Space the piston ring end gaps 120° apart and do
0.20 mm to 0.40 mm not align the gaps with the piston pin bore or the
NEW
(.008 in to .016 in) .
thrust side axis.
SERVICE LIMIT 0.70 mm (.028 in)
OIL SCRAPER RING
0.20 mm to 0.70 mm
NEW
(.008 in to .028 in)
SERVICE LIMIT 1.00 mm (.039 in)

To measure the ring end gap place the ring

in the cylinder in the area of 8 mm to 16 mm
(5/16 in to 5/8 in) from top of cylinder.
NOTE: In order to correctly position the ring in the
cylinder, use piston as a pusher.
Using a feeler gauge, check ring end gap. Replace
ring if gap exceeds above described specified tol-
erance.

Ring Installation
For installation, reverse the removal procedure. 1. DO NOT align ring gap with piston thrust side axis
2. DO NOT align ring gap with piston pin bore axis
Pay attention to the following details.
A. 120°
NOTE: First install spring and then rings of oil
scraper ring.
Install the oil scraper ring first, then the lower
compression ring with the word "N and TOP "
facing up, then the upper compression ring with
the word "N and TOP" facing up.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 08 (TIMING CHAIN)

TIMING CHAIN
SERVICE TOOLS
Description Part Number Page
CAMSHAFT TIMING TOOL 529 036 201 123-124
CRANKSHAFT TDC POSITION TOOL 529 036 200 126-128

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE) 293 800 060 124

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 08 (TIMING CHAIN)

TIMING CHAIN

4.5 ± 0.5 N•m

(40 -± 4 lbf•in)

0.1 N•rn
10 ± 1 N•rn (0.89 lbf•in)
(89 ± 9 lbf•in) Engine oil
Loctite 243
6 ± 0.7 N•rn
(53 ± 6 lbf•in)
Loctite 243

6 ± 0.7 N•rn
(53 ± 6 lbf•in)
Loctite 243

4.5 ± 0.5 N•m

(40 ± 4 lbf•in)

Engine oil
0.1 N•rn
(0.89 lbf•in)

Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)

Loctite 243
10 ± 1 N•rn
(89 ± 9 lbf•in)

Irnr2011 045-001

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 08 (TIMING CHAIN)

GENERAL PROCEDURES
During assembly/installation, use the torque
values and service products as shown in the ex- TIMING CHAIN TENSIONERS
ploded view(s). Timing Chain Tensioner Location
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE 80013 Engine
APPLICATION in INTRODUCTION section.
A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pin, etc.) must
be replaced.

TROUBLESHOOTING
UNUSUAL ENGINE NOISE OR VIBRATION
1. IMPROPER VALVE CLEARANCE ADJUSTMENT
AND/OR WORN OUT ROCKER ARM(S)
- Readjust valve clearance and/or replace defective
part(s), refer to TOP END subsection.

2. DEFECTIVE CHAIN TENSIONER 800R ENGINE - CYLINDER HEAD (FRONT CYLINDER)

1. Timing chain tensioner
- Replace chain tensioner.
1000 Engine
3. WORN OUT TIMING CHAIN GUIDE(S)
- Replace timing chain guide(s).

4. STRETCHED TIMING CHAIN OR WORN OUT

TIMING GEARS
- Replace timing chain and timing gears.
5. LOOSE TIMING GEAR RETAINING SCREWS
- Retighten screws to recommended torque.

6. INCORRECT CAMSHAFT TIMING

- Replace damaged components and readjust
camshaft timing.

ENGINE LACKS ACCELERATION OR

POWER
1. INCORRECT CAMSHAFT TIMING
- Replace damaged components and readjust 1000 ENGINE - FRONT CYLINDER
camshaft timing. 1. Timing chain tensioner

Timing Chain Tensioner Removal

Make sure the respective cylinder is set to TDC
ignition. Refer to CAMSHAFT TIMING GEARS in
this subsection.
Carefully unscrew chain tensioner plug and re-
lease spring tension.

A CAUTION Tensioner is spring loaded.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 08 (TIMING CHAIN)

Remove 0-ring, spring and chain tensioner Check spring condition. Replace if broken or
plunger. worn.

Timing Chain Tensioner Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
NOTE: Before installing the chain tensioner make
sure, that the camshaft timing gear can be moved
back and forth.

1. Chain tensioner plug

2. 0-ring
3. Spring
4. Chain tensioner plunger

Remove chain tensioner housing retaining

screws.
Remove chain tensioner housing and 0-ring.

MOVE GEAR BACK AND FORTH

Apply engine oil on the plunger before installation.

Slightly turn the camshaft timing gear in order to
get the timing chain play on the tensioner side.
Slightly screw the plunger in until the timing chain
allows no more back and forth movement of the

r
camshaft timing gear.
Screw the plunger in an additional 1/8 turn to
reach the required specified torque.
TIMING CHAIN TENSIONER ADJUSTMENT
(TORQUE)
0.1 N•m (.9 lbfein)

1. Screws NOTICE Improper adjustment of the timing

2. Chain tensioner housing chain will lead to severe engine damage.
3. 0-ring
Fit the spring on one side into the slot of the plug
Timing Chain Tensioner Inspection and on the other side into the plunger.
Check the chain tensioner housing and plug for NOTE: Turn spring only clockwise in order to fit
cracks or other damages. Replace if necessary. the spring end into the notch of the plunger and to
Check chain tensioner plunger for free movement avoid loosening the plunger during spring installa-
and/or scoring. tion. Do not preload the spring.
Check if 0-rings are brittle, cracked or hard. Re- NOTE: Do not forget to place the 0-ring on chain
place if necessary. tensioner plug.
Then compress the spring and screw the plug in.

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Subsection 08 (TIMING CHAIN)

NOTE: To avoid overstressed timing chain, the Clean mating surface and threads of camshaft
plug must engage into threads within the first full prior installing camshaft timing gear.
turn.
Remove locking tool and install all other removed
parts.
Finally, tighten the plug.

CAMSHAFT TIMING GEARS

Camshaft Timing Gear Removal
Remove the valve cover, refer to TOP END sub-
section.
Turn crankshaft to TDC ignition of the respec-
tive cylinder and lock magneto flywheel, see
CAMSHAFT TIMING in this subsection.
Unscrew timing chain tensioner. Refer to TIMING
7. Mating surface on camshaft
CHAIN TENSIONERS in this subsection. 2. Threads for camshaft screws
Remove camshaft timing gear retaining screws.
Crankshaft must be set to TDC ignition posi-
tion before installing the timing chain, refer to
CAMSHAFT TIMING in this subsection.
Install the CAMSHAFT TIMING TOOL (P/N 529 036
201).

1. Camshaft timing gear retaining screws NOTE: Align tube of camshaft adjustment tool
2. Camshaft timing gear
properly with machined radius on cylinder head.
Remove the camshaft timing gear.
NOTE: Secure timing chain with a piece of wire.

Camshaft Timing Gear Inspection

Check camshaft timing gear for wear or deteriora-
tion.
If gear is worn or damaged, replace it as a set
(camshaft timing gear and timing chain).
For crankshaft gear, refer to BOTTOM END sec-
tion, see CRANKSHAFT

Camshaft Timing Gear Installation

For installation, reverse the removal procedure.
Pay attention to the following details.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 08 (TIMING CHAIN)

1. Timing chain
CAMSHAFT TIMING TOOL INSTALLED 2. Camshaft timing gear
1. Tube (camshaft adjustment tool) 3. Printed marks on camshaft timing gear
2. Machined radius (camshaft adjustment too!)
3. Cylinder head
Install and adjust timing chain tensioner, refer to
Set camshaft to TDC ignition position by aligning TIMING CHAIN TENSIONER in this subsection.
the camshaft flange flat spot with the tool lever. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on the
NOTE: In addition, to ensure proper camshaft tim- camshaft timing gear retaining screw threads.
ing, press camshaft adjustment tool lever down- Install and tighten camshaft timing gear retaining
wards. screws to specified torque.

PRESS TOOL LEVER DOWN

1. Lever
2. Flat spot 1. Camshaft timing gear
3. Camshaft 2. Timing gear retaining screws

NOTICE Crankshaft and camshaft must CAMSHAFT TIMING GEAR RETAINING

be locked at TDC ignition position to place SCREWS TIGHTENING TORQUE
camshaft timing gear and timing chain in the 10 Nom ± 1 Nom (891bf•in ± 91bf•in)
proper position.
Remove the CAMSHAFT TIMING TOOL (P/N 529 036
Place camshaft timing gear along with the timing
201).
chain on the camshaft.
NOTE: The printed marks on the camshaft timing Camshaft Timing
gear must be parallel to the cylinder head base. NOTE: If a piston (of cylinder 1 or 2) is set to TDC
ignition, the camshaft timing gear of the opposite
cylinder must be in the following position.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 08 (TIMING CHAIN)

1. CPS
TYPICAL 2. Screw
1. Cylinder head base
2. Marks on timing gear of the opposite cylinder Use a 14 mm Allen key to turn crankshaft until
Camshaft Timing Cylinder 2 (rear) piston 2, rear is at TDC ignition.

Turn crankshaft until piston is at TDC ignition as

follows.
Remove spark plug of both cylinders.
Remove valve covers of both cylinders.
Remove the plug and 0-ring of magneto cover.

1. Allen key 14 mm

When rear piston is at TDC ignition, marks on

magneto flywheel "2" and on the magneto cover
are aligned.

1. Plug
2. 0-ring

Remove the crankshaft position sensor (CPS).

Imr2011-045 125
Section 02 ENGINE, CVT AND GEARBOX
Subsection 08 (TIMING CHAIN)

Make sure to match the crankshaft TDC position

tool teeth with the magneto rotor shape.

CYLINDER 2 AT TDC IGNITION

1. Mark "2" on magneto flywheel
2. Notch on magneto cover
3. Crankshaft position sensor location

At TDC ignition, the printed marks on the

camshaft timing gear have to be parallel to cylin-
der head base.
1. Crankshaft TDC position tool teeth

NOTICE Do not use the CRANKSHAFT TDC PO-

SITION TOOL (P/N 529 036 200) to remove or in-
stall drive pulley or magneto retaining screws.

TYPICAL
1. Printed marks on camshaft timing gear
2. Cylinder head base

To lock crankshaft at TDC ignition, proceed as fol- MAGNETO COVER

lows. 1. Crankshaft position sensor bore

Insert CRANKSHAFT TDC POSITION TOOL (P/N 529 NOTICE Tool must be inserted fully.
036 200) in CPS orifice to lock crankshaft in posi-
tion.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection08 (TIMING CHAIN)

1. Magneto cover
2. Tool

Camshaft Timing Cylinder 1 (front)

Turn cylinder 2 (rear) to TDC ignition, see
CYLINDER 1 AT TDC IGNITION
CAMSHAFT TIMING CYLINDER 2 (REAR) in 1. Mark "1" on magneto flywheel
this subsection. 2. Notch on magneto cover
3. Location of crankshaft position sensor
NOTE: Do not lock crankshaft yet.
NOTE: At TDC ignition, the printed marks on the
Using a 14 mm Allen key, turn crankshaft 280°
camshaft timing gear have to be parallel to cylin-
counterclockwise, until marks on magneto fly-
der head base as per following illustration.
wheel "1" and magneto cover are aligned.

TURN CRANKSHAFT 280° COUNTERCLOCKWISE

1. Allen key 14 mm

TYPICAL
1. Printed marks on camshaft timing gear
2. Cylinder head base

Insert the CRANKSHAFT TDC POSITION TOOL

(P/N 529 036 200) in CPS orifice to lock crankshaft
in position.

tm2011-045
127
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 08 (TIMING CHAIN)

Make sure to match the crankshaft TDC position TIMING CHAIN

tool teeth with the magneto rotor shape.
The engine is equipped with two timing chains.
One of the timing chain is located on engine MAG
side behind the magneto cover. The second tim-
ing chain is located on engine PTO side behind the
PTO cover.

Timing Chain Removal (Magneto Side)

Refer to MAGNETO SYSTEM subsection and re-
move following parts:
— Magneto cover
— Rotor
— Sprag clutch gear.
1. Crankshaft TDC position tool teeth
Refer to TOP END subsection and remove follow-
NOTICE Do not use the CRANKSHAFT TDC PO- ing parts:
SITION TOOL (P/N 529 036 200)to remove or in- — Valve cover.
stall drive pulley or magneto retaining screws.
Refer to following procedures in this subsection
and remove following parts:
— Chain tensioner
— Camshaft timing gear.
Remove timing chain guide (tensioner side) and
lower timing chain guide.

1. Crankshaft TDC position tool

NOTICE Tool must be fully inserted.

1. Timing chain
2. Lower timing chain guide
3. Timing chain guide (tensioner side)

NOTE: Mark the operating direction of the timing

chain before removal.
Carefully pull the timing chain downwards and
sideways, then out of the crankcase.

Timing Chain Removal (PTO Side)

Refer to BOTTOM END subsection and remove
1. Magneto cover following parts:
2. Tool
— PTO cover
— Breather gear
— Intermediate gear.

128 tmr2011-045
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 08 (TIMING CHAIN)

Refer to TOP END subsection and remove follow-

ing parts:
— Valve cover.
Refer to following procedures in this subsection
and remove following parts:
— Chain tensioner
— Camshaft timing gear.
Remove timing chain guide (tensioner side) and
lower timing chain guide.

CHECKING TIMING CHAIN RADIAL PLAY

Check chain condition for wear and teeth condi-

tion.

1. Timing chain
2. Lower timing chain guide
3. Timing chain guide (tensioner side)
1. Timing chain
Carefully pull the timing chain sideward and down
from the crankcase. If chain is excessively worn or damaged, replace
NOTE: Mark the operating direction of the timing it as a set (camshaft timing gear and timing chain).
chain before removal. Check timing chain guides for wear, cracks or de-
forming. Replace as required.
Timing Chain Inspection
NOTE: Check also the timing chain guide (ten-
Inspection is the same for both timing chains. sioner side).
Check timing chain on camshaft timing gear for
excessive radial play. Timing Chain Installation
The installation is essentially the reverse of the re-
moval procedure, but pay attention to the follow-
ing details.
NOTE: Installation is the same for both timing
chains.
TIMING CHAIN GUIDE BEARING SCREW
TIGHTENING TORQUE
10 Nom ± 1 Nom (89 lbfoin ± 9 lbfoin)

Install timing chain with camshaft timing gear.

NOTE: Ensure to carry out proper valve timing, re-
fer to CAMSHAFT TIMING GEARSin this subsec-
tion.
NOTICE Improper valve timing will damage
engine components.

tmr2011-045 129
Section 02 ENGINE, CVT AND GEARBOX
Subsection 08 (TIMING CHAIN)

TIMING CHAIN GUIDE

(TENSIONER SIDE)

1. Timing chain guide densioner side)

2 Bearing screw

Timing Chain Guide Removal

(Tensioner Side)
Refer to TIMING CHAINin this subsection.

Timing Chain Guide Inspection

(Tensioner Side)
Check timing chain guide for wear, cracks or de-
forming. Replace if necessary.

Timing Chain Guide Installation

(Tensioner Side)
The installation is the reverse of the removal pro-
cedure.
TIMING CHAIN GUIDE BEARING SCREW
TIGHTENING TORQUE
10 Nom ± 1 Nom (89 lbf *in ± 9 lbf *in)

130 tmr2011-045
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

BOTTOM END
SERVICE TOOLS
Description Part Number Page
CRANKCASE SUPPORT MAG/PTO 529 036 031 144
CRANKSHAFT LOCKING BOLT 529 035 617 146
DRIVE SHAFT OIL SEAL INSTALLER 529 036 028 135
DRIVE SHAFT OIL SEAL PROTECTOR 529 036 029 137
PLAIN BEARING REMOVER/INSTALLER 529 036 032 139
PLAIN BEARING REMOVER/INSTALLER 529 035 917 143-144
PTO COVER OIL SEAL INSTALLER 529 036 033 137

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 5910 293 800 081 136
LOCTITE CHISEL (GASKET REMOVER) 413 708 500 136

tmr2011-014 131
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

ENGINE DRIVE SHAFT

Engine oil
4
10 ± 1 N•m
(89 ± 9 lbf•in)

Loctite 767
(antiseize lubricant)

4
Super Lube
grease

4
Loctite
5910

Loctite
5910

10 ± 1 N•m 6
(89 ± 9 lbf•in)

4
Super Lube
grease

trnr2011-014-001a

132 tmr2011-014
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

CRANKCASE AND PTO COVER

Engine oil

25 ± 3 Nl•rn
(18 ± 8 lb•ft)

10 ± 1 N•rrl Super
(89 ± 9 lbf•ri) Lube
grease
5 ± 0.6 N•rn
(44 ± 5 lbf•in)

Engine
25 ± 3 Nl•rn oil
(18 ± 8 lbf-ft)
0J
0 Engine
oil

10 ± 1 NI•rn
(89 ± 9 lbf•in)
12 ± 1 Nl•rn
(106 ± 9 lbf•in)
Engine oil Loctite 243

Super Lube
grease

10 1 NI•rri
(89 ± 9 lbf•in)

tmr2011-014 133
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

CRANKSHAFT

10 ± 1 N•rn
(89 ± 9 Ilpf•in)

Loctite 243

Engine oil

See torquing
procedure inside

Engine
oil
See torquing
procedure
inside

Engine oil
Engine oil

(1141111110 ± 1 11•rn
(89 ± 9 lbf•in)
*it
Loctite 243

11-m2011-014 003a

134
tmr2011-014
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

GENERAL
During assembly/installation, use the torque
values and service products as shown in the ex-
ploded view(s).
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION in INTRODUCTION section.
A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc.) must be replaced with new ones where REAR OF ENGINE (GEARBOX REMOVED)
1. Electric starter
specified. 2. Drive shaft
3. Oil seal gearbox side

PROCEDURES Use the DRIVE SHAFT OIL SEAL INSTALLER (P/N 529
036 028) to install drive shaft oil seals.
ENGINE DRIVE SHAFT
NOTE: The engine drive shaft transmits the
power from the gearbox to the front differential
and is located inside the crankcase.

Oil Seal Replacement (Engine Drive

Shaft)
Remove the engine, Refer to ENGINE REMOVAL
AND INSTALLATIONsubsection.
To remove the rear oil seal, the gearbox has to Engine Drive Shaft Removal
be removed from the engine, Refer to GEARBOX
AND 4X4 COUPLING UN/Tsubsection. Remove the engine. Refer to ENGINE REMOVAL
AND INSTALLATION subsection.
To replace drive shaft oil seals, the bearing cover
has to be removed. For bearing cover removal At rear of engine, remove the bearing cover and
and installation refer to ENGINE DRIVE SHAFT its 0-ring.
REMOVAL/INSTALLATION in this subsection.

1. Bearing cover screws

2. 0-ring
3. Bearing cover gearbox side
FRONT OF ENGINE
1. Water pump cover
2. Oil seal front side Remove the bearing cover at the front of the en-
3. Oil cooler gine.
4. Drive shaft

tmr201 1-014 135

Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

NOTICE Check ends of the circlip for sharp

edges or burr before removing the drive shaft,
to avoid damaging the oil seal.

1. Bearing cover
2. Drive shaft bearing

Check drive shaft for cracks, bend, pitting or other

visible damages.
1. Bearing cover front drive side
2. Circlip Check drive shaft splines for wear or damages.
3. Drive shaft
Check oil seal running surface of the drive shaft
Split crankcase, refer to CRANKCASE in this sub- for scratches. Replace if necessary.
section.
Engine Drive Shaft Installation
Remove engine drive shaft from the crankcase.
The installation is the reverse of removal proce-
dure. Pay attention to the following details.
Clean all metal components in solvent.
Crankcase surfaces and bearing covers are best
cleaned using a combination of LOCTITE CHISEL
(GASKET REMOVER) (P/N 413 708 500) and a brass
brush. Brush a first pass in one direction then
make the final brushing perpendicularly (90°) to
the first pass.
NOTICE Do not wipe with rags. Use a new
clean hand towel only.
Use a suitable installer for installing bearings.
1. Crankcase MAG side
2. Engine drive shaft Use LOCTITE 5910 (P/N 293 800 081) on mating sur-
faces.
Engine Drive Shaft Inspection IMPORTANT: When beginning the application of
Replace oil seals and/or 0-ring (bearing cover the bearing cover sealant, the assembly and the
gearbox side) if they are brittle, hard or damaged. first torquing should be done within 10 minutes.
Check drive shaft bearings for contamination It is suggested to have all you need on hand to
and/or metal shavings. Check if bearings turn save time.
freely and smoothly. Replace if necessary. Use a plexiglass plate and apply some sealant
on it. Use a soft rubber roller 50 mm - 75 mm
(2 in - 3 in), available in arts products suppliers for
printing, and roll the sealant to get a thin uniform
coat on the plate (spread as necessary). When
ready, apply the sealant on bearing cover sur-
faces.

136 tmr2011-014
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

Finally check for axial play of the drive shaft.

PTO COVER OIL SEAL

To replace oil seal it is not necessary to remove
engine from vehicle.

PTO Oil Seal Removal

Refer to CONTINUOUSLY VARIABLE TRANSMIS-
SION (CVT) subsection to remove the following
parts:
— CVT cover
— Drive pulley
— Driven pulley
— CVT air guide
Remove oil seal with a small flat screwdriver.
Do not apply in excess as it will spread out inside
crankcase. NOTICE Avoid scoring surfaces with tool.
NOTE: It is recommended to apply this specific
sealant as described here to get a uniform appli-
cation without lumps. If you do not use the roller
method, you may use your finger to uniformly dis-
tribute the sealant (using a finger will not affect
the adhesion).
To install bearing cover at gearbox side, fit DRIVE
SHAFT OIL SEAL PROTECTOR (P/N 529 036 029) into
oil seal.

1. PTO cover
2. Oil seal

PTO Oil Seal Inspection

Check oil seal running surface of crankshaft PTO
side for grooves. Replace if necessary.

PTO Oil Seal Installation

The installation is the reverse of the removal pro-
cedure.
Pay attention to the following details.
NOTICE Oil seal must be installed with seal-
ing lip toward the engine.
Push oil seal in place by using the PTO COVER OIL
SEAL INSTALLER (P/N 529 036 033).

1. Drive shaft
2. Bearing cover gearbox side
3. 0-ring
4. Protection sleeve

tmr2011-014 137
Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

OIL SEAL INSTALLER

1. PTO cover
2. PTO cover screws
3. Vent hose nipple
1. PTO cover
2. Oil seal installer PTO Cover Inspection
3. Oil seal
Check the PTO cover for cracks or other damage.
PTO COVER Replace PTO cover if damaged.
PTO Cover Removal Clean oil breather bore in PTO cover from contam-
inations with part cleaner then use pressurized air
Refer to CONTINUOUSLY VARIABLE TRANSMIS- to dry it.
SION (CVT) subsection to remove the following
parts: A WARNING
— CVT cover Always wear skin and eye protection. Chem-
— Drive pulley icals can cause skin rash, skin burns and se-
— Driven pulley vere eye injury.
— CVT air guide.
Disconnect vent hose. Check surface of sealing sleeve for wear or other
damages. Replace PTO cover if damaged.
Remove PTO cover screws and pull PTO cover.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

PLAIN BEARING REMOVER/INSTALLER — PTO COVER

The PTO cover has to be supported from below

1. Oil breather bore
2. Surface of sealing sleeve with suitable support with straight surface, in or-
der to prevent damage of the sealing surface.
Check plain bearings for scorings or other dam-
ages.
NOTE: Measure plain bearing inside diameter
(PTO cover) and compare to crankshaft journal
diameter (PTO cover bearing). Refer to CRANK-
SHAFT in this section. Replace if the measure-
ment is out of specification.

7. PTO cover
2. Plain bearing remover/installer

Plain Bearing Installation

7. Plain bearing
2. Oil bore NOTE: Do not lubricate plain bearings and/or PTO
A. Measure plain bearing inside diameter
cover for installation.
PLAIN BEARING INSIDE DIAMETER Install plain bearings with the proper PLAIN BEAR-
(PTO COVER) ING REMOVER/INSTALLER (P/N 529 036 032) in a
SERVICE LIMIT cool PTO cover.
I 34.120 mm (1.3433 in)
NOTICE Mark position of oil bore on PTO
Plain Bearing Replacement (PTO cover and on plain bearing remover/installer.
Cover) Align mark on plain bearing remover/installer
with mark on PTO cover.
Plain Bearing Removal
NOTICE Unless otherwise instructed, never
use a hammer to install plain bearings. Use a
press only.

Carefully remove the PTO oil seal with a screw-

driver, without damaging the PTO cover.
Push-out the plain bearings from the outside
towards the inside using the PLAIN BEARING RE-
MOVER/INSTALLER (P/N 529 036 032).

tmr2011-014 139
Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

1. Mark position of oil bore on PTO cover

2. Mark position of oil bore on plain bearing remover/installer

Carefully press-in the plain bearings in the same

direction as during disassembly, from the outside
towards the inside. Support PTO cover with suit-
able support with straight surface, in order to pre-
vent damage of the sealing surface.
TIGHTENING SEQUENCE
NOTE: Wrong oil bore position will stop oil supply
to plain bearings and will damage the engine.
DRIVE GEARS
NOTICE The partition of the plain bearings The drive gears are located on the engine PTO
must be positioned near to oil bore in counter- side behind the PTO cover.
clockwise direction.

1. Partition
2. PTO cover (inside) I. Breather gear
3. Oil bore 2. Intermediate gear
3. Water pump drive gear
4. Oil pump drive gear
PTO Cover Installation
For installation, reverse the removal procedure. Drive Gear Removal
Pay attention to the following details. Remove PTO cover (refer to PTO COVER).
NOTE: At installation, replace PTO cover gasket Withdraw intermediate gear and breather gear.
and oil seal.
For oil pump drive gear removal, refer to OIL
Tighten PTO cover screws following the illustrated PUMP in LUBRICATION SYSTEM.
sequence.

140 tmr2011-014
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

To remove water pump gear, pull the shaft assem-

bly a bit out and turn it about one teeth until it
stays out.
Then push water pump gear in.

1. Breather gear
2. Oil seal

Inspect gear for wear or other damage.

Check ball bearing for excessive play and smooth
operation. Replace breather gear assembly if nec-
essary.
1. Water pump drive gear Drive Gear Installation
2. Intermediate shaft
Step 1: Push gear in The installation is essentially the reverse of the re-
moval procedure.
Remove needle pin and pull water pump gear out.
Adequately oil the ball bearing of the breather
Remove thrust washer from intermediate shaft. gear.

CRANKCASE
Crankcase Disassembly
1. Refer to PERIODIC MAINTENANCE PROCE-
DURES subsection and:
1.1 Drain cooling system.
1.2 Drain engine oil.
1.3. Drain gearbox oil.
2. Lock crankshaft. Refer to CRANKSHAFT
LOCKING PROCEDURE in the this section.
3. Refer to CONTINUOUSLY VARIABLE TRANS-
1. Thrust washer MISSION (CVT) section to remove following
2. Water pump drive gear
3. Needle pin parts:
— CVT cover
Drive Gears Inspection — Drive pulley
Intermediate Gear/Oil Pump Drive Gear/Water — Driven pulley
Pump Drive Gear — CVT air guide.
Inspect gears for wear or other damage. Replace 4. Remove engine from vehicle. Refer to ENGINE
if damaged. REMOVAL AND INSTALLATION section.
Breather Gear 5. Detach gearbox from engine. Refer to GEAR-
BOX AND 4X4 COUPLING UNIT
The engine is equipped with a breather gear
which prevents engine oil coming out through 6. Refer to MAGNETO SYSTEM section to re-
the breathing system into the air intake system. move the following parts:
— Magneto cover
Check if oil seal is brittle, hard or damaged. Re-
place if necessary.

tmr2011-014 141
Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

— Rotor with sprag clutch gear

— Starter drive gears.
7. Refer to following procedures in this subsection
to remove the following parts:
— PTO cover
— Drive gears
— Bearing covers of engine drive shaft.
8. Refer to TIMING CHAIN section to remove fol-
lowing parts:
— Chain tensioners
— Camshaft timing gears
— Timing chains
— Timing chain guides.
9. Refer to TOP END section to remove following 1. Four screws M8 x 65
parts: 2. 13 screws M6 x 75
3. Two screws M6 x 25
— Front cylinder head
— Rear cylinder head Carefully split crankcase halves by using a screw-
driver and a soft hammer.
— Cylinders.
10. Refer to COOLING SYSTEM section to re-
move following parts:
— Water pump housing.
11. Refer to LUBRICATION SYSTEMsection to re-
move following parts:
— Oil filter
— Oil cooler
— Oil pump drive gear.
NOTE: Oil pump removal from crankcase is not
necessary, but recommended to see condition
of oil pump (refer to LUBRICATION SYSTEM
section).
12. Remove electric starter.
NOTE: During disassembly, do not damage the
sealing surfaces of the crankcase halves.
Pull crankshaft out of crankcase.
Remove the water pump intermediate shaft and
the water pump gear.

1. Electric starter
2. Screw

NOTE: Before splitting the crankcase, measure

crankshaft axial play. Refer to CRANKSHAFT.
Remove retaining screws of crankcase.

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1. Plain bearing

NOTE: Measure plain bearing inside diameter and

compare to PTO/MAG main journal diameters of
1. Water pump intermediate shaft
2. Water pump gear
crankshaft (refer to CRANKSHAFT). Replace if the
measurements are out of specification.
Remove engine oil strainer.

1. Engine oil strainer

2. Retaining plate
3. Screws
1. Plain bearing
Crankcase Cleaning 2. Oil bore
A. Measure plain bearing inside diameter
A WARNING MAIN BEARING INSIDE DIAMETER (PTO/MAG)
Use safety goggles to avoid eye injuries.
SERVICE LIMIT I 42.100 mm (1.6575 in)
Clean crankcase using a part cleaner.
Plain Bearing Replacement (Main)
Dry crankcase using compressed air.
Blow the oil supply lines. Plain Bearing Removal

Oil Strainer NOTICE Always support crankcase halves

properly when plain bearings are removed.
Clean the engine oil strainer (same procedure as
Damages to crankcase halves may occur if this
for the crankcase).
procedure is not performed correctly.
Crankcase Inspection NOTE: Always use a press for removal of plain
Check crankcase halves for cracks or other dam- bearings.
age. Replace if damaged. Remove plain bearings with the PLAIN BEARING
Check main bearings in MAG and PTO crankcase REMOVER/INSTALLER (P/N 529 035 917).
half for scorings or other damages.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

Install plain bearings with the proper PLAIN BEAR-

ING REMOVER/INSTALLER (P/N 529 035 917) in a
cool crankcase. Do not lubricate plain bearings
and/or crankcase for installation.
NOTE: Place the proper crankcase support sleeve
under crankcase halves before installing the plain
bearings (refer to BEARING REMOVAL PROCE-
DURE).
PLAIN BEARING REMOVER/INSTALLER (P/N 529 035 917) Carefully press in the plain bearings in the same di-
rection as during disassembly, from the crankcase
Carefully push the plain bearings out, from the
inside towards the outside.
crankcase half inside towards the outside.
During reassembly, make sure not to damage the
NOTE: Place the proper CRANKCASE SUPPORT
sealing surfaces of the crankcase halves.
MAG/PTO (P/N 529 036 031) under crankcase halves
before removing plain bearings. NOTE: Use an 0-ring (0 42 x 1 mm to 1.5 mm
(.04 in to .06 in) thickness) to hold plain bear-
ings in place during installation. The 0-ring will
disappear in the groove of the plain bearing re-
mover/installer.
NOTICE Mark position of plain bearing oil
bore on plain bearing remover/installer.
NOTICE Mark position of oil bore on
crankcase half. Align mark on plain bear-
CRANKCASE SUPPORT SLEEVE (P/N 529 036 031) ing remover/installer with mark on crankcase
half.
NOTE: During disassembly, make sure not to
damage the sealing surfaces of the crankcase
halves.

3 1. Oil bore position marked on plain bearing remover/installer

2. Plain bearing oil bore
3. Oil bore position marked on crankcase
tmr2011 014-02i., a

PUSH PLAIN BEARINGS OUTSIDE NOTE: Wrong oil bore position will stop oil supply
1. Crankcase half to plain bearings and will cause engine damage.
2. Plain bearing remover/installer
3. Crankcase support sleeve (P/N 529 036 031)
NOTICE The partition of the plain bearings in
Plain Bearing Installation (Main) crankcase half MAG side must be positioned
near to oil bore in clockwise direction.
NOTICE Unless otherwise instructed, never
use hammer to install plain bearings. Use
press only.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

Tightening sequence for screws on crankcase is

as per following illustration.

1. Crankcase half MAG (inside surface)

2. Partition
3. Oil bore

NOTICE The partition of the plain bearings

in crankcase half PTO side must be positioned
near to oil bore in counterclockwise direction. TIGHTENING SEQUENCE

CRANKSHAFT

1. Partition
2. Oil bore
3. Crankcase half PTO (inside)

Crankcase Assembly
1. Crankcase MAG
The assembly of crankcase is essentially the re- 2. Crankshaft
verse of removal procedure. However, pay atten-
tion to the following details. Crankshaft Locking Procedure
Clean oil passages and make sure they are not NOTE: When crankshaft is locked, the rear piston
clogged. (cylinder 2, rear) is at TDC. Crankshaft can not be
Clean all metal components in a solvent. locked at cylinder 1 (front) TDC.
Install a new crankcase gasket. NOTICE To see if the rear piston (cylinder
Oil the plain bearings before mounting the crank- 2, rear) is at TDC ignition refer to CAMSHAFT
shaft. TIMING GEAR in the TIMING CHAIN section.

NOTICE Correctly reinstall crankshaft (refer Remove:

to CRANKSHAFT). 1. spark plug cables and spark plugs of both cylin-
ders
Properly reinstall engine oil strainer and screws.
2. plug screw and 0-ring of magneto cover
Reinstall water pump shaft shafts/gears (refer to
COOLING SYSTEM section).

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

1. Plug screw
2. 0-ring 1. Allen key 14 mm

3. crankshaft position sensor When rear piston is at TDC marks on magneto fly-
wheel "2" and on the magneto cover are aligned.

1. Crankshaft position sensor

2. Screw

4. plug screw with sealing ring.

1. Mark "2" on magneto flywheel
2. Notch on magneto cover
3. Crankshaft position sensor location

Use a screwdriver to check if the groove in the

crankshaft is aligned with the hole.

1. Sealing ring
2. Plug screw
3. Crankcase PTO side, front side

Use a 14 mm Allen key to turn crankshaft until

piston 2, rear is at TDC.
1. Screwdriver

Lock crankshaft with CRANKSHAFT LOCKING BOLT

(P/N 529 035 617).

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Crankshaft Axial Play

NOTE: Axial play needs to be measured before
splitting the crankcase.
Measure play on PTO end, using a dial indicator.
CRANKSHAFT AXIAL PLAY
0.200 mm to 0.500 mm
NEW
(.008 in to .02 in)
SERVICE LIMIT 0.6 mm (.024 in)

If play is out of specification, replace crankcase

and/or crankshaft.
Connecting Rod Big End Axial Play
Using a feeler gauge, measure distance between
butting face of connecting rods and crankshaft
counterweight. If the distance exceeds specified
7. Crankshaft locking bolt tolerance, replace the crankshaft.

Gradually insert the tool in the crankshaft groove.

Make sure that the tool tip enters the groove and
does not jam on the crankshaft balancer surface.

Crankshaft Removal
Refer to CRANKCASE

Crankshaft Inspection
NOTE: Check each bearing journal of crankshaft
for scoring, scuffing, cracks or other signs of wear.
NOTE: Replace crankshaft if the gears are worn
or otherwise damaged.
NOTICE Components out of specifications
always have to be replaced. If this is not ob-
served, severe damage may be caused to the
engine.

1. Crankshaft
2. Connecting rods
3. Feeler gauge

CONNECTING ROD BIG END AXIAL PLAY

800R Engine
0.200 mm to 0.500 mm
NEW
(.008 in to .02 in)
SERVICE LIMIT 0.6 mm (.024 in)
1000 Engine
0.25 mm to 0.55 mm
1. Crankshaft timing gears
NEW
(.01 in to .022 in)

SERVICE LIMIT 0.6 mm (.024 in)

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

Connecting Rod/Piston Pin Clearance Carry out the tightening procedure described in
Refer to TOP END section. CRANKSHAFT ASSEMBL Yin this subsection.

Connecting Rod Big End Radial Play

NOTE: Prior to remove connecting rod from the
crankshaft, mark big end halves together to en-
sure a correct reinstallation (cracked surface fits
in only one position).
Remove connecting rods from crankshaft.
NOTICE Connecting rod screws are not
reusable. Always discard screws and replace
by new ones. It is recommended to install new A. Connecting rod big end plain bearing
plain bearings when reinstalling connecting
rods. BOOR Engine
CRANKSHAFT PIN DIAMETER
40.009 mm to 40.025 mm
NEW
(1.5752 in to 1.5758in)
SERVICE LIMIT 39.990 mm (1.5744 in)
CONNECTING ROD BIG END DIAMETER
SERVICE LIMIT I 40.100 mm (1.5787 in)
CONNECTING ROD BIG END RADIAL
1. Connecting rod screws CLEARANCE

Measure crankpin. Compare to inside diameter of SERVICE LIMIT I 0.09 mm (.0035 in)
connecting rod big end. 1000 Engine
CRANKSHAFT PIN DIAMETER
41.986 mm to 42.010 mm
NEW
(1.653 in to 1.6539 in)
SERVICE LIMIT 41.967 mm (1.6522 in)
CONNECTING ROD BIG END DIAMETER
SERVICE LIMIT I 42.100 mm (1.6575 in)
CONNECTING ROD BIG END RADIAL
CLEARANCE
SERVICE LIMIT 1 0.09 mm (.0035 in)

If crankshaft pin diameter is out of specification,

replace crankshaft.
If connecting rod big end diameter or radial clear-
ance is out of specification, replace plain bearings
and recheck.

Crankshaft Radial Play MAG/PTO Side

1. Micrometer
2. Crankpin area for plain bearing Measure crankshaft on MAG/PTO side. Compare
to inside diameter of MAG/PTO plain bearing (re-
To measure the connecting rod big end diameter, fer to CRANKCASE).
use the OLD connecting rod screws.
Install the OLD plain bearings as they were
mounted initially.

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 Section 02 ENGINE, CVT AND GEARBOX
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Crankshaft Radial Play

(PTO Cover Bearing)
Measure crankshaft journal diameter (PTO cover
bearing). Compare to plain bearing inside diame-
ter (PTO cover). Refer to PTO COVER in this sub-
section.

1. Micrometer
2. Crankshaft area for MAG plain bearing

1. Micrometer
2. Crankshaft journal (PTO support bearing)

CRANKSHAFT JOURNAL DIAMETER

(PTO COVER BEARING)
34.016 mm to 34.040 mm
NEW
(1.339 in to 1.34 in)
SERVICE LIMIT 34.010 mm (1.339 in)

CRANKSHAFT RADIAL PLAY

(PTO COVER BEARING)
1. Micrometer
2. Crankshaft area for PTO plain bearing SERVICE LIMIT 0.10 mm (.0039 in)

CRANKSHAFT MAIN BEARING JOURNAL If crankshaft journal diameter is out of specifica-

DIAMETER (MAG/PTO SIDE) tion, replace crankshaft.
42.016 mm to 42.040 mm If crankshaft radial play (PTO cover bearing) out of
NEW
(1.6542 in to 1.6551 in) specification, replace plain bearings and recheck.
SERVICE LIMIT 42.000 mm (1.6535 in)
Crankshaft Assembly
CRANKSHAFT RADIAL PLAY (MAG/PTO SIDE) For assembly, reverse the disassembly proce-
dure. Pay attention to following details.
SERVICE LIMIT 0.07 mm (.0028 in)
Put plain bearings correctly in place and clean the
split surface on both sides (cracked area) carefully
with compressed air.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

1. Half plain bearing of connecting rod big end

2. Split surface of the connecting rod
3. Nose of plain bearing in line with connecting rod groove

NOTE: Oil the plain bearing surface of the con-

necting rod and crank pin before installation.
Oil NEW connecting rod screws.
Thread screws in the connecting rods, then 1. Angle torque wrench
tighten as per following procedure.
NOTICE Failure to strictly follow this proce-
NOTICE Always use NEW connecting rod dure may cause screw to loosen and lead to se-
screws at final assembly. They are not vere engine damage.
reusable.
NOTE: The running direction of the big end bear-
800R Engine: ings and of the piston pins must not change.
Tighten screws in the following sequence:
1000 Engine:
CONNECTING RODS SCREWS TIGHTENING
SEQUENCE NOTICE Connecting rods are asymmetric.
There must be no gap between the small ends
1. Tighten to 1/2 of specified torque when they face each other.
Tighten to 20 N•rn ± 2 Nom
2.
(15 lbf•ft ± 1 lbf•ft)
Torque by an additional 60 ± 5° turn using
3.
an angle torque wrench

NOTE: Do not apply any thread locker.

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Subsection 09 (BOTTOM END)

1. Connecting rod small ends

2. Connecting rod offset
3. Connecting rod screws

Tighten screws in the following sequence:

CONNECTING RODS SCREWS TIGHTENING
SEQUENCE
1. Tighten to 1/2 of specified torque 1. Angle torque wrench

Tighten to 30 Nom ± 2 Nom NOTICE Failure to strictly follow this proce-

2.
(22 lbf•ft ± 1 lbf•ft) dure may cause screw to loosen and lead to se-
Torque by an additional 90 ± 5° turn using vere engine damage.
3.
an angle torque wrench
Crankshaft Installation
NOTE: Do not apply any thread locker. For installation of crankshaft in crankcase reverse
the removal procedure. Pay attention to the fol-
lowing details.
Do not mix up the connecting rods of cylinders 1
and 2 during installation.
NOTICE Observe the correct installation po-
sition when fitting the crankshaft with the
connecting rods. The connecting rod MAG
side has to face cylinder 1.

tmr2011-014 151
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 09 (BOTTOM END)

1. Crankcase half MAG side

2. Connecting rod cylinder 1
3. Connecting rod cylinder 2

152
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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)
SERVICE TOOLS
Description Part Number Page
CLUTCH PULLER 529 035 746 159
DRIVE PULLEY HOLDER (CVT) 529 006 400 158
DRIVEN CLUTCH HOLDER 529 035 771 166
GEAR LOCK PIN 529 035 747 157

SERVICE PRODUCTS
Description Part Number Page
ISOFLEX GREASE TOPAS NB 52 293 550 021 164
PULLEY FLANGE CLEANER 413 711 809 161, 168

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Isoflex grease
Topas NB 52

Pulley flange
cleaner

Loctite 243

10 ± 1 N•rn
(89 ± 9 lbf•in)
00
60 ± 7 N•rn
Isoflex grease (44 ± 5 lbf•ft)
Topas NB 52

5 ± 0.6 N•rn
(44 ± 5 lbf•in)

120 ± 8 N•m
(89 ± 6 lbf•ft)

7 ± 0.8 N•rn
(62 ± 7 lbf•in)

Component must be replaced when removed.

tmr2011-015-001a

154
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tmr2011-015 155
Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

GENERAL PROCEDURES
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle. CVT COVER
To perform the following instructions, it is not nec- CVT Cover Access
essary to remove engine.
1. Refer to BODYand remove:
This CVT is lubrication free. Never lubricate any
— LH seat
components except drive pulley one-way clutch.
— LH lateral console panel.
During assembly/installation, use the torque val-
ues and service products as in the exploded 2. Remove under seat storage compartment.
views. NOTE: The CVT cover lower screws are accessi-
Clean threads before applying a threadlocker. Re- ble through the square holes in the central skid
fer to SELF-LOCKING FASTENERS and LOCTITE plate.
APPL/CATIONat the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices must be replaced (e.g.: lock-
ing tabs, elastic stop nuts, cotter pin, etc.).

A WARNING
Never touch CVT while engine is running. 1. Central skid plate
Never drive vehicle when CVT cover is re- 2. Access holes

moved.
CVT Cover Draining
A WARNING If water is present in CVT cover, it can be drained
as follows:
Any drive pulley repairs must be performed
by an authorized Can-Am dealer. Subcompo- 1. Remove drain screw.
nent installation and assembly tolerances re-
quire strict adherence to procedures detailed.

NOTICE Never use any type of impact

wrench at drive pulley removal and instal-
lation.

A WARNING
The clutch assembly is a precisely balanced
unit. Never replace parts with used parts
from another clutch assembly.

NOTICE These pulleys have metric threads. 1. Drain screw

Do not use SAE threads puller. Always tighten
puller by hand to ensure that the drive pulley 2. Let water drain from CVT cover.
has the same type of threads (metric vs SAE) 3. Reinstall drain screw.
prior to fully tightening.
NOTICE If any debris entered the CVT cover,
CVT must be cleaned and inspected.

CVT Cover Removal

Remove CVT cover screws.

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Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

NOTE: Remove the center top screw last. This Open driven pulley with the GEAR LOCK PIN
screw allows to support the cover during removal. (P/N 529 035 747).
Remove the CVT cover and its gasket.

Screw tool in the threaded hole of driven pulley

and tighten to open the pulley.

1. CVT cover screw

2. CVT cover
3. Gasket

CVT Cover Installation

Install the center top screw of first.
Tighten the CVT cover screws as per following se-
quence.
TYPICAL
1. Driven pulley expander
2. Fixed sheave of driven pulley

To remove belt, slip the belt over the top edge of

fixed sheave, as shown.

CVT COVER TIGHTENING SEQUENCE

CVT COVER SCREWS TIGHTENING TORQUE

7 N•m ± 0.8 Nom (62 lbf•in ± 7 lbf•in)

DRIVE BELT Drive Belt Installation

Drive Belt Removal For installation, reverse the removal procedure.
Pay attention to following details.
NOTICE In case of a drive belt failure, the
The maximum drive belt life span is obtained
CVT, cover and air outlet must be cleaned.
when the drive belt has the proper rotation direc-
Remove CVT COVER. tion. Install it so that the arrow printed on belt
is pointing towards front of the vehicle, viewed
from top.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

1. Arrow printed on belt

2. Drive pulley (front) 1. Crankshaft locking bolt
3. Driven pulley (rear) 2. Engine drive shaft (front side)
4. Rotation direction 3. Oil cooler

DRIVE PULLEY Second Locking Method:

Block drive pulley with the DRIVE PULLEY HOLDER
Drive Pulley Removal (CVT) (P/N 529 006 400).
Remove DRIVE BELT
Prior to removing the drive pulley, mark sliding
sheave and governor cup to ensure correct index-
ation at reinstallation.

529006.100

1. Mark on drive pulley sliding sheave

2. Mark on governor cup
1. Pulley holding tool
Block the drive pulley using one of the following 2. Drive pulley sliding sheave
3. Area to place holding tool hook
methods:
NOTICE Do not lean the tool hook on the
First Locking Method:
slider shoe guides.
Remove spark plugs.
Lock crankshaft at TDC position. Refer to BOT-
TOM END section.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

NOTICE Make sure to use the specified tool.

Using another tool will damage the crankshaft
threads.

1. Wrong tool hook positioning (slider shoe guides)

2. Correct tool hook positioning (outside slider shoe guides)

Drive Pulley Removal Continuation

Loosen the drive pulley screw.
NOTE: Do not unscrew the drive pulley screw
completely. If governor cup is stuck, hit it using
a soft hammer.
Apply axial pressure with your hand on the sliding
1. Drive pulley puller
sheave and governor cup. 2. Fixed sheave
Remove drive pulley screw with its conical spring
washer and thrust washer. Drive Pulley Disassembly

A CAUTION Sliding sheave of drive pulley is

Governor Cup
spring loaded. Carefully lift governor cup until slider shoes come
at their highest position into guides.

1. Thrust washer
2. Conical spring washer
3. Drive pulley screw
4. Sliding sheave with governor cup
1. Governor cup
Step 1: Push
2. Slider shoes
3. Sliding shave
Slowly release and remove sliding sheave. 4. Guides

Screw CLUTCH PULLER (P/N 529 035 746) in fixed NOTE: The following procedure is not necessary
sheave to remove fixed pulley. except if roller must be removed. Refer to IN-
SPECTION before proceeding.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Remove slider shoes out of each bearing sleeve.

Use a flat screwdriver if necessary.

1. Removal direction
2. Assembly direction

NOTE: Whenever removing a governor cup with

already two marked boxes replace it by a new one.

1. Slider shoe

Put governor cup on a vice to push out bearing

sleeve of roller in the foreseen direction (against
arrow). Use an appropriate punch (diameter of
punch must be smaller than the bearing sleeve
diameter).
NOTICE Do not clamp the governor cup in
the vice to push out bearing sleeve. Governor
cup will be damaged.
Sliding Sheave
NOTE: Use protection plates to avoid marks Unscrew lock nut and remove centrifugal lever
and/or damages to the governor cup. pivot bolt. This drive pulley is equipped with 6
NOTICE Always replace all rollers at the levers.
same time. Partly worn rollers may cause Remove centrifugal lever and both thrust wash-
damage to the CVT system. ers.

1. Lock nut
1. Punch 2. Centrifugal lever pivot bolt
2. Vice 3. Centrifugal lever
4. Thrust washers

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Fixed Sheave Drive Pulley Cleaning

A WARNING Clean pulley faces and shaft with fine steel wool
and dry cloth.
Always wear safety glasses to remove spring
sleeves. Using a paper towel with PULLEY FLANGE
CLEANER (P/N 413 711 809) cleaning solvent,
clean crankshaft tapered end and the taper inside
Pull and rotate one-way clutch slowly until the
sheave of spring sleeves are visible. the fixed sheave of the drive pulley, crankshaft
threads and threads of drive pulley screw.
NOTICE Avoid contact between cleaner and
crankshaft seal because damage may occur.

Remove all hardened oil deposits that have baked

on crankshaft and pulley tapered surfaces with
coarse or medium steel wool and/or sand paper
no. 600.
NOTICE Do not use any other type of abra-
sive.
Reclean mounting surfaces with paper towel and
PULLEY FLANGE CLEANER (P/N 413 711 809).
Wipe off the mounting surfaces with a clean, dry
paper towel.
NOTICE Mounting surfaces must be free of
any oil, cleaner or towel residue.
1. One-way clutch
2. Fixed sheave
3. Spring sleeve area

Hold both spring sleeves with fingers and release

when one-way clutch is disengaged.

1. Taper of fixed sheave

Only use petrol base cleaner when cleaning bush-

ings of sliding sheave.
NOTICE Do not use acetone to clean bush-
1. Springs ing.
2. Spring sleeves

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

1. Roller
2. Slider shoe
1. Sliding sheave
2. Bushings A. Roller outer diameter

Drive Pulley Inspection ROLLER OUTER DIAMETER

13.70 mm to 13.80 mm
Bushings NEW
(.539 in to .543 in)
For bushing inspection, refer to SLIDING SHEAVE
SERVICE LIMIT 13.20 mm (.519 in)
in this subsection.
ROLLER INNER DIAMETER
Governor Cup
8.05 to 8.15 mm
Check governor cup for cracks or other visible NEW
(.317 to .321 in)
damage. Replace if necessary.
SERVICE LIMIT 9 mm (.354 in)
Roller and Slider Shoe
Check each roller for roundness of external diam- Centrifugal Lever Pivot Bolt
eter. Measure diameter of centrifugal lever pivot bolt,
Check if rollers move freely. replace if it is out of specification.
NOTICE Whenever replacing rollers and
slider shoes, always replace all rollers and
slider shoes at the same time.

Check slider shoes for visible wear and replace if

damaged.
NOTE: If necessary, use a screwdriver to remove
slider shoes. 1. Centrifugal lever pivot bolt
A. Measure diameter here

CENTRIFUGAL LEVER PIVOT BOLT DIAMETER

6.078 mm to 6.100 mm
NOMINAL
(.239 in to .24 in)
SERVICE LIMIT 6.00 mm (.236 in)

Centrifugal Lever
Check bushing diameter in the centrifugal lever for
wear. Replace centrifugal lever if necessary.

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1. Centrifugal lever
2. Bushing
A. Bushing inner diameter

CENTRIFUGAL LEVER BORE DIAMETER

6.035 mm to 6.078 mm
NOMINAL
(.238 in to .239 in) A. Centrifugal lever pivot bolt bore diameter
SERVICE LIMIT 6.200 mm (.244 in)
CENTRIFUGAL LEVER PIVOT BOLT BORE
Replace centrifugal lever, thrust washers, cen- DIAMETER .
trifugal lever pivot bolts and lock nuts if the 6.113 mm to 6.171 mm
NOMINAL
contact surfaces show heavy visible wear. (.241 in to .243 in)
SERVICE LIMIT 6.300 mm (.248 in)

Measure bushing diameters of sliding sheave.

Use a dial bore gauge to measure bushing di-
ameter. Measuring point must be at least 5 mm
(1/4 in) from bushing edge.

1. Lock nut
2. Centrifugal lever pivot bolt
3. Centrifugal lever
4. Thrust washers
5. Contact surface to the roller

A WARNING
Whenever replacing centrifugal levers, al-
ways replace all lever at the same time.
Otherwise, unbalanced drive pulley will oc-
cur because of levers difference. 1. Bushing on fixed sheave side
A. Bore diameter of bushing
Sliding Sheave
SLIDING SHEAVE LARGE BUSHING
Check sliding sheave for cracks and sliding con-
tact surface for excessive wear. Replace sliding 55.000 mm to 55.040 mm
NOMINAL
sheave if necessary. (2.165 in to 2.167 in)
Measure centrifugal lever pivot bolt bores. Re- SERVICE LIMIT 55.200 mm (2.173 in)
place sliding sheave if bores are out of specifica-
tion or otherwise damaged.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Spring
Measure spring free length and squareness. If
spring is out of specification, replace by a new
one.
CLUTCH SPRING SQUARENESS
SERVICE LIMIT I 4 mm (.157 in)

One-Way Clutch
Check bearings for excessive play and smooth op-
eration. Replace one-way clutch if necessary.
NOTICE Be careful not to damage the inside
of one-way clutch during bearing removal.

7. Bushing on governor cup side

A. Bore diameter of bushing

SLIDING SHEAVE SMALL BUSHING

32.000 mm to 32.040 mm
NOMINAL
(1.26 in to 1.261 in)
SERVICE LIMIT 32.200 mm (1.268 in)

Replace sliding sheave if one of the bushings is

out of specification. Visually inspect coatings.
Fixed Sheave
1. One-way clutch
Check fixed sheave contact surface to the gover- 2. Bearings

nor cup for scratches or other damages. If so, re-

Measure length of spring sleeves and check if
place fixed sheave.
edges on top of the spring sleeve are excessively
worn. If they out of specifications, replace both
spring sleeves at the same time.
SPRING SLEEVE LENGTH
9.2 mm to 9.4 mm
NOMINAL
(.362 in to .37 in)
SERVICE LIMIT 9 mm (.354 in)

Drive Pulley Assembly

For assembly, reverse the disassembly proce-
dure. Pay attention to following details.
One-Way Clutch
Clean parts.
7. Visually check here
Lubricate springs, spring sleeves and between
one way clutch bearings using ISOFLEX GREASE
Check for any marks on fixed sheave plate. Re- TOPAS NB 52 (P/N 293 550 021). Push grease inside
place if necessary. bearings to ensure adequate lubrication.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

NOTE: Ball bearings have a seal on one side only.

Install bearings with the seal towards the outside
of the one-way clutch.

1. Top edge of bearing sleeve

2. Mating surface of slider shoes
3. Vice

Each time when replacing the bearing sleeves

1. One-way clutch
2. Bearing
sign the foreseen box with a punch.
3. Retaining ring
4. Seal NOTICE Do not tap too hard. Violent damage
of the governor cup may appear.
Sliding Sheave
Install centrifugal levers with their thrust washers.
NOTICE Centrifugal levers must move easily
after installation.
Governor Cup
Rebuild governor cup with new bearing sleeves,
thrust washers, rollers and slider shoes.
NOTICE Final position has to be aligned with
the contact surface of the slider shoes (no pro-
trusion).

NOTICE Rollers must move easily after in-

stallation.
Insert slider shoes into governor cup to properly
slide in guides.

Drive Pulley Installation

For installation, reverse the removal procedure.
Pay attention to the following details.

A WARNING
Do not apply antiseize or any lubricant on
crankshaft and drive pulley tapers.

NOTICE Never use any type of impact

wrench at drive pulley removal and instal-
lation.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Clean mounting surfaces as described in CLEAN-

ING above.
Install drive pulley on crankshaft extension.
NOTICE Do not forget to place thrust washer
prior to install conical spring washer.
Install conical spring washer with its concave
side towards drive pulley then install drive pulley
screw.

1. Pulley holding tool (P/N 529 006 400)

2. Drive pulley removal/installation area

NOTICE Do not lean the tool hook on the

slider shoe guides.

1. Drive pulley screw

2. Conical spring washer
3. Thrust washer

A WARNING
Never substitute conical spring washer
and/or screw with jobber ones. Always use
BRP genuine parts for this particular case.

1. Wrong tool hook positioning (slider shoe guides)

To tighten the drive pulley screw, lock the drive 2. Correct tool hook positioning (outside slider shoe guides)
pulley. Refer to the DRIVE PULLEY REMOVAL in
this subsection for locking procedures.
DRIVEN PULLEY
Tighten drive pulley screw to specified torque.
Driven Pulley Removal
DRIVE PULLEY SCREW TIGHTENING TORQUE
Remove DRIVE BELT.
120 N•m ± 8 N•m (89 lbf•ft ± 6 lbf•ft)
Using the DRIVEN CLUTCH HOLDER (P/N 529 035
771), hold the driven pulley and loosen the driven
pulley screw.
NOTE: Do not unscrew the driven pulley screw
completely.

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Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

1. Driven pulley screw

2. Pulley holding tool 1. Fixed sheave of driven pulley
2. Sliding sheave of driven pulley
3. Spring
Apply axial pressure with your hand on driven pul- 4. Cam
ley and maintain during screw removal.
Remove driven pulley screw, locking washer and Driven Pulley Disassembly
washer. Fixed Sheave
Discard locking washer. Remove retaining ring and lift torque gear.

A CAUTION Driven pulley is spring loaded.

Hold driven pulley tight and slowly remove the
driven pulley screw to release spring tension.

1. Retaining ring
2. Torque gear
3. Fixed sheave of driven pulley

1. Driven pulley screw NOTE: The following procedure is not necessary

2. Thrust washer
3. Locking washer except if ball bearing or shaft must be removed.
Refer to INSPECTION before proceeding.
Remove the driven pulley with the spring and the
Heat ball bearing area up to 100°C (212°F) before
cam.
removing ball bearing.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

1. 0-ring
1. Ball bearing 2. Distance sleeve
2. Shaft
3. Fixed sheave of driven pulley
Driven Pulley Cleaning
Use a soft hammer to push shaft with bearing out When a dust deposit has to be removed from the
of fixed sheave. cam or the shaft, use dry cloth.
Clean pulley faces and shaft with fine steel wool
and dry cloth.
Use PULLEY FLANGE CLEANER (P/N 413 711 809) to
clean driven pulley.
Clean the CVT air guide area from contamination.
Using a paper towel with PULLEY FLANGE
CLEANER (P/N 413 711 809) to clean counter-
shaft end and the inside of the shaft.
NOTICE To avoid damage, make sure cleaner
does not contact the countershaft oil seal.

1. Soft hammer
2. Shaft

Remove shaft from ball bearing.

Remove distance sleeve and 0-ring from counter-
shaft.
Replace 0-ring if brittle, hard or damaged.

1. Countershaft support
2. Countershaft oil seal

Driven Pulley Inspection

Sliding Sheave
Check sliding sheave for cracks and sliding con-
tact surface for excessive wear. Replace sliding
sheave if necessary.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Check bushings for cracks, scratch and for free

movement when assembled to sliding sheave.
Using a dial bore gauge measure bushing diam-
eter. Measuring point must be at least 5 mm
(1/4 in) from bushing edge.
This bushing can not be replaced. Replace sliding
sheave if bushings are out of specification. Visu-
ally inspect coatings.

1. Bushing
2. Fixed sheave of driven pulley

BUSHING BORE DIAMETER

30.060 mm to 30.100 mm
NOMINAL
(1.183 in to 1.185in)
SERVICE LIMIT 30.200 mm (1.189 in)
1. Bushings
2. Backside of sliding sheave of driven pulley Check torque gear for visible damage and cracks.
BUSHINGS BORE DIAMETER Measure wear limit with a caliper.
30.060 mm to 30.100 mm
NOMINAL
(1.183 in to 1.185 in)
SERVICE LIMIT 30.200 mm (1.189 in)

Fixed Sheave
Check fixed sheave for cracks and excessive
wear. Replace fixed sheave if necessary.
Check ball bearing for free play and smooth oper-
ation. Replace if necessary.
Check shaft for heavy wear or visible damage. Re-
place if necessary.
If the shaft is removed, using a dial bore gauge,
measure bushing diameter. Measuring point A. Measurement inside
must be at least 5 mm (1/4 in) from bushing edge. B. Measurement outside

This bushing can not be replaced. Replace fixed WEAR ON TEETH BOTH SIDES
sheave if bushing is out of specification. Visually
SERVICE LIMIT I 7.500 mm (.295 in)
inspect coatings.
Cam
Check cam for visible damage and wear limit with
a caliper.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Driven Pulley Assembly

For installation, reverse the removal procedure.
Pay attention to following details.
Heat ball bearing area up to 100°C (212°F) before
ball bearing installation.
NOTE: Place new ball bearing in a freezer for 10
minutes before installation.
Install ball bearing with the writing on top and
push only on the outer ring.

1. Caliper
2. Contact surface
A. Width to be measured due to wear on contact surface

WIDTH ON TOP SURFACE

SERVICE LIMIT I 9.00 mm (.354 in)

1. Ball bearing
2. Fixed sheave of driven pulley

NOTICE Do not use hammer, use press ma-

chine only.

7. Caliper
2. Sliding sheave
3. Contact surface
A. Wear to be measured

WEAR ON CONTACT SURFACE

SERVICE LIMIT I 1.00 mm (.039 in)
1. Shaft
2. Fixed sheave
Spring 3. Press machine

Measure spring free length and squareness. If Install torque gear then secure it with retaining
spring is out of specification, replace by a new. ring.
SPRING FREE LENGTH
SERVICE LIMIT I 125 mm (4.921 in)
CLUTCH SPRING SQUARENESS
SERVICE LIMIT I 3.8 mm (.15 in)

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

1. Countershaft splines
2. Cam

Install sliding sheave into fixed sheave.

1. Retaining ring
2. Torque gear Place spring behind sliding sheave then align
3. Fixed sheave of driven pulley
driven pulley with cam.
Driven Pulley Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Place 0-ring on countershaft splines and move it
with distance sleeve in end position.
NOTICE Chamfer on inside diameter of the
distance sleeve must face gearbox side.

1. Cam
2. Spring
3. Sliding sheave
4. Fixed sheave

With your hand, push the driven pulley on the

shaft to compress the spring. Install the driven
pulley screw, locking washer and thrust washer.
NOTE: Insert locking washer tab through thrust
washer hole, then in the shaft slot.
1. 0-ring
2. Distance sleeve
3. Chamfered area of distance sleeve

Install cam on countershaft end the right way on

the countershaft splines.

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 10 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

CVT Air Guide Inspection

Clean CVT air guide from contamination
Check 0-rings if brittle, hard or damaged. Replace
if necessary.

1. Driven pulley screw

2. Thrust washer
3. Locking washer
4. Shaft slot

NOTE: Driven pulley end-play is 0 (zero).

Tighten driven pulley screw. 7. CVT air guide
2. 0-rings
DRIVEN PULLEY SCREW TIGHTENING TORQUE
CVT Air Guide Installation
60 N•m ± 7 N•m (44 lbf•ft ± 5 lbf•ft)
For installation reverse the removal procedure.
Bend the locking washer in order to lock the driven
pulley screw.

1. Bent locking washer

CVT AIR GUIDE

CVT Air Guide Removal
Remove the DRIVE PULLEY and the DRIVEN
PULLEY.
Unscrew the clamps retaining the CVT air hoses.
Remove CVT air guide.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

GEARBOX AND 4X4 COUPLING UNIT

SERVICE TOOLS
Description Part Number Page
BLIND HOLE BEARING PULLER SET 529 036 117 189
DRIVE SHAFT OIL SEAL INSTALLER 529 036 028 182
ECM ADAPTER TOOL 529 036 166 178
FLUKE 115 MULTIMETER 529 035 868 176, 180
HANDLE 420 877 650 182
OIL SEAL INSTALLER (GEARBOX) 529 035 758 182
OIL SEAL INSTALLER 529 036 204 183

SERVICE TOOLS - OTHER SUPPLIER

Description Part Number Page
FLUKE RIGID BACK PROBE
- TP88 176

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 5910 293 800 081 180, 195
LOCTITE CHISEL (GASKET REMOVER) 413 708 500 195
SUPER LUBE GREASE 293 550 030 177, 180, 183

tmr2011-016 173
Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM

10 ± 1 N•m Super Lube
(89 ± 9 lbf•in) 5 grease The shaded parts are not serviceable.
Gearbox replacement is required.
5± 0.6 N•m 10 _± 1 N-m
(44 ± 0.5 lbf•in) (89 ± 9 lbf•in)

25 ± 3 N•m
(18 ± 8 lbf•ft)

20 ± 2 N•m
(15 ± 1 lbf•ft)

25 ± 3 N•rn
(18 ± 8 lbf•ft)

10 ± 1 N•m
(89 ± 9 lbf•in) Loctite 5910
3 ± 0.3 N•m
(27_ 3 lbf•in)
25 ± 3 N•m
(18 ± 8 lbf•ft) Engine oil
Loctite 243
28.3 N•m
(21 ± 2 lbf•ft)

EWA
Super Lube
grease
6 -±- 0.7 N•rn
(53 ± 6 lbf•in)
Loctite 243
6
Engine 6 Loctite 243
10 ± 1 N•m
oil
(89 ± 9 lbf•in)

Engine oil

Engine oil

Engine oil
10 ± 1 N•m
(89 ± 9 lbf•in)

10 ± 1 N•m
Loctite (89 ± 9 lbf•in)
10 -± 1 N•m Loctite 648
(89 ± 9 lbf•in)

per Lube

0 441
-5 grease

10 ± 1 N•rn
[ZEM = Component must be replaced when removed. (89 ± 9 lbf•in) Sr Engine oil
Irr):1011-016 001a

174 tmr2011-016
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
etc.) must be replaced. 1. Center housing
2. Left cover
3. Countershaft
4. Output shaft
NOTICE Hoses, cables and locking ties re- 5. Shift shaft
moved during a procedure must be reinstalled
as per factory standards.
TROUBLESHOOTING
GEARBOX OVERVIEW UNUSUAL GEARBOX NOISE AND/OR
VIBRATIONS
1. Low oil level in gearbox.
- Oil leakage from gearbox. Replace damaged gas-
ket(s) and/or oil seal(s).

2. Defective bearings.
- Bearing(s) do(es) not turn smoothly. Replace
bearing(s).
3. Damaged or worn gears.
- Inspect gears for damages or missing teeth. Re-
place respective gears.

GEAR INDICATION FAILS

1. Defective gearbox position sensor (GBPS).
7. Gearbox position sensor (GBPS)
2. Right cover - Perform a gearbox position sensor test.
3. Vehicle speed sensor (VSS) - Damaged wires. Repair as required.
4. Actuator
5. 4WD indicator switch
GEAR(S) IS (ARE) HARD TO SHIFT
1. Incorrect shifter cable adjustment.
- Adjust shifter cable (refer to SHIFTER CABLE in
SHIFTER subsection.

4 WHEEL DRIVE INDICATION FAILS

1. 4WD indicator switch failure.
- Test 4WD indicator switch. Replace as required.
- Bad contact. Check for corrosion or loose con-
nector.
- Damaged wires. Repair as required.

tmr2011-016 175
Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

4 WHEEL DRIVE DOES NOT ENGAGE OR VSS Circuit Protection

DISENGAGE CONDITION CIRCUIT PROTECTION
1. Defective 4WD switch. Fuse 5 of fuse block 1
Supplied with main
- Check 4WD switch operation. relay activated (from main relay R2)
2. Defective actuator.
- Test actuator. VSS Input Voltage Test
3. Damaged or worn shifting fork or sleeve. 1. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and select Vdc.
- Remove actuator and inspect shifting fork and
sleeve. 2. Turn ignition switch ON.
3. Back-probe the VSS connector using FLUKE
PROCEDURES RIGID BACK-PROBE (P/N TP88) or equivalent.
4. Measure voltage as per following table.
VSS (VEHICLE SPEED SENSOR)
VEHICLE SPEED SENSOR INPUT VOLTAGE TEST
VSS Location RESULT
TEST PROBES
The vehicle speed sensor is located on the right (KEY ON)
housing of the gearbox behind the actuator.
P IN C
PIN A
(BLACK/GREEN Battery voltage
(RED wire)
wire)

If voltage is not as specified, test positive and

ground separately.

VSS Signal Test

1. Lift rear of vehicle so that rear wheels are off
the ground.
2. Set transmission to 2WD and to Neutral.
3. Back-probe the VSS connector using FLUKE
RIGID BACK-PROBE (P/N TP88) or equivalent.
4. Turn ignition switch ON.
5. Set multimeter to Vdc.
7. Right housing of gearbox 6. Measure voltage while slowly rotating rear
2. Actuator
3. VSS (Vehicle Speed Sensor)
wheels by hand.
VEHICLE SPEED SENSOR SIGNAL TEST
VSS Access
RESULT
To reach the VSS, remove the following parts: TEST PROBES (WHILE ROTATING
— Passenger seat WHEELS)
— RH lateral console panel PIN B PIN C Alternate reading
— Fuel tank cowl. (WHITE (BLACK/GREEN between battery
wire) wire) voltage and 0 Vdc
VSS Wire Identification
NOTE: Since we measure pulsating voltage, the
FUNCTION PIN COLOR
numeric display will continuously change. The
12-volt input from fuse F5 A RED analog display may be easier to follow.
Speed signal
B WHITE
(to ECM-A El)
Ground (to ECM-A D4) C BLACK/GREEN

176 tmr2011 -016

 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

Apply SUPER LUBE GREASE (P/N 293 550 030) on

VSS

GBPS (GEARBOX POSITION

SENSOR)
GBPS Reset
When replacing the gearbox position sensor
(GBPS), it is required to reset (re-zero) its values
for proper operation.
1. Analog display A reset must be carried out each time any of the
following parts has been replaced:
VSS Removal — Gearbox assembly
Remove screw retaining the VSS. — Shift drum
— GBPS
— ECM.
1. Connect vehicle to the latest applicable version
of B.U.D.S. software, refer to COMMUNICA-
TION TOOLS AND B.U.D.S. subsection.
NOTE: Ignition key must stay ON during the reset
procedure. If the key is turned off, the procedure
must be carried out again.
2. In B.U.D.S., select the following:
— Read Data button
— Setting page tab
— ECM tab.

1. Screw
2. VSS

Turn sensor and weave it out of the gearbox right

cover.

1. Read data button

2. Setting page tab
3. ECM tab

3. Make sure that gearbox is set to NEUTRAL po-

sition.
4. In the Gear Position Sensor Initialization field,
click on the Reset button.

VSS Installation
For installation, reverse the removal procedure.
Pay attention to the following.

tmr2011-016 177
Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

Thralti, pf; on senacr iNIIA0a11011

Set shift lever in NEUTRAL position.
Ttrottle Optfmn
0.0% Unplug the GBPS connector.
Test as follow:
MULTIMETER PROBE POSITIONS VOLTAGE
PIN 1 and PIN 3 of the GBPS connector

5 volts
m
V90011-010 091 _a u

GEAR POSITION SENSOR INITIALIZATION

1. Reset button

A message will be displayed if the operation is

If voltage is adequate, check GBPS communica-
successful. tion link (CAN).
If an error occurred or the GBPS is not within the
If there is no voltage, check each GBPS input as
allowed range while resetting, the ECM will gen- follows.
erate a fault code and will not accept the setting.
5. If a fault message is displayed, follow the in- MULTIMETER PROBE POSITIONS VOLTAGE
structions in the message(s). GBPS connector (pin 1) and
6. Check for fault codes. battery ground

If a fault code is generated:

5 volts
— Carry out the service action
— Reset the fault code
— Repeat the reset procedure. —-
7. Close and disconnect B.U.D.S. GBPS connector (pin 3) and
NOTE: Do not turn ignition key OFF. battery + terminal
8. Verify gears engagement. .,..:
r Battery
8.1 With the vehicle on ground and in NEU- •1 3 , • voltage
TRAL position, start engine. __..
8.2 During 4-5 seconds, rev engine to 2500 ±
200 RPM.
8.3 Let engine returns to idle. If there is no voltage, check wires and connector
8.4 Select an other position (P, R, H or L). Re- pins. Replace or repair defective parts and reset
peat substeps 8.2 and 8.3 until all position fault codes.
are verified.
GBPS Communication Link Continuity
NOTE: The vehicle must be in movement to Test
complete the procedure on R, H and L posi-
tion. Unplug connector "A" from ECM and connect it
to the ECM ADAPTER TOOL (P/N 529 036 166).
GBPS Access
To reach the GBPS sensor, remove the following
parts:
— Passenger seat
— RH lateral console panel
— Fuel tank cowl.

GBPS Input Voltage Test

NOTE: Prior to conduct testing, check fault codes
in B.U.D.S.

178 tmr2011-016
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

RESISTANCE
MULTIMETER PROBE
@ 20°C
POSITIONS
(68°F)
GBPS connector (pin 2) and ECM
adapter tool (pin F4)

0
.• Y
Below 1 It

If resistance is out of specification, check wires

and connectors. Repair and reset fault codes.
7. Flat on shift drum shaft
If resistance is good and the other tests suc-
ceeded, replace the GBPS and reset fault codes. Reset the GBPS. Refer to GBPS RESET in this
NOTE: The GBPS must be reset. subsection.

GBPS Removal 4WD INDICATOR SWITCH

Set shift lever in NEUTRAL position.
4WD Indicator Switch Access
Unplug GBPS connector.
To reach the 4WD indicator switch, remove the
Remove screws and withdraw GBPS. following parts:
— Passenger seat
— RH lateral console panel
— Fuel tank cowl.

4WD Indicator Switch Removal

Disconnect 4WD indicator switch connector.

1. Screws
2. Gearbox Position Sensor (GBPS)

GBPS Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
1. 4 WD indicator switch
Shift lever must be in the NEUTRAL position. 2. Actuator

Align GBPS with the flat on the shift drum shaft.

4WD Indicator Switch Test
Measure switch resistance as follows.
SWITCH
SWITCH WIRE RESISTANCE
POSITION
BLACK/ Engine
2WD Infinite (OL)
BEIGE ground

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Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

If the resistance is out of specification, replace the If the selector is out of specifications, check
4WD indicator switch. wires, connectors and replace the selector if nec-
essary.
4WD Indicator Switch Installation If the selector is good, check the vehicle harness.
For installation, reverse the removal procedure. If the vehicle harness is good, replace the actua-
Pay attention to the following details. tor.
Take care do not damage indicator switch threads
during installation. Actuator Removal
Apply carefully some LOCTITE 5910 (P/N 293 800 NOTE: Before beginning any servicing on the ac-
081) on threads of indicator switch. tuator, make sure the vehicle is in 4WD position.
No need to remove engine from vehicle.
NOTICE Do not apply Loctite 5910 on switch
plunger, as it will lead to switch malfunction. Place a drain pan under actuator.
Remove actuator screws.
ACTUATOR
Actuator Access
To access the actuator, remove the following
parts:
— Passenger seat
— RH lateral console panel
— Fuel tank cowl.
Remove screws securing fuel tank and move tank
on passenger's floor without disconnecting hoses
and connector from fuel pump.

Actuator Test
Using the FLUKE 115 MULTIMETER (P/N 529 035
868), check if the 2WD/4WD selector works prop-
erly. 1. Actuator
2. Washer
3. Screw

When all actuator bolts are removed, pull the ac-

tuator out of housing.

Actuator Installation
Apply a small amount of SUPER LUBE GREASE
(P/N 293 550 030) on actuator 0-ring.

Unplug actuator connector.

Turn ignition key ON.
Measure vo tage as follows.
SWITCH VOLTAGE
SWITCH WIRE
POSITION
2WD WHITE/BLUE Battery
WHITE
4WD WHITE/BLACK voltage 1. Actuator 0-ring

180 tmr2011-016
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

Verify if coupling fork is in 4WD position. The cou- Turn front wheels. The front propeller shaft
pling fork should be positioned toward the front of should not turn (the PARK position must be se-
vehicle. lected).
If the front propeller shaft turns, the actuator is not
installed correctly. Remove actuator and reinstall
it.
Place ignition switch to ON position and select the
2WD position.
Turn front wheel again. The front propeller shaft
should turn easily.
If the front propeller shaft does not turn, the ac-
tuator is not installed correctly. Remove actuator
and reinstall it.
NOTICE Refill missing gearbox oil, refer to
GEARBOX OIL REPLACEMENT in PERIODIC
MAINTENANCE PROCEDURES subsection.
1. Coupling fork in 4WD position Install all other removed parts.
Align the actuator fork with the pin on coupling
fork then push the actuator in the housing. See GEARBOX OIL SEALS
the following illustration to position the actuator Gearbox Oil Seal Replacement
correctly.
Replace oil seals if they are brittle, hard or dam-
aged.
A small flat screwdriver can be used to remove
most of these oil seals.
NOTICE Avoid scoring parts during oil seal
removal.

When replacing an oil seal, take this opportunity

to inspect the following:
— Check bearings behind each oil seal for contam-
ination and/or metal shavings.
— Check oil seal running surfaces for scratches.
Countershaft Oil Seal
1. Actuator To replace the countershaft oil seal, remove:
2. Actuator fork
3. Coupling fork — Drive and driven pulleys
— CVT air guide.
Rotate the actuator counterclockwise until it ori-
ents itself to mounting position. NOTE: When oil seal is removed also inspect
0-ring behind distance sleeve.
NOTICE Do not cut or break the actuator
0 - ring.
Install all actuator screws and tighten them.
PART TORQUE
25 N•m ± 3 N•m
Actuator screws
(18 lbf•ft ± 2 lbf•ft)

Connect actuator.
Lift the front of vehicle.

tmr2011-016 181
Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

1. Countershaft oil seal

2. Distance sleeve
1. Countershaft oil seal
2. Oil seal installer

Shift Shaft Oil Seal

To replace the shift shaft oil seal, remove:
— RH lateral console panel and fuel tank cowl, re-
fer to BODYsubsection.
— Shift plate from shift shaft.
The shift shaft oil seal can be removed without
removing the gearbox from the vehicle.
Use a suitable tube with the proper diameter to
install the oil seal.
If gearbox housing is apart, use the OIL SEAL IN-
STALLER (GEARBOX) (P/N 529 035 758) and the HAN-
DLE (P/N 420 877 650) for shift shaft oil seal instal-
lation.

1. Distance sleeve
2. 0-ring

Install countershaft oil seal with the DRIVE SHAFT

OIL SEAL INSTALLER (P/N 529 036 028).

OIL SEAL INSTALLER NOTICE Oil seal must be installed with seal-
ing lip toward gearbox.
Shift Drum Shaft Oil Seal
To replace the shift drum shaft oil seal, remove
the GBPS (GEARBOX POSITION SENSOR). See
procedure in this subsection.
Use a suitable tube with the proper diameter to
install the oil seal.

182 tmr2011-016
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

NOTICE Oil seal must be installed with seal- Apply SUPER LUBE GREASE (P/N 293 550 030) on
ing lip toward gearbox. sealing lips.

Output Shaft Oil Seal Apply engine oil on outer diameter of oil seal to
avoid damaging it during installation.
To replace the output shaft oil seal, proceed as fol-
lows: Place oil seal on output shaft using the OIL SEAL
INSTALLER (P/N 529 036 204) with a flat washer
Remove propeller shaft screw from gearbox out- (P/N 250 200 102) and a M12 x 1.25 x 35 hexag-
put shaft. onal screw (P/N 207 683 544).
Remove rear final drive bolts.
Move the rear final drive rearward to dislodge the
propeller shaft from the gearbox output shaft.

1. Shift shaft oil seal

2. Shift drum shaft oil seal
3. Output shaft oil seal

Punch a sharp screwdriver through oil seal for re-

moval.
NOTE: Position screwdriver only in marked areas
1. Output shaft oil seal
to avoid damaging the ball bearing underneath oil 2. Oil seal installer
seal during removal. 3. Flat washer (P/N 250 200 102)
4. M12 x 1.25 x 35 hexagonal screw (P/N 207 683 544)
5. Apply engine oil on outer diameter of oil seal

GEARBOX
Gearbox Removal
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION for the proce-
dure.
Refer to CONTINUOUSLY VARIABLE TRANSMIS-
SION (C VT) subsection to remove following parts:
— CVT cover
— Drive and driven pulleys
— CVT air guide.
1. Marked areas for removal
2. Output shaft oil seal Drain gearbox. Refer toGEARBOX OIL RE-
PLACEMEIVTin PERIODIC MAINTENANCE PRO-
Before beginning the installation ensure gearbox CEDURES subsection.
is set to PARK position.

tmr2011-016 183
Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

Remove ACTUATOR, see procedure in this sub-

section.
Unscrew the four (4) nuts that attach the gearbox
to the engine.

1. 3 screws M6 x 35
2. 13 screws M6 x 55

Place the center housing on a wood stand, left

cover pointing upwards.
Using a big flat screwdriver and a soft hammer to
LH SIDE OF ENGINE lift the left cover.
1. Nut M8

POSITION FOR SOFT HAMMER

RH SIDE OF ENGINE
1. Nut M8

Pull gearbox to separate it from engine.

Gearbox Disassembly
NOTE: During gearbox disassembly, inspect the
condition of each part closely.
Gearbox Left Cover
Set gearbox to NEUTRAL position.
Unscrew all bolts retaining the gearbox left cover.

POSITION FOR BIG FLAT SCREWDRIVER

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection '11 (GEARBOX AND 4X4 COUPLING UNIT)

Index Lever and Index Washer

Set gearbox to NEUTRAL position.
Remove screw retaining the index washer to the
shift drum.

1. Washer
2. Index lever
3. Step ring
4. Index spring

1. Screw Main Shaft and Shift Forks

2. Index washer
Remove bearing pin, reverse intermediate gear
Insert a flat screwdriver in the slot of index lever. and thrust washers.
Turn screwdriver clockwise and remove index NOTE: Take care not to lose lower thrust washer
washer. during removal.

1. Index lever
2. Index washer 1. Bearing pin
3. Shift drum 2. Reverse intermediate gear
3. Needle bearing
Remove the index lever with washer, step ring 4. Thrust washers

and spring.
Remove shift fork shaft.
Disengage shift forks from shift drum.

tmr2011-016 185
Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

1. Shifting sleeve (HIGH range gear)

2. Shift fork

When required, remove from main shaft assem-

1. Shift fork shaft
2. Shift fork bly:
3. Shift drum
— Snap ring (discard)
Remove main shaft assembly with shift fork. — HIGH range gear
— LOW range gear
— Needle bearings.

1. Main shaft assembly

2. Shift fork
1. Snap ring
Remove shifting sleeve (HIGH range gear) and 2. Free pinion (HIGH range gear)
3. Free pinion (LOW range gear)
shift fork. 4. Needle bearing
5. Main shaft assembly

Remove from main shaft assembly:

— Snap ring (discard)
— Shifting sleeve (LOW/REVERSE range gear)
— Snap ring (discard)
— REVERSE range gear
— Needle bearing.

tmr2011-016
186
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

POSITION FOR BIG FLAT SCREWDRIVER

1. Snap ring
2. Shifting sleeve (LOW/REVERSE range gear)
3. Snap ring
4. Free pinion (REVERSE range gear)
5. Needle bearing
6. Main shaft assembly

Gearbox Right Cover

Remove ACTUATOR and GBPS (GEARBOX PO-
SITION SENSOR), see procedures in this subsec-
tion.
Unscrew all bolts retaining the gearbox right
cover.

POSITION FOR BIG FLAT SCREWDRIVER

Shift Shaft and Shift Drum

Withdraw shift shaft assembly.

1. 5 screws M8 x 55
2. 2 screws M6 x 85
3. 2 screws M6 x 55
4. 8 screws M6 x 35
7. Shift shaft assembly
To remove cover, use 2 big screwdrivers.
Remove screw retaining the shifting intermediate
gear.

tmr2011-016 187
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

1. Screw 1. Shift drum

2. Washer 2. Thrust washer
3. Intermediate gear
4. Dowel pin Output Shaft and 4x4 Coupling Mechanism
Remove shift fork shaft. Remove output shaft from center housing and
withdraw 4x4 coupling sleeve.
Disengage shift forks from shift drum.
NOTICE Use a soft hammer to remove output
shaft.

1. Shift fork shaft 1. Output shaft

2. Shift fork 2. 4x4 coupling sleeve
3. Shift drum 3. Soft hammer

Remove shift drum and thrust washer. Remove set screw, coupling fork shaft and cou-
pling fork from right cover.

188 tmr2011-016
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

To remove ball bearings of countershaft (right

cover) and main shaft (left cover) use the BLIND
HOLE BEARING PULLER SET (P/N 529 036 117).

1. Set screw
2. Coupling fork shaft
3. Coupling fork

Countershaft
Use a soft hammer to push out countershaft from
gearbox CVT side.
Remove distance sleeve and 0-ring.
Remove screw securing the countershaft bearing
in the left cover.
For ball bearings of countershaft (left cover) and
main shaft (center housing) push with a suitable
puller from outside in.

1. Countershaft
2. Distance sleeve
3. 0-ring
1. Ball bearing countershaft
2. Right cover
Gearbox Bearings
If necessary heat housing up to 100°C (212°F) be-
fore removing ball bearings.

A WARNING
Clean oil, outside and inside, from housing
before heating.

NOTICE Always support gearbox housings

properly when ball bearings are removed.
Housing damages may occur if this procedure
is not performed correctly.

tmr2011-016 189
Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

Check free pinions for wear.

1. Screw
2. Ball bearing countershaft
3. Ball bearing main shaft TYPICAL
4. Left cover 1. Micrometer
2. Free pinion

DIAMETER FREE PINION

29.000 mm to 29.013 mm
NEW
(1.1417 in to 1.1422 in)
SERVICE LIMIT 29.015 mm (1.1423 in)

Shifting Sleeves
Check shifting sleeves for worn inner splines and
rounded or damaged engagement dogs.

1. Ball bearing main shaft

2. Center housing

Gearbox Inspection
Always verify for the following when inspecting
gearbox components:
- Gear teeth damage
- Worn or scoured bearing surfaces
- Rounded engagement dogs and slots
- Worn shift fork engagement groove TYPICAL
1. Inner splines
- Worn splines on shafts and shifting sleeves. 2. Engagement dogs

Bearings Measure the width of shift fork engagement

Check if ball bearings turn freely and smoothly. groove.
Check all bearings, bearing points, tooth flanks
and taper grooves.
Free Pinions
NOTE: Always replace snap rings and use special
pliers to install them.

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 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

A. MAG side
B. Bearing journal CVT side

TYPICAL COUNTERSHAFT BEARING JOURNALS

1. Shifting sleeve
A. Width of shift fork engagement groove
MAG SIDE
19.977 mm to 19.990 mm
WIDTH OF SHIFT FORK ENGAGEMENT GROOVE NEW
(.786 in to .787 in)
5.30 mm to 5.40 mm SERVICE LIMIT 19.973 mm (.786 in)
NEW
(.209 in to .213 in)
CVT SIDE
SERVICE LIMIT 5.50 mm (.217 in)
24.977 mm to 24.990 mm
NEW
Shafts (.983 in to .984 in)

Check bearing pin of reverse intermediate gear for SERVICE LIMIT 24.970 mm (.983 in)
wear.
Check main shaft for wear.

1. Bearing pin
A. Outer diameter

BEARING PIN OUTER DIAMETER

InIr2011-016-059a
24.987 mm to 25.000 mm A. Bearing journal MAG side
NEW
(.984 in to .984 in) B. Free pinion bearing
C. Bearing journal CVT side
SERVICE LIMIT 24.977 mm (.9833 in)

Check countershaft bearing journals for wear.

tmr2011-016 191
Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

MAIN SHAFT
FREE PINION BEARING
24.987 mm to 25.000 mm
NEW
(.984 in to .984 in)
SERVICE LIMIT 24.984 mm (.984 in)
BEARING JOURNAL CVT/MAG SIDE
16.980 mm to 16.991 mm
NEW
(.669 in to .669 in)
SERVICE LIMIT 16.976 mm (.668 i n)

Shift Shaft
I. Micrometer
Check shift shaft for worn splines and gears.
A. Shift fork claw thickness
Check shift shaft spring for damages.
SHIFT FORK CLAW THICKNESS
Shift Drum
5.10 mm to 5.20 mm
NOTICE Do not disassemble shift drum. NEW
(.201 in to .205 in)

Check if shifting gates move easily on shift drum SERVICE LIMIT 5.00 mm (.197 in)
splines and check condition of springs.
Shift Fork Shaft
Check shift drum tracks for scouring or heavy
wear, like rounded engagement slots. Check shift fork shaft for visible damage or wear.
Check if shift fork shaft is straight.
Index Lever and Parking Lever
Index lever with roller must move freely.
Check parking lever for cracks or other damages.
Output Shaft
Check output shaft and its gear for cracks, bend,
pitting or other visible damages.
Check output shaft splines for wear or other dam-
ages.
Check if the output shaft bearings turn freely and
smoothly.
1. Track for the low/reverse range gear shift fork
2. Track for the high range gear shift fork Replace oil seal if brittle, hard or damaged.
3. Springs
4x4 Coupling Sleeve
Shift Forks
Check splines of coupling sleeve for wear or other
Check both shift forks for visible damage, wear or damages.
bent shift fork claws.
Check engagement rollers for wear and smooth
movement.
Measure the shift fork claw thickness.

1. Inspect splines

192 tmr2011-016
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

Measure the coupling sleeve groove width. If necessary heat housings up to 100°C (212°F)
before installing ball bearings.

A WARNING
Clean oil, outside and inside, from housing
before heating.

Place new bearing in freezer for 10 minutes be-

fore installation.
Use a suitable installer for installing ball bearings
of countershaft and main shaft.
NOTE: Place gearbox housings on a wood stand
A. Groove width before installing ball bearings.
COUPLING SLEEVE GROOVE WIDTH Install new oil seals with the proper installer (refer
to OIL SEALS in this subsection).
5.25 mm to 5.35 mm
NEW
(.207 in to .211 in) Main Shaft and Shift Forks
SERVICE LIMIT 5.50 mm (.217 in) Install NEW snap rings.
NOTE: Ensure snap rings are installed in the
Coupling Fork grooves properly.
Check coupling fork for visible damage, wear or Install free pinion (REVERSE range gear) and shift-
bent coupling fork claws. ing sleeve (LOW/REVERSE range gear) properly.
Check coupling fork claw thickness.

1. Coupling fork
2. Micrometer
1. Main shaft
COUPLING FORK CLAW THICKNESS 2. Free pinion (REVERSE range gear)
3. Snap ring
4.95 mm to 5.05 mm 4. Shifting sleeve (LOW/REVERSE range gear)
NEW 5. Shifting dogs (REVERSE range gear)
(.195 in to .199 in)
SERVICE LIMIT 4.80 mm (.189 in) Collars of free pinion (LOW range gear) and free
pinion (HIGH range gear) must point together.

Gearbox Assembly
The assembly of gearbox is essentially the reverse
of disassembly procedure. However, pay atten-
tion to the following details.
Gearbox Bearings
Unless otherwise instructed, never use hammer
to install ball bearings. Use press machine only.

tmr2011-016 193
Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

1. Bearing pin
2. Reverse intermediate gear
3. Needle bearing
4. Thrust washers
1. Free pinion (LOW range gear), 44 T
2. Collar Finally engage shift forks in shift drum and install
3. Free pinion (HIGH range gear), 36 T
4. Collar shift fork shaft.
NOTE: Run all gears as a final function check be-
Place shifting sleeve (HIGH range gear) with shift
fore installing left housing.
fork in the center of on main shaft bearing in cen-
ter housing. Index Lever and Index Washer
Fit.step ring into index lever.

1. Shifting sleeve (HIGH range gear)

2. Shift fork

Carefully fit main shaft assembly with shift fork

(LOW/REVERSE range gear) into inner splines of 1. Index spring
shifting sleeve (HIGH range gear). 2. Step ring
3. Index lever
Install reverse intermediate gear. 4. Washer
5. Screw

Install index washer on shift drum.

Insert a flat screwdriver in the slot of the index
lever, turn screwdriver clockwise and engage
lever in index washer in neutral position as per
following illustration.

194 tmr2011-016
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

1. Index lever 1. Shift shaft assembly

2. Index washer 2. Shifting intermediate gear
3. Neutral position 3. Shift drum gear
4. High range gear position 4. Marks
5. Low range gear position
6. Parking position
7. Reverse range gear position
Engage both shift fork pins in their corresponding
groove on the shift drum.
Output Shaft and 4x4 Coupling Mechanism
Install shift fork shaft.
Install coupling sleeve onto the output shaft.
NOTE: Turn gears to validate proper operation.
Place the output shaft with oil seal and coupling
sleeve into the center housing. Sealing Compound Application
NOTE: If same oil seal is installed, turn oil seal 90° NOTE: Unless otherwise specify, the procedure
offset to its original position to avoid leakage at to apply the sealant is the same for right or left
housing mating surface. cover.
Install coupling fork, coupling fork shaft and set Clean all metal components in a solvent.
screw in right cover before applying sealant to the Gearbox housing mating surfaces are best
mating surface. cleaned using a combination of LOCTITE CHISEL
(GASKET REMOVER) (P/N 413 708 500) and a brass
brush. Brush a first pass in one direction then
make the final brushing perpendicularly (90°) to
the first pass cross (hatch).
NOTICE Do not wipe with rags. Use a new
clean hand towel only.
IMPORTANT: When beginning the application of
the gear housing sealant, the assembly and the
first torquing should be done within 10 minutes.
It is suggested to have all you need on hand to
save time.
Use LOCTITE 5910 (P/N 293 800 081) on mating sur-
faces.
1. Coupling fork
2. Coupling fork shaft Use a plexiglass plate and apply some sealant
3. Set screw
on it. Use a soft rubber roller (50 mm - 75 mm
Shift Shaft and Shift Drum (2 in - 3 in)), available in arts products suppliers for
printing, and roll the sealant to get a thin uniform
Install shift drum and shift shaft. coat on the plate (spread as necessary). When
Install shifting intermediate gear. Align its marks ready, apply the sealant on gear housing mating
with the marks on shift drum gear and shift shaft. surfaces.

tmr2011-016 195
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

nstall 0-ring including distance sleeve on counter-

Do not apply in excess as it will spread out inside
shaft CVT side.
gear housing.
NOTE: It is recommended to apply this specific NOTICE Place 0-ring including distance
sealant as described here to get a uniform appli- sleeve right away. Chamfered bore of distance
cation without lumps. If you do not use the roller sleeve has to face the gearbox.
method, you may use your finger to uniformly dis-
tribute the sealant (using a finger will not affect
the adhesion).
Left Cover
Apply sealing compound on mating surfaces of
central housing. Refer to SEALING COMPOUND
APPLICATION.
At installation of left cover, engage parking lock
lever slot onto index washer pin.

COUNTERSHAFT END CVT SIDE

1. 0-ring
2. Distance sleeve
3. Countershaft end CVT side

Right Cover
Apply sealing compound on mating surfaces of
central housing. Refer to SEALING COMPOUND
APPLICATION.
To install the right cover align the coupling fork
with the groove in the coupling sleeve.
Install all screws on right cover and tighten them
as per following sequence.
1. Left cover
2. Parking lock lever slot
3. Index washer pin

Install all screws on left cover and tighten them as

per following sequence.

196 tmr2011-016
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 11 (GEARBOX AND 4X4 COUPLING UNIT)

Install the actuator, refer to ACTUATOR.

Gearbox Installation
For installation reverse the removal procedure.
Pay attention to following.
Before gearbox installation check 0-ring in bearing
cover if brittle, hard or damaged. Replace if nec-
essary.

7. Bearing cover
2. 0-ring

After installation refill gearbox oil, refer to PERI-

ODIC MAINTENANCE PROCEDURES

tmr2011-016 197
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 12 (SHIFTER)

SHIFTER

15.5 ± 1.5 N•rn

(137 ± 13 lbf•in) CE Model

24.5 ± 3.5 N•rn

(18 ± 3 lbfqt)

24.5 ± 3.5 N•rn

(18 ± 3 lbf•t)

9 ± 1 N•rn
(80 ± 9 lbf•in)

trnr2011 017-100a

tmr201 1-017 199

Section 02 ENGINE, CVT AND GEARBOX
Subsection 12 (SHIFTER)

GENERAL
Before performing any servicing on shifter sys-
tem, be sure the shift lever is on NEUTRAL
position and the vehicle is secured using wheel
blocks.
During assembly/installation, use the torque val-
ues and services products as in the exploded
view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
1. Shift lever handle

A WARNING 5. On CE models, remove locking device from ve-

Torque wrench tightening specifications hicle.
must strictly be adhered to.
Locking devices must be replaced when re-
moved (e.g.: locking tabs, cotter pins, etc.).

NOTICE Hoses, cables and locking ties re-

moved during a procedure must be reinstalled
as per factory standards.

PROCEDURES
SHIFT LEVER
Shift Lever Access CE MODELS
1. Locking device
1. Refer to BODYsubsection and remove the fol-
lowing components: 6. Detach shifter cable from shift lever by remov-
— Seats ing nut and washer.
— Lower console
— RH and LH lateral console panels.
NOTE: Move upper console upwards to access to
lower console.

Shift Lever Removal

1. Remove body parts as required. Refer to SHIFT
LEVER ACCESS in this subsection.
2. Place shift lever in NEUTRAL position.
3. Secure vehicle using wheel blocks.
4. Unscrew shift lever handle.

1. Shift lever nut

2. Shift lever washer

7. Remove shift lever pivot bolt, washers and nut.

200 tmr2011-017
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 12 (SHIFTER)

SHIFTER CABLE
Shifter Cable Adjustment
1. Place shift lever in NEUTRAL position.
NOTICE Move vehicle back and forth to en-
sure gearbox is set in neutral position.

2. Secure vehicle using wheel blocks.

3. Remove body parts as required. Refer to SHIFT
LEVER ACCESS in this subsection.
4. Loosen cable adjustment nuts.
7. Shift lever pivot bolt
2. Shift lever pivot washers
3. Shift lever pivot nut

8. Remove shift lever.

Shift Lever Inspection

Check shift lever for bending or cracks.
Check spring and bushing condition.
Replace all damaged parts.

Shift Lever Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. tmr2011-C17-Uzu_a

1. Adjustment nuts
Adjust shift lever handle as per the following illus-
tration. 5. Adjust cable nuts in order to center shift lever
in neutral notch.

SHIFT LEVER HANDLE ANGLE

A. 78° ± 5°

Tighten shift lever handle nut to specification.

CORRECT ADJUSTMENT
SHIFT LEVER HANDLE NUT TORQUE A. Shift lever centered in neutral notch

15.5 N•m ± 1.5 N•m (137 lbf•in ± 13Ibf•in)

Adjust shifter cable, refer to SHIFTER CABLE AD-

JUSTMEIVTin this subsection.
Check if shift lever works properly in all positions.

tmr2011-017 201
Section 02 ENGINE, CVT AND GEARBOX
Subsection 12 (SHIFTER)

10. Test the shifter to confirm that the system

works properly in all positions.

A WARNING
After adjustment, make sure that PARK posi-
tion works properly.
WRONG ADJUSTMENT
A. Shift lever centered in neutral opening
SHIFT PLATE
6. Tighten cable adjustment nuts to specification.
Shift Plate Removal
ADJUSTMENT NUTS TORQUE
NOTE: Do not remove shift plate needlessly.
24.5 N•m ± 3.5 N•m (18 lbf•ft ± 3 lbf•ft) 1. Remove shifter cable from shift plate.

7. Move shift lever in R position then in H position.

8. Place shift lever in NEUTRAL position.

1. Shift plate
9. Check if shift lever is properly centered in neu- 2. Shifter cable
tral notch. Readjust as required.
2. Index shift plate and shift shaft.
NOTE: To properly check shift lever alignment
into notch, move shift lever toward the RH side
then let it return to position.

202 tmr2011-017
 Section 02 ENGINE, CVT AND GEARBOX
Subsection 12 (SHIFTER)

TYPICAL
1. Trace a mark on both parts

3. Remove shift plate nut and bolt.

SHIFT PLATE ANGLE FROM VERTICAL PLANE

A. 20° ± 2.5°

Adjust shifter cable, refer to SHIFTER CABLE AD-

TYPICAL JUSTMEIVTin this subsection.
1. Shift plate bolt
Tighten shift plate nut to specification.
4. Remove shift plate.
SHIFT PLATE NUT TORQUE
Shift Plate Inspection 9 N•m ± 1 Nom (80 lbf•in ± 91bf•in)
Check shift plate for:
— Cracks
— Bending
— Spline condition.

Shift Plate Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Place gearbox in NEUTRAL position before shift
plate installation.
Install and align shift plate using marks previously
traced.
If shift plate is installed on a new engine, adjust it
as per the following illustration.

tmr201 1-017 203

204
 Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS))

ENGINE MANAGEMENT SYSTEM (EMS)

FRONT

VSS-1.- -4-CPS
GBPS-110-- -4-0PS
CTS-IIP- -TPS
INJ 2-4- 01.-ETA
INJ 1 -4-
IGN COIL-4- ECM -4--MAPTS
COOLING FAN
IN -44 I IGN SW
III, I ECM TAS -44 START SW
OUT SPORT SW STARTER SOLENOID
I [ECM I SEAT BELT SW FUEL PUMP
trnr2011-018-100_a

COOLING FAN INJ 2 = Injector 2

CPS = Crankshaft Position Sensor MAPTS = Manifold Air Pressure/Temperature Tensor
CTS = Cooling Temperature Sensor OPS = Oil Pressure Switch
ECM = Engine Control Module OUT = Output
ETA = Electric Throttle Actuator SEAT BELT SWITCH
FRONT SPORT SWITCH
FUEL PUMP START SWITCH
GBPS = GearBox Position Sensor STARTER SOLENOID
IGN COIL = Ignition coil SW = Switch
IGN SW = Ignition switch TAS = Throttle Accelerator Sensor
IN = Input TPS = Throttle Position Sensor
INJ 1= Injector 1 VSS = Vehicle Speed Sensor

trnr2011-018 205
Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS))

GENERAL The ECM reads input signals from various

switches, controls, and sensors, that it compares
SYSTEM DESCRIPTION to pre-determined parameters, makes computa-
tions, and provides control signal outputs required
A highly advanced engine management system for proper engine management.
(EMS) is used to ensure a high power output with The ECM also interacts through CAN bus with
cleaner combustion. the gauge module for various functions, informa-
There are 7 main systems that are controlled by tion exchange and display of messages. Refer
the engine management system (EMS): to CONTROLLER AREA NETWORK (CAN) and
1. Electronic Fuel Injection (EFI) LIGHTS, GAUGE AND ACCESSORIES subsec-
2. Intelligent throttle control tions.
3. Cooling system (cooling fan) The ECM also features a permanent memory that
4. Ignition system will store the information on the various ignition
keys programmed to the vehicle, fault codes, cus-
5. Starting system
tomer information, and other engine information,
6. Fuel pump system even when the battery is removed from the vehi-
7. D.E.S.S. system. cle.
NOTE: For further information related to these
systems, refer to the applicable subsection. Diagnostic Mode
The ECM (Engine Control Module) is the central The ECM features a self-diagnostic mode that is
point of the engine management system. activated on system power up (ignition key ON)
for certain systems and components, and when
the engine is running for others. Refer to DIAG-
NOSTIC SYSTEM AND FAULT CODESsubsection
for more information.

Monitoring System
The MONITORING SYSTEM monitors various
electrical and electronic components of the en-
gine control systems such as the:
— ETA (Electric Throttle Actuator)
TYPICAL - ECM
— TPS (Throttle Position Sensor)
The ECM is located under the dashboard on the — TAS (Throttle Accelerator Sensor)
driver's side, above the control pedals. — ECM (Engine Control Module).
The engine management system provides for re-
dundancies in these components should a failure
or partial failure occur to which it will adjust sys-
tem operation to protect the vehicle and most of
importantly, the driver.
Should the engine management system not re-
spond (or not respond correctly) to a failure, then
the monitoring system will react to ensure vehicle
and driver safety.
The monitoring system therefore ensures the en-
gine management system is functioning correctly.

Limp Home Mode

The ECM may automatically put the engine in
TYPICAL - ECM LOCATION LIMP HOME MODE using default parameters
7. ECM location when certain major faults are detected. LIMP
HOME MODE may also be manually engaged

206 tmr2011-018
 Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS))

under certain fault conditions. For more informa-

tion, refer to DIAGNOSTIC SYSTEM AND FAULT
CODES

tmr2011-018
207
 Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 02 (COMMUNICATION TOOLS AND B.U.D.S.)

COMMUNICATION TOOLS AND

B.U.D.S.
SERVICE TOOLS
Description Part Number Page
MPI-2 DIAGNOSTIC CABLE 710 000 851 211
MPI-2 INTERFACE CARD 529 036 018 211-212

SERVICE TOOLS - OTHER SUPPLIER

Description Part Number Page
MALE-FEMALE EXTENSION SERIAL CABLE DB9 211

GENERAL USB LIGHT

STATUS WHAT TO DO
Refer to PROCEDURES for instructions on the
communication tools. — Check USB connection between MPI-2
If communication problems occur, refer to TROU- Light is and PC computer.
BLESHOOTING in this subsection. OFF — Check USB operation on PC computer
(hardware or Windows drivers).
TROUBLESHOOTING Light is — Connections are GOOD.
Communication can take place on
GREEN
DIAGNOSTIC TIPS USB side.

IMPORTANT: Make sure all connections are Prerequisite for CAN Communication:
made and vehicle is powered up before starting — MPI-2 connected to diagnostic connector on ve-
B.U.D.S. to allow proper communication between hicle.
the vehicle and B.U.D.S. software.
— ECM turned on (electrical system powered up
MPI-2 Connection Troubleshooting without engine started).
— Ignition key installed and turned to ON.
MPI-2 Status Lights — B.U.D.S. started and logged on.
The MPI-2 includes 2 status lights that indicate the
CAN LIGHT
connection condition: USB and CAN. Both lights
must be GREEN for the MPI-2 to function prop- STATUS WHAT TO DO
erly. Otherwise, refer to the following charts.
Light is Check connection between MPI-2 and
OFF diagnostic connector on vehicle.
Light is
Check CAN wires/connectors on vehicle.
RED
Light is Connections are GOOD. Communication
GREEN can take place on CAN side.

Prerequisite for USB Communication:

— PC Computer turned on.
— MPI-2 connected to PC computer.

tmr2010-019 209
Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 02 (COMMUNICATION TOOLS AND B.U.D.S.)

Communication Problems when Using

B.U.D.S.
Missing Module
If one or more "ECU" is (are) not communicating
with the MPI, a module(s) may not be powered or
may be defective. TYPICAL
1. To see which module is missing in B.U.D.S.,
1. Check connections between the PC computer
first select the Read Data button at the top of
and the vehicle.
the B.U.D.S. page.
2. Activate the vehicle electrical system without
2. Then click on Module in the menu bar to ex-
starting the engine. Refer to POWER DISTRI-
pand its submenu.
BUTION SYSTEM subsection.
3. Look at the list of modules in the submenu. If a
3. Ensure both USB and CAN lights on the MPI-2
module is not visible in the submenu list, then
are GREEN. Refer to MPI-2 CONNECTION
it is not communicating with the MPI.
TROUBLESHOOTING subsection.
4. If B.U.D.S. is trapped in a loop that continually
File View MPI Module Too Help displays the following message box, press on
ECM the Try active detection mode button in the
message box. This will test if there is commu-
Cluster
nication with the vehicle.

111
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TRY ACTIVE DETECTION MODE

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Message Box: "Some of the Information
TYPICAL - MODULE SUBMENU LIST
Normally Displayed..."
MODULE LIST If the following message box is displayed in
MODULES VEHICLE MODEL B.U.D.S.:

ECM Commander 800R and

Cluster 1000 models at (h. ■ NO ■ ril3i1.2floormAily
Ef:

4. Ensure the missing module is properly con-

nected.
,2009-028-016
5. If the module is connected, remove the connec-
tor from the module and test for the following: 1. Click on the OK button in the box.
— Proper input voltage to the module 2. Click on the Read Data button in B.U.D.S.
— Ground circuit continuity
— CAN bus continuity. Message Box: "Engine must be Stopped..."
Refer to the applicable WIRING DIAGRAM or If the following message box is displayed in
appropriate subsection for details. B.U.D.S.:
No Vehicle Detected
If an "X" is shown in the status bar and the pro-
tocol tool is blinking between Kw2000 500K and
Kw2000, it means that no "ECU" is communicat-
ing with the MPI.

210 tmr2010-019
 Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection02 (COMMUNICATION TOOLS AND B.U.D.S.)

Connecting the PC to the Vehicle

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1. Locate the 6-pin diagnostic connector, refer to
DIAGNOSTIC CONNECTOR LOCATION in this
subsection.
sn111 009-028 015
2. Disconnect the 6-pin diagnostic connector from
its holder (protective cap).
1. Click on the Cancel button in B.U.D.S. 3. Connect one end of the MPI 2 DIAGNOSTIC CA-
-

2. Continue with the procedure undertaken prior BLE (P/N 710 000 851) to the vehicle connector.
to the appearance of the message box.

PROCEDURES
M PI-2
The MPI-2 (Multi-Purpose Interface-2) in conjunc-
tion with the MPI-2 diagnostic cable is used with
B.U.D.S. software to communicate with the ECM
(engine control module) and other modules.

MPI-2 Power 1. Diagnostic cable connected to vehicle

The MPI-2 interface card uses the power from the
4. Connect the other end of diagnostic cable to the
PC computer's USB port.
MPI-2 INTERFACE CARD (P/N 529 036 018).
Diagnostic Connector Location
The 6-pin diagnostic connector is located under
the dashboard on the driver's side. It is stored in
its protective cap on the lower RH side of the bat-
tery rack.

NOTE: An optional MALE-FEMALE EXTENSION SE-

RIAL CABLE (P/N DB9) available at electronic retail
outlets can be used between diagnostic cable and
MPI 2 interface. Do not exceed 7.6 m (25 ft).
-

1. Diagnostic connector

NOTE: Do not mismatch the diagnostic connector

with the one on the LH side of the battery rack.
This connector has only 2 wires attached to it and
is for manufacturer's use only.

tmr2010-019 211
Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 02 (COMMUNICATION TOOLS AND B.U.D.S.)

nent monitoring, activation of certain components

for diagnostic purposes, and to carry out setting
changes.
For more information pertaining to the use of the
B.U.D.S. software, use its Help menu which con-
tains detailed information on its functions.
Always use the latest applicable B.U.D.S. version
available on BOSSWeb.

How to Establish Communication

Using B.U.D.S. Software
IMPORTANT: Ensure all connections have been
made before starting B.U.D.S. to allow proper
operation. Refer to MP/--2 in this subsection.
1. Turn ignition switch to ON using any of the keys
OPTIONAL MALE-FEMALE EXTENSION SERIAL CABLE provided with the vehicle. Do not start the en-
5. Connect the MPI-2 INTERFACE CARD (P/N 529
gine.
036 018) to the USB port of a PC (personal 2. Start B.U.D.S. and logon.
computer). 3. Ensure the status bar shows the Kw2000
(500K) protocol and the appropriate number of
modules to its right according to the vehicle
model.
VEHICLE NUMBER OF
PROTOCOL
MODEL MODULES
Commander
Kw2000 (500K) 2
800R and 1000

DIAGNOSTIC CABLE CONNECTED TO MPI-2 INTERFACE CARD 1—*

Kiii.21.1001.11F
E;001‹. •- mg4

Imr2011-019-002 a

TYPICAL - SUCCESSFUL CONNECTION

1. Connection protocol
2. Number of modules read

4. Read ECUs by clicking the Read Data button.

File View MPI Module Tool.: Help

MPI-2 INTERFACE CARD CONNECTED TO USB PORT

1.1
6. Use B.U.D.S. software as described further in
B.U.D.S. SOFTWARE. Read Data Write Data
B.U.D.S. SOFTWARE
B.U.D.S. (Bombardier Utility and Diagnostic Soft- B.U.D.S. is now ready to use.
ware) is designed to allow programming key(s) to
the vehicle, allow electrical and electronic compo-
212 tmr2010-019
 Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 02 (COMMUNICATION TOOLS AND B.U.D.S.)

When clicking on the Read Data button, B.U.D.S. File View MPI® Module Tools Help
will read the cluster and the ECM modules
ECM ►
through CAN bus.
Cluster ►
Electronic Modules ("ECU") Updates
NOTICE Failure to strictly follow a procedure
to update a module may permanently damage
the module. amt
Whenever B.U.D.S. is started, check for an up- Read Data
date icon in the B.U.D.S. status bar.

TYPICAL - MODULE SUBMENU LIST

1. If the Update option is greyed out, no update

file is available for this module.
2. If the Update option is black, an update file is
available for this module.

smr2010-030 002_5

TYPICAL

If the icon is visible, it indicates that a file is avail-

able in B.U.D.S. to update at least one of the elec-
tronic modules:
NOTE: If an update file is available on BOSSWeb
but the B.U.D.S. software being used is not up 1. Greyed out: No update to perform
Black: Update file available
to date, the update icon will not appear. Refer to
the Service Bulletins to see if there is an update Before applying an update, log onto BOSSWeb
available. and look in Service menu for the Unit history to
Use the Module submenu and check all modules find out if any information or publication related to
one at a time to see which module(s) can be up- the vehicle is available. If so, carefully follow the
dated. given instructions.

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tmr2010-019 213
Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 02 (COMMUNICATION TOOLS AND B.U.D.S.)

NOTE: When selecting the update menu in 2. After the write data operation, turn the ignition
B.U.D.S., a dialog box will appear and the update key to the OFF position.
file description may give some clue to finding the Disconnect MPI connections and store the vehicle
vehicle-related information in BOSSWeb. diagnostic connector in its protective cap.

TYPICAL
1. File description

Writing Changes (Saving) to a Module

1. When making a data or setting change in a mod-
ule using B.U.D.S., save the new data (or set- TYPICAL
1. Diagnostic connector in its storage cap
ting) in the module by clicking the Write Data
button. NOTICE Failure to secure the diagnostic con-
nector in its protective cap may result in corro-
sion or other damage to the terminals.
Fde View MPIO Module Tools Help
NOTE: There is a 120 52 resistor in the protective
cap to minimize the possibility of communication
error.

NOTE: If the word Modified appears in the ve-

hicle file identification number at the top of the
B.U.D.S. page, then a change has been made that
requires selecting the Write Data for the change
to be saved.

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214 tmr2010-019
 Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 03 (DIAGNOSTIC SYSTEM AND FAULT CODES)

DIAGNOSTIC SYSTEM AND FAULT

CODES
GENERAL If a more important fault occurs, engine RPM may
be limited. The engine/vehicle will continue to op-
DIAGNOSTIC SYSTEM erate with reduced performance.
If a major component of the EMS fails, engine
The EMS features a diagnostic system that self-di-
RPM will be limited as well as vehicle speed.
agnoses various electrical and electronic compo-
nents. This mode becomes active when the igni- These strategies are used to protect
tion key is turned ON. engine/electrical system from damage and
to maintain safe operation of the vehicle. In ex-
NOTE: Some components require the engine to treme cases, the engine may also be completely
be running for them to be monitored for normal
shut down.
operation (fuel injectors for example).
The diagnostic system continuously validates that Pilot Lamps
the components (control modules, sensors and When a problem is detected, a pilot lamp will turn
actuators) are not faulty or defective. When a on or blink in the multifunction gauge. If the fault
malfunction is detected, the related electronic that caused the pilot lamp to come on is momen-
module(s):
tary, the pilot lamp may turn off automatically, or
— Sets an active fault code. may need to be reset by powering down the ve-
— Adapts the proper protection strategy accord- hicle and then restarting it.
ing to the failure. A message may also be displayed to provide ad-
— Sends out signals to the multifunction gauge to ditional information related to the fault that turned
inform the rider of a particular condition. on the pilot lamp. Refer to the following chart.
If a minor fault occurs, the engine and vehicle will
continue to operate without noticeable loss of per-
formance.
MULTIFUNCTION
PILOT LAMP CAUSE ADDITIONAL INFORMATION
GAUGE MESSAGE

Turns on when engine temperature

ON HI TEMP Engine is overheating.
0 reaches 114°C (237°F).

An engine management A fault code is active or has been activated

ON CHECK ENGINE component is not that requires attention. No engine
functioning properly. limitation.
An active fault code pertaining to a critical
IC:3
An important engine engine function has been activated that
Blinks LIMP HOME management component is requires attention as soon as possible.
not working properly. Engine behavior is modified or engine
RPM is limited to protect engine.
Turns ON when brake switch is activated
PARK BRAKE
Brake pedal held pushed in continuously for 15 seconds. Brake
(Early production
or faulty brake light switch. pressure felt at switch or switch failed in
models)
closed position.
ON
(0 BRAKE Turns ON when brake switch is activated
ACTIVATION Brake pedal held pushed in continuously for 15 seconds above 5 km/h
(Later production or faulty brake light switch. (3 MPH). Brake pressure felt at switch or
models) switch failed in closed position.
"E" displayed instead of selected gear. GBPS fault or related part. GBPS signal fault or communication error.

tmr2011-020 215
Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 03 (DIAGNOSTIC SYSTEM AND FAULT CODES)

Limp Home Mode All types of fault codes may be viewed in the
When a major component of the EMS is not oper- Faults page of B.U.D.S. Only fault codes in an
ating properly, limp home mode will be set. active state may be viewed in the multifunction
gauge.
Engine RPM will be limited and/or engine behav-
ior and control may be modified depending on the Active Fault Codes
cause of the failure. An active fault code is an indication of a fault
This mode allows the rider to return home, which that is presently active. The active fault may or
would otherwise not be possible without this ad- may not compromise normal operation of the
vanced system. system(s) in question as indicated by the fault
code(s). Service action should be taken to correct
LIMP HOME will be displayed in the multifunction
the problem that caused the fault code.
gauge and the CHECK ENGINE light symbol will
be on in the gauge. Once the cause of the active fault is corrected,
the fault code must be cleared using B.U.D.S. to
prevent it from being retained in memory.
FAULT CODES
A fault code is an indication that a glitch or mal- Occurred Fault Codes
function is detected by the monitoring system of An occurred fault code indicates a fault that was
the vehicle. active, but no longer is. The occurred fault does
A fault code consists of 5 digits that starts by a not presently affect system or component opera-
letter followed by a 4 digit code that may be com- tion but is retained as a history of the faults that
prised of numbers and/or letters. The first letter were detected.
defines the type of fault code while the remaining The fault may have been generated due to a
digits refer to a unique fault. system or component that was momentarily op-
There are 2 types of fault codes used on the vehi- erating outside normal parameters. Repeated
occurred faults of this type should be considered
cle:
when troubleshooting a problem, and may require
— "P" for power train and related system faults that maintenance action be taken.
(Pxxxx)
— "U" for communication faults (Uxxxx) An occurred fault may also be generated when
disconnecting and reconnecting a component, re-
There are 2 modules that generate and store the placing a burnt fuse, when the software update of
fault codes: an electronic module has been carried out, or may
— ECM (Engine Control Module) be due to a momentary high or low voltage.
— Multifunction Gauge.
Inactive Fault Codes
The ECM stores mainly "P" codes and some "U"
An inactive fault code represents a fault code that
codes.
is neither active, nor occurred. It is simply part of
The multifunction gauge stores a few "P" and "U" a list of all possible faults that can be monitored
codes. by the ECM and multifunction gauge, which may
When many fault codes that may or may not be become active or occurred if the monitoring sys-
related to a specific system are set at the same tem detects an applicable fault. These codes can
time, it is likely to be the result of low battery volt- be viewed in B.U.D.S.
age, a burnt fuse(s) or a faulty relay.
How to Read Fault Codes Using
NOTE: The faults detected are saved in the ECM
(Engine Control Module) or multifunction gauge
B.U.D.S. Software
even if the battery is disconnected. 1. Connect vehicle to the applicable version of
B.U.D.S. software, refer to COMMUNICATION
Fault Code States TOOLS AND B.U.D.S. SOFTWAREsubsection.
Fault codes have 3 possible states: 2. Click on the Read Data button.
— Active state 3. Select the Faults tab.
— Occurred state
— Inactive state.

216 tmr2011-020
 Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 03 (DIAGNOSTIC SYSTEM AND FAULT CODES)

1. Read Data button

2. Faults page tab
3. Recorded fault code
4. Fault code state 1. M (mode) button
5. Fault code description 2. S (set) button (pressed repeatedly to toggle secondary display)

For more information pertaining to the fault codes

and report, refer to B.U.D.S. online help.

How to Read Fault Codes Using the

Multifunction Gauge
A fault code must be active to be displayed in the
multifunction gauge. If a fault code is occurred, it
must be read using B.U.D.S.
Analog/Digital Gauge
Proceed as follows to view the active fault codes:
1. Turn ignition key to ON with lights position.

1. Toggle this digital display to Hr

4. Press and hold the M (mode) button while

quickly toggling the HI - LO beam switch to
enter the fault code display function.
NOTE: A minimum of 3 HI - LO toggles must be
completed within 2 seconds.

GNITION SWITCH POSITION

1. OFF
2. ON with lights (turn key to this selection)
3. ON

2. Wait for the multifunction gauge to complete its

self test function.
3. Press the S (set) button repeatedly until Hr
(hour) is displayed in the secondary digital dis-
play.

Imr2011-020 217
 Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 03 (DIAGNOSTIC SYSTEM AND FAULT CODES)

2. Press the selector button on the gauge repeat-

edly until Engine Hour (EH) is displayed on the
gauge.

1. Selector button to toggle indication

7. Low/High beam headlight switch

If a fault code is active, it will be displayed in the

main digital display.
If no fault code is active, a scrolling NO ACTIVE
FAULT CODE message will be displayed.
If there are multiple fault codes, the display will
cycle through each fault code repeatedly. A maxi-
mum of 10 fault codes may be displayed.
If the fault code display function has been inter-
rupted by another message, a fault code(s) may TYPICAL - EH (ENGINE HOUR DISPLAY)
not have been displayed. Repeat the fault code
display procedure to view all active fault codes. 3. Press and HOLD the M button while QUICKLY
To exit the fault code display function, press both toggling HI - LO beam switch to enter the fault
the M and S buttons simultaneously. code display function.
NOTE: A minimum of 3 HI - LO toggles must be
LCD Gauge completed within 2 seconds.
1. Turn ignition key to ON with lights position.

1. Low/High beam headlight switch to toggle quickly

GNITION SWITCH POSITION

1. OFF If no P-Code is active, a "No Active P Codes"
2. ON (with lights) scrolling message will be displayed.
3. ON
If there is an active P-Code, it will be displayed.

218 tmr2011-020
 Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 03 (DIAGNOSTIC SYSTEM AND FAULT CODES)

If there are multiple fault codes, the display will TAS Fault
cycle through each fault code. If one TAS (throttle accelerator sensor) signal is
Once the last fault code is displayed, the gauge missing, LIMP HOME MODE will be activated and
displays END then defaults back to normal opera- the check engine light will come ON. Pressing and
tion. holding the OVERRIDE button will allow normal
control of the accelerator pedal.
How to Clear Fault Codes Using If both sensors in the TAS are at fault, a TAS
B.U.D.S. Software FAULT message will appear in the gauge, the
The fault(s) (occurred state only) can be cleared check engine light will come ON and the engine
by pressing the Clear Occurred Faults button in will run at idle. The accelerator pedal will not
B.U.D.S. have any affect on engine RPM. However, the
vehicle may be driven in LIMP HOME MODE by
pressing the OVERRIDE button.
When limp home mode is engaged using the
Clear Occured Faults override button, a MANUAL LIMP HOME mes-
sage will appear in the gauge. The OVERRIDE
rmr2C0B-039009 button can then be used as the accelerator,
FAULTS PAGE TAB, CLEAR OCCURRED FAULTS vehicle speed is controlled by pressing and/or
releasing the button.
This will reset the appropriate counter(s) and will
also record that the problem has been fixed in the PARK BRAKE Fault Message in Gauge
related ECU memory.
Early Production Models (Only)
NOTE: An active fault code cannot be cleared.
In other words, the problem relevant to the fault Although this vehicle is not equipped with a park
code must be repaired before the fault can be brake, a PARK BRAKE message will be displayed
cleared. in the gauge if a brake signal is received continu-
ously for 15 seconds.
SPECIFIC FAULTS BRAKE ACTIVATION Fault Message in
TPS Fault Gauge
A TPS fault may be considered to be a major fault Late Production Models
as the TPS provides the most important feedback If a brake signal is received continuously for 15
(2 signals) to the ECM on throttle position. seconds above 5 km/h (3 MPH), a BRAKE ACTIVA-
A TPS fault affects engine control as the throttle TION message will be displayed in the gauge.
plate is moved by the ETA (electric throttle actua-
tor) which, is controlled by the ECM (see INTEL-
LIGENT THROTTLE CONTROL (/TC) subsection).
A TPS fault is generally followed by LIMP HOME
mode and the engine is brought back to idle, or
may be completely shutdown.

Low Battery Voltage Fault

If the battery voltage is low when the engine is
running at idle RPM, the ECM will command an
increase in RPM to a set value, thereby increasing
the charging system output in order to prevent the
battery from being discharged, and to allow nor-
mal system operation.

trnr2011-020 219
 Section 04 FUEL SYSTEM
Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC))

INTELLIGENT THROTTLE CONTROL

OTC)
GENERAL Performance Key
When a performance key is used, engine delivers
SYSTEM DESCRIPTION 100% of the accelerator pedal demand (less if nor-
mal mode is selected). The vehicle speed is lim-
The iTC is an electronic throttle control system
ited to 120 km/h (75 MPH).
that includes:
— Throttle accelerator sensor (TAS) Work Key (Option)
— Electric throttle actuator (ETA) When a work key is used, engine delivers approxi-
— Throttle position sensor (TPS). mately 50% of the accelerator pedal demand (less
if normal mode is selected). Vehicle speed is lim-
The TAS is part of the accelerator pedal module.
ited to 40 km/h (25 MPH).
The ETA and TPS are comprised in the throttle
body.
Normal/Sport Modes
The iTC is often referred to as a "throttle by wire"
When sport mode is selected, the full potential of
system (no throttle cable is used).
the specific ignition key is deployed except when
According to the accelerator pedal position and gearbox is in reverse or low gear.
other EMS inputs, the ECM powers the ETA
When normal mode selected, the full potential of
motor using pulse width modulation (PWM), to
the specific ignition key is not reached and the ac-
control the throttle plate. When the ECM de-
celerator pedal response is smoother than in sport
tects through the TPS that the throttle plate has
mode.
reached the targeted position, the ECM stops the
throttle actuator. Reverse Override Function
Depending on various conditions and the type of In reverse gear, engine delivers less than the
key used, the iTC can modify the ETA response, accelerator pedal demand and vehicle speed is
limit the engine torque or vehicle speed. limited to 20 km/h (12 MPH). Also, the accelera-
For torque limitation, the ECM processes the TAS tor pedal response is smoother than in high gear.
input differently depending on the specific mode.
If the override button is depressed, vehicle speed
In other words, the driver's demand may not nec-
and engine acceleration are increased. Even with
essarily result in the corresponding throttle open-
the override is activated, the ECM will not allow
ing.
the engine to deliver 100% of the accelerator
For vehicle speed limitation, the iTC controls the pedal demand.
throttle opening to maintain a maximum set speed
even if the accelerator is pedal fully depressed.
SYSTEM OTHER FEATURES
SYSTEM MAIN FEATURES Driver's Seat Belt Monitoring
The use of the iTC allows the following features: If driver's seat belt not fastened, speed is limited
to approximately 15 km/h (9 MPH).
— Key modes
— Normal/Sport modes Brake Monitoring
— Override functions.
If the ECM receives a brake switch signal while
Key Modes gearbox is in gear and the vehicle moving, the
ETA will decrease throttle plate opening and en-
Normal Key gine speed will drop to idle.
When a normal key is used, engine delivers ap- NOTE: A defective brake light switch that would
proximately 70% of the accelerator pedal demand stay in a closed position would force the engine to
(less if normal mode is selected). Vehicle speed is run at idle.
limited to 70 km/h (43 MPH).

tmr201 1-021
221
Section 04 FUEL SYSTEM
Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC))

Low Range Operation SEAT BELT SWITCH

When gearbox is in low range, engine delivers Seat Belt Switch Wire Information
less than the accelerator pedal demand and the
accelerator pedal response is smoother than in FUNCTION PIN COLOR
high gear. Signal (to ECM B pin E3) 1 YELLOW/GREY
Half Shaft Saver Ground through ECM
2 ORANGE/VIOLET
(to ECM B pin A1)
In a case where the drive wheels would momen-
tarily leave the ground while the driver holds the
throttle, this mode protects the drive system. OVERRIDE SWITCH
The system will enter the half shaft saver mode if
Override Switch Wire Information
the ECM detects an excessive wheel acceleration
rate. In such a case, the iTC will reduce the engine FUNCTION PIN COLOR
torque. When the wheels slow down, the system
Normal position signal
returns to normal mode. 1 VIOLET/YELLOW
(to ECM B pin D3)
Engine Temperature Monitoring Ground through ECM
2 VIOLET/GREY
(to ECM B pin B1)
If coolant gets too hot, engine will deliver less
than the accelerator pedal demand. The limitation Override position signal
3 VIOLET/ORANGE
is proportional to the overheat degree. (to ECM B pin F3)

Battery Voltage Monitoring

THROTTLE ACCELERATOR
If the battery voltage gets low, the engine
idle RPM will be increased at approximately
SENSOR (TAS)
1500 RPM. TAS Description
Drowned Mode The throttle accelerator sensor (TAS) is a double
hall effect sensor that sends a signal to the ECM
In case of a fuel flood, the engine can be cranked which is proportional to the accelerator pedal. The
without fuel injection. redundancy is used for security purposes.
To enter the drowned mode, depress and hold ac- The voltage output of the hall effect sensors are
celerator pedal (at least 20% of the travel) while different.
cranking engine.
TAS Removal and Installation
Limp Home Mode
The TAS is part of the accelerator pedal.
When certain faults are occurring, the ECM will
enter the limp home mode. In this mode, the en- 1. Note the wire routing and tie-wrap position.
gine will deliver less than the accelerator pedal de- 2. Disconnect electrical connector.
mand. 3. Remove both accelerator pedal retaining nuts
by outside the passenger compartment. Reach
PROCEDURES nuts by the RH side of the vehicle.

SPORT/NORMAL SWITCH
Sport/Normal Switch Wire Information
FUNCTION PIN COLOR
Signal (to ECM B pin D4) 1 BROWN/GREEN
Ground through ECM 2 ORANGE/VIOLET
(to ECM B pin Al)

tmr2011-021
222
 Section 04 FUEL SYSTEM
Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC))

Connect to the latest applicable B.U.D.S. soft-

ware. Refer to COMMUNICATION TOOLS AND
B.U.D.S section.
Select the Monitoring and ECM tabs.
Look at the TAS (%) window as you depress the
accelerator pedal.

3000 ; 9000

2000 ^ C-4:- 10000 r- 13

1000 ''11000 3
,1" :1';:
`<f RPM
U 12000
4-0
Into All Ma nifolc
1. Steering column Engine Speed 0 RPM
2. Accelerator pedal retaining nuts 8 10
intake (PSI)- [14.3

To install, reverse the removal procedure, how- 1i 9

TPS (%)
ever pay attention to the following:
TAS (Si)
Route and attach wires correctly. Eav

Tighten nuts to the specified torque. trnr2011-021-001_a

1. TAS % window
ACCELERATOR PEDAL RETAINING NUTS
TIGHTENING TORQUE The TAS signal should vary from near 0% to near
100% depending on the pedal position, which
13 Nom ± 1 Nom (1151bf•in ± 9Ibf•in)
confirms the TAS signal reaches the ECM.
Carry out the ECM FIRST INITIALIZATION, refer to
ELECTRONIC FUEL INJECTION (EF/) subsection.

TAS Wire Information

FUNCTION PIN COLOR
Signal A BLUE/GREEN
Ground through ECM B BLUE/RED
Voltage input (5 volt) C BLUE/ORANGE
Voltage input (5 volt) D BLUE/BLACK
Signal E BLUE/PINK
Ground through ECM F BLUE/VIOLET

TAS Failure
If one TAS signal fails, the vehicle will enter the
limp home mode. In this case, depressing the
override button will temporarily restore accelera-
tor pedal operation (while button is depressed).
If both TAS signals fail, the engine speed will drop
to idle. Depressing the override button will force
the ECM to open the ETA to an angle that allows
the vehicle to move.

TAS Test with B.U.D.S.

The TAS signal can be monitored in B.U.D.S.

tmr2011-021
223
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

ELECTRONIC FUEL INJECTION (EFI)

SERVICE TOOLS
Description Part Number Page

DIGITAL INDUCTION TACHOMETER 529 014 500 226

ECM ADAPTER TOOL 529 036 166 229,241,243-246
FLUKE 115 MULTIMETER 529 035 868 229,235,241,244-245
OETIKER PLIERS 295 000 070 238

SERVICE PRODUCTS
Description Part Number Page

LOCTITE 243 (BLUE) 293 800 060 246

XPS SYNTHETIC GREASE 293 550 010 243

GENERAL Electrical System

A WARNING ECM (Electronic Control Module)
Fuel is flammable and explosive under cer- From input signals, the ECM acknowledges
tain conditions. Ensure work area is well ven- driver demands and converts them to an engine
tilated. Do not smoke or allow open flames or torque requirement through calculation of several
sparks in the vicinity. variables. Then, the ECM controls the iTC, the
injection system and the ignition system to meet
the torque requirement.
A WARNING
The ECM manages the engine torque require-
Fuel lines remain under pressure at all times.
ments and controls engine operation to ensure
Always proceed with care and use appropri-
it is delivering optimum performance and fuel
ate safety equipment when working on pres-
economy. The ECM also controls idle RPM and
surized fuel system. Wear safety glasses.
limits maximum engine speed through the iTC
Wipe off any fuel spillage. Do not allow fuel
system.
to spill on hot engine parts and/or on electri-
cal connectors. EFI Sensors
The ECM reads the inputs from the sensors
A WARNING which it compares to predetermined parameters
Replace any damaged, leaking or deteri- stored in the ECM, makes computations, and ac-
orated fuel lines or connections. Always, tivates the outputs accordingly (injectors, ignition
pressurize the fuel system if any fuel related coils etc.).
component was disconnected or removed.
Signals from sensors are used by the ECM to de-
Proceed with care when removing/installing
termine the injection and ignition parameters (ref-
high pressure test equipment.
erenced to fuel maps) as required to maintain the
optimum air-fuel ratio.
SYSTEM DESCRIPTION
Air Intake System
The electronic fuel injection system (EFI) is com-
prised of various sensors used for detecting ongo- Air Filter
ing operating conditions of the engine and vehicle, Air, drawn into the air filter housing, first passes
and includes all the components that perform the through an inlet duct.
required adjustments to the engine.
After it passes through the air filter, an air duct
(intake adapter) is used to channel the air to the
throttle body.

tmr2011-022
225
Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

Throttle Body Fuel Injectors

The throttle body is mounted on the front end of The fuel injectors are used to inject fuel into the
the plenum, aft of the air filter housing. intake ports of the cylinder head. One injector is
Air for combustion, drawn in by the engine, flows used per cylinder.
through the air intake system, then through the Fuel Pump
throttle body where it is regulated by a throttle
plate. An electric fuel pump with an integrated pressure
regulator and fuel system filters is used. For more
details on the fuel pump unit, refer to FUEL TANK
AND FUEL PUMP subsection.

ADJUSTMENT
IDLE SPEED
Idle speed is not adjustable. The ECM controls
the idle speed of the engine primarily through con-
trol of the throttle plate position.
The vehicle multifunction gauge can provide an ac-
curate digital readout of the engine's idle speed.
If desired, the engine RPM can be verified using
1. Throttle body a DIGITAL INDUCTION TACHOMETER (P/N 529 014
2. ETA and TPS 500).
3. MAPTS (Manifold Air Pressure Temperature Sensor)
4. Plenum Install the tachometer wire on a spark plug cable.
5. Air intake manifold

Fitted on the throttle body, an electric throttle ac-

tuator (ETA) allows the ECM to electronically con-
trol the throttle plate opening which regulates the
amount of air that enters the engine, and there-
fore engine torque.
There is no idle air control valve (IACV).
The TPS is also incorporated in the throttle body.
It provides a signal to the ECM of the actual throt-
tle plate position.
Plenum
After the air flows through the throttle body, it
enters the plenum. The plenum provides a reso-
nance effect which leads to an improved cylinder
charge.
VERIFYING ENGINE RPM USING A DIGITAL INDUCTION
TACHOMETER
Fuel System
The engine RPM may also be verified using the ap-
Fuel Rail
plicable B.U.D.S. software version, refer to COM-
Two fuel rails, one for each injector, are mounted MUNICATION TOOLS AND B.U.D.S. subsection.
on the intake manifold. The fuel rails, which are
In B.U.D.S., select the following:
used to secure the injectors to the manifold, also
provide to the injectors the fuel pressure that they — Read Data button
receive from the fuel pump. — Monitoring page tab
The fuel pressure applied to the fuel rails is regu- — ECM tab.
lated by the fuel pressure regulator located in the
fuel pump module.

tmr2011-022
226
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

— Fuses
— Ground connections
— Wiring and connectors.
Ensure that all electronic components are genuine
OEM. Any modification to the wiring harness may
lead to poor system operation or generate fault
Intak: Air memo.. pR,3 codes.
ik■

Electrical Connections
Pay particular attention to ensure that terminals
and pins are not out of their connectors, corroded,
cements vow. or out of shape.
2M 1 022-00'i,
When probing terminals, pay attention not to de-
,

VERIFYING ENGINE RPM USING B.U.D.S.

1. Monitoring page tab form the terminals as this could cause a loose or
2. Engine RPM indication intermittent connection that would be difficult to
troubleshoot.
NOTE: The multifunction gauge and B.U.D.S. use
the same signal to provide the engine RPM indi-
cation. PROCEDURES

TROUBLESHOOTING ENGINE CONTROL MODULE

(ECM)
DIAGNOSTIC TIPS NOTE: As a first troubleshooting step, always
Engine problems are not necessarily related to the check for applicable fault codes using B.U.D.S.
fuel injection system. software.
It is important to ensure that the engine and Quick Test to Validate ECM Operation
propulsion system, fuel delivery and electrical
systems are functioning normally. Turn ignition key to ON.
For diagnostics purposes, use B.U.D.S. software. NOTE: Setting the ignition switch to ON wakes
See COMMUNICATION TOOLS AND B.U.D.S. up the ECM, which then turns on the following.
subsection. QUICK INDICATION THAT ECM IS FUNCTIONING
After a problem has been solved, be sure to clear (assuming the observed component is
the fault(s) in the ECM using the B.U.D.S. soft- in good working order)
ware. Multifunction gauge turns ON.

A WARNING Fuel pump turns on for approx. 5 seconds.

Electrical actuators and electronic modules Rear lights turn on.
may be powered up as soon as the ignition
Headlamps turn on (ignition key on with lights
switch is set to ON. Always disconnect the position).
battery prior to disconnecting any electrical
or electronic parts.
ECM First Initialization
Never use a battery charger to temporarily substi- This procedure performs a reset of the following
tute the battery as it may cause the ECM to func- values in the ECM:
tion erratically, or not at all. — TAS (Throttle Accelerator Sensor)
Check related-circuit fuse solidity and condition — TPS (Throttle Position sensor)
with an ohmmeter. A visual inspection could lead — GBPS (Gearbox Position Sensor).
to a false diagnosis.
This reset must be carried out whenever the ECM
Electrical Related Problems has been replaced.

It is important to check the following in the elec-

trical system:
— Battery voltage

tmr2011-022 227
Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

This reset may be carried out whenever any of 5. Check for fault codes.
the following components have been replaced in- If a fault code is generated, carry out the service
stead of their respective reset procedures: actions, reset the fault and repeat the reset pro-
— Throttle body (for TPS) cedure.
— GBPS (Gearbox Position Sensor). 6. Start engine and make sure it operates normally
1. Connect vehicle to the applicable B.U.D.S. ver- throughout its full engine RPM range.
sion, refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection. ECM Access
2. In B.U.D.S., select the following: The ECM is located under the dashboard, driver's
— Read Data button side, above the control pedals.
— Setting page tab
— ECM page tab

3 TYPICAL - ECM LOCATION

1. ECM location

ECM Connector Identification

2011-022002. 3
There are 2 connectors connected to the ECM:
7. Read Data button
2. Setting page tab — Engine harness connected to ECM-A
3. ECM page tab — Vehicle system control harness connected to
ECM-B.
3. In the ECM first initialization field, click on the
Reset button.

ECM first

r02011 - 022 004_ a

ECM FIRST INITIALIZATION

1. Reset button
1. Connector A
4. Follow the instructions in the message boxes 2. Connector B
that appear in B.U.D.S.
The ECM connectors have 48 pins.
If the operation is successful, a message will be
displayed stating that the reset was successful. NOTE: For connector information, cleaning and
probing, refer to CONNECTOR INFORMATION
If an error occurred or a component is out of
subsection.
range, a message may be displayed. Follow the
instructions in the message and repeat the pro-
cedure.
tmr2011-022
228
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI ► )

ECM Adapter Tool ECM BATTERY

RESISTANCE
To probe ECM connector terminals, use the ECM ADAPTER POST
ADAPTER TOOL (P/N 529 036 166). Pins B-L1, Close to 052
Ground
B-M2 and B-M3 (continuity)

NOTE: This tool will prevent deforming or enlarg-

ing terminals which would lead to bad ECM ter-
minal contact creating intermittent or permanent f any measurement is out of specification, check
the following:
problems.
— Engine ground
ECM Power Supply Test — Battery ground
1. Disconnect connector "B" from the ECM. — Frame ground.
2. Install ECM connector "B" on the ECM ADAPTER
TOOL (P/N 529 036 166).
3. Install a jumper wire between B-H2 and B-M2
on the ECM adapter tool.
4. Turn the ignition switch to ON.
5. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and select Vdc.
6. Check for voltage as follows.
ECM
BATTERY VOLTAGE
ADAPTER
B-M4 Negative post Battery voltage

If voltage is not measured, check the following:

— Main relay
— Wiring and connections, refer to the WIRING 1. Voltage regulator/rectifier
2. Frame ground stud
DIAGRAM 3. Negative (-) battery post
4. Battery ground wire
5. Engine ground wire
Continuity Test of ECM Ground
Circuits
ECM Removal
1. Disconnect connector "B" from ECM.
NOTE: If a new ECM is to be installed, first read
2. Install the ECM ADAPTER TOOL (P/N 529 036 166) the procedures in ECM REPLACEMENT in this
on ECM-B connector. subsection.
3. Use the FLUKE 115 MULTIMETER (P/N 529 035 1. Disconnect battery cables.
868) and select Q.
NOTICE Always disconnect the BLACK nega-
4. Probe adapter terminals as per following table.
tive (—) battery cable first, then disconnect RED
positive (+) cable.
2. Disconnect both ECM connectors from ECM.

tmr2011-022 229
Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

3. Unscrew all retaining screws and remove the ECM Automated Data Transfer
ECM from its support. To transfer the information recorded in the faulty
ECM to the new ECM, carry out the following.
1. Connect vehicle to the applicable B.U.D.S. ver-
sion. Refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
2. Turn ignition switch to ON to wake up the
ECM.
3. In B.U.D.S., click the Read Data button to
load the information from the faulty ECM into
B.U.D.S.

File View MPIO Module Tools Help

Int f°1
_
.M• ____
7.
2.
ECM
Retaining screws ler
3. Voltage regulator/rectifier
4. Battery Read Data ` Write Data
ECM Installation vn,2006 01 2 '00 n

Reverse removal procedure however, pay atten- 4. Keep B.U.D.S. running while replacing ECMs.
tion to the following. The data will remain stored in the PC computer
ECM INSTALLATION as long as B.U.DS. is running.
2 N•rn ± 0.2 N•m 5. Remove the old ECM. Refer to ECM REMOVAL
TORQUE (18 lbf•in ± 2 lbf•in) in this subsection.
6. Install and connect the new ECM. Refer to ECM
1. Reconnect ECM connectors. INSTALLATION in this subsection.
2. Reconnect battery cables. 7. Turn ignition switch to ON to wake up the new
ECM.
A WARNING 8. From the Module menu at the top of the
Always reconnect the RED positive (+) battery B.U.D.S. page, choose:
cable first, then reconnect BLACK negative (—)
— ECM
cable.
— Replace.
3. If a new ECM is installed, refer to ECM RE-
PLACEMENT in this subsection.

ECM Replacement
Prior to replacing an ECM, ensure that all the rec-
ommendations in the general introduction of this
section have been followed.
NOTE: Proceed with an ECM FIRST INITIALIZA-
TION as it may resolve the problem.
If the ECM is replaced, data must be transferred
or entered into the new ECM using one of the fol-
lowing methods:
— If the faulty ECM can be read with B.U.D.S.,
refer to ECM AUTOMATED DATA TRANSFER. TYPICAL
1. ECM Replace function in B.U.D.S.
— If the faulty ECM cannot be read with B.U.D.S.,
refer to ECM MANUAL DATA ENTRY.
tmr2011-022
230
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (M))

B.U.D.S. will automatically write the data from the Double click on the AutoSave folder.
PC computer into the new ECM.
9. Program the vehicle ignition Open
keys into the new ECM, refer to Look in [ ,.L) BUDS P2.3.18 cl C71-
Digital Encoded Security System (D.E.SS.)
w Aut °Save
subsection. _...)Customer \_;)SVE
10. Perform the ECM FIRST INITIALIZATION pro- . I.JectsteFies

cedure, refer to ENGINE CONTROL MODULE

in this subsection. FIN

11. Reinstall any remaining removed parts.

Fde name: Open
ECM Manual Data Entry
Flea of type: I MPEM lies' F. mpem) Cancel
There are 2 possible methods to collect the re-
quired information. The 1st being the easiest:
1. Use B.U.D.S. to obtain the data from a saved
.mpem file on your PC computer. NOTE: You may have to go to another AutoSave
folder from a previous version of B.U.D.S.
2. Collect the information from the vehicle and
BOSSWeb. 4. Choose the latest file saved for this specific ve-
hicle.
1st Collecting Method: Obtaining the Data
from a Saved .mpem File
Open
1. Use the B.U.D.S.
Look AutoSave
NOTE: It is not necessary to perform any connec-
228P5EK8C68M168_20M0206_111640.mpern
tion. The PC computer can be used alone. fleP2.3.22,12 28P5CX9859V000101_20090206_104554sneem
F1.3 .22 .12_2BPSCX985.9V000101 20090206.1 04546.ropem
2. In B.U.D.S., click on the Open button.
deP2.3 22. i22inv48580A909_2000. 206_141803.ropem
01P2.3.22.12_2151SCX9859V00010120090228_104558.ropero
disP2.3.22.12_28PSCX96S9V00010130K190229_104558.mpom
111P2.3.22.12 28PSCX98S9V000101_20090114_114558.mpero

Fie prow IP2 3 22 12_28PSBK8C68V000168_20090206_ Open

Fries d lype. iMPEM Nes )'.mpem) Cancel

(1 00(3

MPORTANT: Be sure to use the file that specifi-

cally matches the vehicle you are servicing.
NOTE: The file name structure is as follows:
B.U.D.S. version_VIN_date read lyyyymmddl_hour read
3. Click once on the Folder Up button in the Open (hhmmss).mpem
box.
Example:

P2.3.22.12_2BPSBK8C68V000168_20090206_111640.mpem
Therefore:
B.U.D.S. version: P2.3.22.12
VIN: 2BPSBK8C68V000168
Date: 2009 02 06
Hour: 11h 16m 40s

5. Select the Vehicle page tab and record (write

down) the following information.
1. Vehicle serial number
2. Engine serial number (without the leading
"M")

Imr2011-022 231
Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

3. Vehicle model number

4. Customer name.
BOSSWeb
RVS4 I TS sire
Yee Vibe, sw-ru twO ow

1111 1.71 4,,G66919.56 CE kLRE

0 Er=2211111111.111111111.11ewes
" c ;yr,
V.h, d. Vey: ;,e11.mg 1,9113 Keta , y.
,-11.11,N3 ,11airr,

Pl;u ■ 13,
qr., =Jed,
Morw.mn,
XXMOODDOM sirs- nee oftiivelv u fpdam

Glick Here it.f.7, 11ut M.rstan

d of Season
s. xxxxxxxxx
to Access Gear Sale

sa82009-030 001 a
minr 2009 18 011
VEHICLE TAB SERVICE, UNIT HISTORY

6. Enter recorded data in ECM as detailed in 3. Enter the recorded data in the new ECM as de-
ENTERING THE COLLECTED INFORMATION tailed in ENTERING THE COLLECTED INFOR-
INTO THE ECM. MATION INTO THE ECM
2nd Collecting Method: Collect the Entering the Collected Information Into the
Information from the Vehicle and BOSSWeb ECM
1. Record engine serial number. 1. Use the applicable B.U.D.S. version. Refer to
COMMUNICATION TOOLS AND B.U.D.S. sub-
section.
2. Turn ignition key to ON position.
3. In B.U.D.S., click the Read Data button to read
the new ECM.

File View MPI® Module Tools Help

NT •• I
Read Data Write Data
TYPICAL - RH SIDE OF ENGINE
1. Engine serial number ,„ 0 1 2 100 1,

2. Record the following numbers using The following screen window will pop up.
BOSSWeb. Look in Service menu and
choose Unit history.
1. Vehicle serial number
2. Vehicle model number BUDS canna (*team* Vie type of yericie you are connected to because. Po
Attociti anottoi is missing The veitio3r) model must *Oh*, be SF ,A€", eli
3. Customer name. an-An:numerical value or ar entirely numerical yaw Enter Eire appropriate Yebitte
rneael in file Oa boo below ,

'

3.8r2002 023 100

4. Enter the vehicle model number.

232 1ml-2011-022
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

NOTICE Enter only the appropriate product r ump

model number as obtained when gathering the Calpisc3.M.im -41(-- 2
information.
Add Pan
=1=221111.1111111111111111111111111111111.1111111NINW1
Part Type
r➢ jine

B LI.C, 0 cannot aeternune the ripe of Muck you ak: conr,ocwd to Cecou..:,-, :•: - •
volut is frodtol as rrassne) The vehnie model new eaten be "SE:0AT*, an
ECM 4
4410nuffitiriCed ratue or en entlriAy aurneneal value Enter tie eppropnete yerm de
rradei ,D the et11t.C,, belOvv.

istAla 13 4.0A

,m r 2000 11211 100 0

ADDING PART IN HISTORY
I. History page tab
5. Select the Vehicle tab and enter the informa- 2. Part Replacement tab
3. Add part in history button
tion you recorded previously. 4. ECM selection
1. Vehicle serial number 5. Add ECM serial number here

2. Engine number (do not enter the "M" at the NOTE: The ECM serial number can be found on
beginning of the engine number) the ECM sticker that also identifies the part num-
3. Customer name. ber.
8. Click on the OK button.
9. Click on the Write Data button.

IderdEtLallon

Whrlie (VN )0000303000< Ciastomer Se dos

Pfgr. XXXXXXXK .1eln.oy DA, 03.0245

Model. XXXXKCCia

smr2009 030-001 a

VEHICLE TAB

6. Click on the following tabs:

— History
— Part Replacement
10. Perform the ECM FIRST INITIALIZATION re-
— Add Part in History. set.
7. Enter the old ECM serial number in the Add 11. Program the vehicle ignition
Part In History window. keys into the new ECM, refer to
Digital Encoded Security System (D. E. S. S.)
subsection.
12. Reinstall any remaining removed parts.

FUEL INJECTOR
Fuel Injector Operation Test Using
B.U.D.S. (Dynamic)
NOTE: As a first troubleshooting step, always
check for applicable fault codes using B.U.D.S.
1. Connect vehicle to the applicable B.U.D.S. ver-
sion. Refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
tmr201 1-022 233
Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

2. Start engine. 2. Connect vehicle to the applicable B.U.D.S.

3. In B.U.D.S., select the following: software version. Refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection.
— Read Data button
— Monitoring page tab 3. Turn the ignition key to ON.
— ECM page. 4. In B.U.D.S., select the following:
4. Using the B.U.D.S., shut down fuel injection to — Read Data button
each engine cylinder one at a time by clicking — Activation page tab.
on the button under the applicable cylinder. 5. In B.U.D.S., click on the Fuel Pump button to
activate fuel pump.

uel Pump

--- Enabled 12isabled

Activate

Fuel Pump-4(

,cooling Fan

Accesory Relay

trnr2011-011-017A

1. Fuel Pump activation button

1. Click on cylinder number to be tested 6. Fuel pressure must be within specification. Re-
fer to FUEL TANK AND FUEL PUMP subsec-
If the engine RPM drops momentarily when click- tion. Re-activate fuel pump as necessary.
ing on a cylinder, the injector on this cylinder is
7. In B.U.D.S., energize fuel injector no. 1.
functioning normally.
If the engine RPM does not drop momentarily
when clicking on a cylinder, this cylinder is not
functioning properly. Check the following:
— Fuel injector operation. Refer to FUEL INJEC-
TOR BALANCE TEST USING B.U.D.S.
— Spark plug and ignition coil. Refer to IGNITION
SYSTEM subsection.
— Engine condition.

Fuel Injector Balance Test Using

B.U.D.S.
NOTICE After fuel injector activation using
B.U.D.S., always crank engine in drowned
mode to ventilate engine and prevent a po-
tential backfire due to fuel accumulation in
engine.
1. Click on injector to activate
1. Install a fuel pressure gauge as described in
FUEL PUMP PRESSURE TEST of FUEL TANK 8. Record the fuel pressure drop for injector no. 1.
AND FUEL PUMP subsection. 9. In B.U.D.S., click on the Fuel Pump button to
activate fuel pump.

234 tmr2011-022
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

10. Repeat the procedure for fuel injector no. 2 If the injector does not function, carry out the
and record the pressure drop for each injector. FUEL INJECTOR RESISTANCE TEST.
11. The maximum fuel pressure drop between in-
jectors should not exceed the following spec- Fuel Injector Resistance Test
ification: Disconnect connector "A" from the ECM.
MAXIMUM FUEL PRESSURE DROP ALLOWED Disconnect the engine connector (HIC).
BETWEEN FUEL INJECTORS NOTE: The HIC connector is located to the right
10 kPa (1.5 PSI) of the ECM.

If pressure drop of any fuel injector is greater than

the specification, replace that injector then repeat
the test.
12. Using the valve on the fuel pressure gauge,
release the pressure in the system (if so
equipped).
13. Remove fuel pressure gauge and reinstall re-
moved parts.

Fuel Injector Leak Test

Carry out the FUEL PUMP PRESSURE TEST as
detailed in the FUEL TANK AND FUEL PUMPsub-
section.

Fuel Injector Activation Test Using HIC CONNECTOR LOCATION

B.U.D.S. 1. Accelerator pedal (not visible)
2. ECM
Turn ignition key to ON. 3. HIC connector

On the Activation page of B.U.D.S. software, en- Using a FLUKE 115 MULTIMETER (P/N 529 035 868),
ergize the fuel injector to be tested. check resistance value between terminals as fol-
lows.
FUEL INJECTOR RESISTANCE TEST AT
HIC CONNECTOR
ECM
HIC RESISTANCE
INJECTOR CONNECTOR
CONNECTOR @ 20°C (68°F)

800R and 1000 Engines

FRONT A-J1
D 11.4 - 12.6 12
REAR A-K1

If resistance value obtained is incorrect, remove

injector connector and check resistance value be-
tween injector pins as follows.
FUEL INJECTOR RESISTANCE TEST AT
INJECTOR CONNECTOR
TYPICAL RESISTANCE @
1. Click on injector to activate INJECTOR INJECTOR PIN
20 C (68°F)
You should hear the injector functioning. 800R and 1000 Engines
This will validate the injector mechanical and elec- FRONT
trical operation. 1 2 11.4 - 12.6 (2
REAR

tmr2011-022 235
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

INJECTOR
CYLINDER CONNECTOR MEASUREMENT
WIRE
FRONT VIOLET/ Battery
12 Vdc
REAR BLUE ground

TYPICAL

If readings are out of specifications, replace injec-

tor.
TYPICAL
If readings are good, carry out a FUEL INJECTOR
INPUT VOLTAGEtest. If supply voltage is not good, check continuity
between fuse F5 and injector (see WIRING DIA-
Fuel Injector Input Voltage Test GRAMS).
Disconnect the fuel injector connector. NOTE: Probe fuse exactly as shown. This vali-
NOTE: If the connector is hard to unlock, gently dates fuse at the same time.
use a screwdriver to release connector. Use a multimeter and set it to Q. Read resistance.
INJECTOR CIRCUIT
CYLINDER MEASUREMENT
WIRE
FRONT
VIOLET/
Fuse F5 Close to 0 Q
REAR BLUE

If continuity is good, check relay and wiring from

battery.
If continuity is faulty, check fuse and if OK,
repair/replace wiring going to injector.
If supply voltage is good, check ground circuit
between injector and ECM (see WIRING DIA-
GRAMS).
— If ground circuit is faulty, repair/replace wiring
TYPICAL and connectors.
— If ground circuit is good, refer to ECM RE-
NOTE: It is not necessary to activate the injector PLACEMENT.
since it is continuously powered when the ignition
key is set to ON. Fuel Injector Removal
Use a multimeter and set it to Vdc. Read voltage. To remove the injector, first remove the fuel rail
refer to FUEL RAIL for the procedure.

236 tmr2011-022
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

TYPICAL - FUEL RAIL ASS'Y

1. Fuel rail
2. Fuel injector
3. Injector top 0-ring
4. Injector bottom 0-ring
5. Manifold 0-ring

Then pull fuel injector out of the fuel rail.

Firmly push injector until it bottoms out.
Fuel Injector Installation Reinstall fuel rail.
For the installation, reverse the removal proce-
dure. Pay attention to the following details. FUEL RAIL
Apply a thin film of engine oil to 0-rings to ease
insertion in rail.
Fuel Rail Replacement
Install fuel injector with your hand. Do not use any Fuel Rail Removal
tool. 1. Connect vehicle to the applicable B.U.D.S. soft-
FUEL INJECTOR INSTALLATION
ware version and select the following:
— Read Data button
0 RINGS I
- New I Lubricate with engine oil
— Activation page tab
Position the manifold 0-ring on injector as in fol- — ECM page tab
lowing illustration. — Fuel pump Disabled.

Fuel Pump
1
," enabled j2isabled

Activate

Fgel Pump

C.00ling Fan

Accessory Relay
TYPICAL - MANIFOLD 0-RING POSITION
0:7 r
Carefully insert injector in manifold paying atten- 1. Click here to disable the fuel pump
tion to the manifold 0-ring.
2. Release fuel pressure by running engine until it
NOTICE Gently push 0-ring in evenly all
runs out of gas.
around while inserting injector. 0-ring must
be completely inserted and not visible, before 3. Turn ignition key OFF.
completing the insertion of the injector.
tmr2011-022 237
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

4. Wrap a rag around the inlet hose and release FUEL RAIL INSTALLATION
the quick fitting.
RETAINING SCREW
INJECTOR 0-RINGS
TORQUE
NEW 10 N•m ± 1 N•m
(Lubricate with engine oil) (89 Ibt•in ± 91bf•in)

After securing fuel hose quick fitting to injector,

re-enable fuel pump using B.U.D.S.

Fuel Pump
1
TYPICAL ,; Enabled DisaPied
5. Unscrew rail retaining screws.
Activate
6. Gently pull rail off by hand.

Fuel Pump

(Doling Fan

Acce5sory Relay

trnr2011-011 017_0

7. Click here to enable the fuel pump

A WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL TANK AND
FUEL PUMP. Run engine and check for leaks.

TYPICAL THROTTLE BODY

To disconnect fuel rail from hose, cut clamp on Throttle Body Description
fuel hose using OETIKER PLIERS (P/N 295 000 070).
Refer to FUEL TANK AND FUEL PUMP for clamp
removal/installation procedures.
NOTE: If fuel rail is removed for access to fuel in-
jector, it is not necessary to cut hose clamp. Only
to replace fuel rail.
Fuel Rail Installation
For installation, reverse the removal process how-
ever, pay attention to the following.
Install new clamps using pliers as per removal (if
fuel rail was replaced).
Install fuel rail and evenly tighten screws a little at
a time each side.
1. Throttle body
2. Throttle plate
3. Electric throttle actuator (electric motor inside)
4. Throttle position sensor (TPS) (inside)

238 tmr2011-022
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

Throttle Body Access To remove connector from throttle body, simulta-

neously press the end of both connector locking
Refer to AIR INTAKE SYSTEM and remove the fol-
tabs illustrated.
lowing parts:
— Air filter housing
— Air intake adapter.

Throttle Body Lubrication

No lubrication is required.

Throttle Body Cleaning

1. Remove air inlet hose from throttle body.
2. Check throttle body cleanliness using a flash-
light. Fully open throttle plate and verify:
— Throttle body bore
— Throttle plate edge.
Look for:
— Dirt
THROTTLE BODY CONNECTOR- PRESS HERE TO UNLOCK
— Oily surfaces
— Carbon and salt deposits on throttle plate and 3. Remove screws retaining throttle body to
the surrounding bore. plenum.
3. Clean as necessary.
4. Use a throttle body cleaner such as GUNK IN-
TAKE MEDIC or an equivalent.
NOTICE Only use an appropriate throttle
body cleaner that will not damage 0-rings and
EFI sensors.

A CAUTION Use the product in a well ven-

tilated area. Refer to product manufacturer's
warnings.
5. To avoid getting dirt into engine, spray cleaner
on a clean rag then rub rag against throttle plate
and bore. A toothbrush may also be used.
7. Throttle body connector
A CAUTION Ensure ignition key is removed 2. Screws (4)
3. Plenum
so that nobody can activate the electrical sys-
tem, otherwise the ECM would turn on and the 4. Pull throttle body off plenum.
throttle actuator (ETA ► would cycle. This could
cause serious finger injury as the throttle plate Throttle Body Installation
moves quickly. Installation of the throttle body is the reverse of
6. Gently open throttle plate and hold fully open to the removal procedure. However, pay attention to
reach all surfaces. the following.
7. To remove residual dirt, spray cleaner on throt- TORQUE FOR THROTTLE BODY RETAINING
tle plate and on bore. SCREWS
8. Reinstall removed parts. 10 Nom ± 1.2 N•m (89 lbfain ± 11 lbf•in)

Throttle Body Removal 1. Perform the THROTTLE POSITION SENSOR

1. Disconnect air inlet hose from throttle body. INITIALIZATION reset procedure. Refer to
2. Disconnect throttle body connector. THROTTLE POSITION SENSOR (TPS) in this
subsection.

tmr2011-022 239
Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

THROTTLE POSITION SENSOR

(TPS)
TPS Description
NOTE: The TPS is part of the throttle body.
The throttle position sensor (TPS) is a double po-
tentiometer that sends signals to the ECM that
are proportional to the throttle plate angle.
NOTE: As a first troubleshooting step, always
check for applicable fault codes using B.U.D.S.
software.

Throttle Position Sensor Initialization

NOTE: The TPS iniatialization procedure must be
carried out whenever the throttle body is replaced, trn 2011-022-002 a

unless an ECM first initialization reset is carried 1. Read Data button

out. 2. Setting page tab
3. ECM page tab
This operation performs a reset of the TPS basic
values in the ECM. This reset is very important as 3. Ensure the accelerator pedal is fully released
the TPS values are part of the basic parameters and at the idle position.
for all fuel mapping calculations and control of sev- 4. In the Throttle position sensor initialization
eral settings such as for idle speed, LIMP HOME field, click on the Throttle Opening Reset but-
mode and maximum RPM of the engine. ton.
NOTICE An improperly set TPS may lead to
Throttlesensor inittahzahon
improper idle speed (too low or too high), poor
engine performance, poor engine starting and Throttle Opening
0,0%
engine stop on deceleration, fault codes and
possible engine damage. Emission compli-
ance may also be affected. Eleset

1. Connect vehicle to the applicable B.U.D.S. r position sensor iritiahzatio

software version, refer to COMMUNICATION

TOOLS AND B.U.D.S. subsection.
Heset
2. In B.U.D.S., select the following:
— Read Data button trn r2011 - 022 - 003 a

— Setting page tab THROTTLE POSITION SENSOR INITIALIZATION

1. Throttle Opening Reset button
— ECM tab.
A message will be displayed if the operation is
successful.
If an error occurred or the TPS is not within the
allowed range while resetting, the ECM will gen-
erate a fault code and will not accept the setting.
5. If a fault message is displayed, follow the in-
structions in the message(s).
6. Check for fault codes.
7. If a fault code is generated,
— Carry out the service actions
— Reset the fault
— Repeat the reset procedure.
8. Start engine and make sure it operates normally
throughout its full engine RPM range.

tmr2011-022
240
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

TPS Wear Test

1. With the engine turned off, slowly press on the
accelerator pedal and pay attention for smooth
operation without physical stops.
2. Activate the electrical system to wake up the
ECM.
3. Connect vehicle to the applicable B.U.D.S.
software version. Refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection.
4. In B.U.D.S., select the following:
— Monitoring page tab
— ECM page tab.
5. Slowly and regularly move the accelerator 1. Push here
pedal.
6. Observe the Throttle Opening indication move- 8. Check the indication movement again.
ment in B.U.D.S. — If the indication moves as expected, check
the throttle accelerator sensor (TAS). Refer to
THROTTLE ACCELERATOR SENSOR (TAS) in
this subsection.
— If the indication does not move as expected,
perform the TPS RESISTANCE TESTin this sub-
section.

RP11.1 TPS Resistance Test

lyre ,
1. Ensure the throttle body connector is properly
10

Intake (PSI).
1,1 connected.
TPS (%) 2. Disconnect ECM connector A from the ECM
and install it on the ECM ADAPTER TOOL (P/N 529
TAS (%)
COMmaymwot 036 166).
tmr2011 022 009
3. Use the FLUKE 115 MULTIMETER (P/N 529 035
1. Monitoring page tab
2. TPS indication 868) and select a
4. Probe circuit as per following table while using
NOTE: The indication should move gradually and
your hand to manually move throttle plate.
regularly as you move the accelerator pedal. If
the TPS indication is erratic or suddenly drops off, FULLY CLOSED FULLY OPEN
it may indicate a worn TPS that needs to be re- ECM THROTTLE THROTTLE
placed. An initial slight delay after the accelerator ADAPTER PLATE (1) PLATE
pedal is moved and before the indication starts to RESISTANCE (Q)
move is normal.
PIN MIN. MAX. MIN. MAX.
If the indication behavior is not as expected, pro-
ceed with the following steps. A-A2 A-K4 875 1625 875 1625
7. Manually move the throttle plate in the throttle A-A2 A-K3 954 1934 228 585
body using a blunt tool (without sharp tip).
A-A2 A-F3 254 634 980 1983

A CAUTION Do not move throttle plate with A-K3 A-K4 228 585 954 1934
your fingers. Otherwise, if ECM should turn A-K3 A-F3 1385 2315 1385 2315
off, it would quickly close the throttle plate
A-K4 A-F3 980 1983 254 634
which could cause finger injury.
(1) To obtain the fully c osed position, it is necessary
to push against the throttle plate in the throttle body
with your hand and hold it in this position for the
measurement.

tmr2011-022 241
Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

CRANKSHAFT POSITION
SENSOR (CPS)

f any resistance value is incorrect, check wire

continuity between ECM and throttle body before
assuming the TPS is at fault. Refer to WIRING
DIAGRAM subsection.

TYPICAL - RH SIDE OF ENGINE

1. CPS location

NOTE: Take into account that a CPS fault can be

triggered by bent or missing encoder wheel teeth.
First check fault codes using B.U.D.S., then check
the encoder wheel teeth condition if necessary
(refer to MAGNETO SYSTEM).

CPS Resistance Test

Disconnect CPS wiring harness connector.

THROTTLE BODY CONNECTOR PIN-OUT

TPS Replacement
Carry out a THROTTLE POSITION SENSOR INI-
TIALIZATIONprocedure as detailed in THROTTLE
BODY of this subsection.

TYPICAL - LH SIDE OF VEHICLE

1. CPS connector location

Probe terminals as per following table.

CPS CONNECTOR MEASUREMENT
RESISTANCE 52
PIN
@ 20°C (68°F)
1 1 2 700 - 900 9

If resistance is not within specifications, replace

the CPS.

242 tmr2011-022
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

If resistance tests good, reconnect the CPS con-

nector and disconnect the connector "A" on the
ECM.
Install ECM-A connector on ECM ADAPTER TOOL
(P/N 529 036 166).

TYPICAL
1. CPS
Using a multimeter, recheck resistance as per ta- 2. Retaining screw
ble.
Install new CPS and secure harness with a new
ECM CONNECTOR MEASUREMENT locking tie.
RESISTANCE SI CPS INSTALLATION
PIN
@ 20°C (68°F)
PRODUCT
A-H 1 A-K2 700 - 900 9
0-RING XPS SYNTHETIC GREASE
If resistance value is correct, refer to ECM RE- (P/N 293 550 010)
PLACEMENT. TORQUE
SENSOR
If resistance value is incorrect, repair the connec- 10 N•m ± 1 N•rn
SCREW
tors or replace the wiring harness between ECM (89 lbf•in ± 9 lbf•in)
connector and the CPS.

CPS Replacement MANIFOLD AIR PRESSURE

Disconnect CPS connector and cut harness lock- AND TEMPERATURE SENSOR
ing tie. (MAPTS)
Remove CPS retaining screw and pull up on CPS
to remove it.

1. Manifold air pressure and temperature sensor (MAPTS)

NOTE: This sensor is a multifunction device.

tmr201 1-022 243

 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

MAPTS Pressure Function MAPTS PRESSURE FUNCTION QUICK TEST

Before the engine is started, when power is ap- RESULT SERVICE ACTION
plied to the system, the sensor measures the am-
bient air atmospheric pressure. The ambient pres- Circuit
sure is, at that moment, stored in the ECM. There- Continuity MAPTS
Repair or
after, once the engine is started, it measures the NO Test of Input
replace
READING MAPTS Voltage
air pressure in the inlet end of the plenum at op- wiring
Pressure Test
erating RPMs. Function
The sensor must be correctly installed on plenum.
VALUE IS
Otherwise, the MAPTS could generate a fault OUT OF Replace MAPTS
code for an unexpected sensor range at idle RANGE
when it reads the atmospheric pressure. If this is
the case, remove sensor and check for oil or dirt MAPTS Input Voltage Test
on its end and if problem persists, check throttle
plate condition/position and the wiring harness. Check the voltage output from ECM to the pres-
Perform the following tests. sure sensor.
1. Turn ignition key ON.
MAPTS Pressure Function Quick Test
2. Remove electrical connector from MAPTS.
1. Connect vehicle to the applicable B.U.D.S. soft-
ware version. 3. Using a FLUKE 115 MULTIMETER (P/N 529 035
868), measure for input voltage as per following
2. In B.U.D.S., select the following: table.
— Read Data
MAPTS CONNECTOR MEASUREMENT
— Monitoring page tab
— ECM page. PIN VOLTAGE
1 1 3 5 Vdc
aul
If voltage test is good, replace the MAPTS.
If voltage test is not good, carry out the MAPTS
CIRCUIT CONTINUITY TEST (PRESSURE FUNC-
TION).
MAPTS Circuit Continuity Test (Pressure
Function)
1. Disconnect the ECM "A" connector.
2. Install ECM-A connector on ECM ADAPTER
Intake Air
TOOL (P/N 529 036 166).
3. Using a multimeter, check continuity of the fol-
lowing circuits.
MAPTS CIRCUIT CONTINUITY TEST
(PRESSURE FUNCTION)
ECM IAA Voltage
MAPTS RESISTANCE
v1,2011-022-011 a ECM -A
CONNECTOR VALUE
1. Monitoring page tab
2. MAPTS pressure reading Pin B4 Pin 3
3. Look for and take note of the MAPTS pressure Pin G4 Pin 4 Close to 0 12
reading while the engine is stopped.
Pin H2 Pin 1
4. Perform the same test with a new MAPTS and
compare both readings. If resistance is not within specification, repair or
Values have to be within ± 3.4 kPa (0.5 PSI). replace the wiring harness between ECM connec-
tor and the MAPTS.

244 tmr2011-022
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

MAPTS Temperature Function MAPTS MEASUREMENT

The sensor monitors the temperature in the inlet RESISTANCE 52
of the plenum. PIN
@ 20°C (68°F)
MAPTS Quick Test (Temperature Function) 1 I 2 2280 - 2740
1. Connect vehicle to the applicable B.U.D.S. soft-
ware version. If resistance is not within specification, replace
the MAPTS.
2. In B.U.D.S., select the following:
If resistance tests good, reconnect the MAPTS
— Read Data and disconnect the connector "A" from the ECM.
— Monitoring page tab
Install ECM-A connector on ECM ADAPTER TOOL
— ECM page.
(P/N 529 036 166).
3. Look for the Intake Air temperature reading
while the engine is stopped.

erg Mondormg Actwahon Faul

2,1 °F
MS

73

.40

Intake Air Using a multimeter, recheck resistance value as

per following table.

I
2
ECM CONNECTOR

PIN
MEASUREMENT
RESISTANCE t2
@ 20°C (68°F)

ECM Input Vouge A-H2 I A-H3 2280 - 2740

tmr2017 - 022 014 b

1. Monitoring page tab MAPTS TEMPERATURE SENSOR TEST RESULTS

2. MAPTS temperature reading
RESULT SERVICE ACTION
4. Perform the same test with a new MAPTS and Circuit
compare both readings. Continuity MAPTS
Repair or
If the engine's MAPTS temperature reading is sig- NO Test of Input
replace
nificantly different than the new MAPTS, replace READING MAPTS Voltage
wiring
it. Temperature Test
Function
NOTE: Both sensors must feel same ambient air
temperature. INCORRECT
RESISTANCE Replace MAPTS
If there is no reading, carry out a MAPTS RESIS- VALUE
TANCE TEST (TEMPERATURE FUNCTION).
MAPTS Resistance Test (Temperature
Function)
Disconnect the connector from the MAPTS.
Using the FLUKE 115 MULTIMETER (P/N 529 035
868), check the resistance of the sensor itself as
shown.

tmr2011-022 245
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

MAPTS Circuit Continuity Test (Temperature

Function)
MAPTS CIRCUIT CONTINUITY TEST
(TEMPERATURE FUNCTION)
MAPTS RESISTANCE
ECM -A
CONNECTOR VALUE
Pin H2 Pin 1
Close to 0 S2
Pin H3 Pin 2

MAPTS Replacement

TYPICAL - LH SIDE OF THE ENGINE, AFT CYLINDER

1. Coolant temperature sensor (CTS)

CTS Resistance Test

1. Disconnect the plug connector from the CTS
and check the resistance of the sensor itself.
CTS SENSOR MEASUREMENT
RESISTANCE 12
PIN
@ 20°C (68°F)

1. MAPTS
1 1 2 2280 - 2740
2. MAPTS connector
3. Retaining screw
4. Plenum
5. Throttle body

Disconnect MAPTS connector and remove the

MAPTS from the plenum.
Install new MAPTS as per following table.
TORQUE PRODUCT
6 N•rn ± 0.7 N•rn LOCTITE 243 (BLUE)
(53 lbf•in ± 6 lbf•in) (P/N 293 800 060)

CTS (COOLANT TEMPERATURE

SENSOR)
CTS Access
The CTS is located on the LH of the engine, aft
cylinder. To access it, remove the:
TYPICAL
— Driver's seat
— LH lateral console panel. If resistance is out of specification, replace the
CTS.
If resistance test is good,reconnect the CTS and
disconnect the ECM connector "A" from the
ECM.
2. Install ECM-A connector on ECM ADAPTER
TOOL (P/N 529 036 166).

246 tmr2011-022
 Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

3. Using a multimeter, recheck resistance from

the ECM connector as per table.
ECM "A CONNECTOR MEASUREMENT
Resistance 52
PIN
g 20°C (68°F)
Al I J2 2280 - 2736

If resistance value is correct, refer to ECM RE-

PLACEMENT
If resistance value is incorrect, repair the connec-
tors or replace the wiring harness between ECM
connector and the CTS.

CTS Replacement
1. Disconnect CTS connector and remove CTS.
2. Install the new CTS and torque as specified.
CTS TORQUE
16 N•m ± 2 N•m (142 lbf•in ± 181bf•in)

3. Reinstall remaining removed parts.

4. Refill and bleed the cooling system, refer to
COOLING SYSTEM subsection.

tmr2011-022 247
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

FUEL TANK AND FUEL PUMP

SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL 529 036 166 259
FLUKE 115 MULTIMETER 529 035 868 258
FUEL HOSE ADAPTER 529 036 023 253
OETIKER PLIERS 295 000 070 256
PRESSURE GAUGE 529 035 709 253
VACUUM/PRESSURE PUMP 529 021 800 252, 263

SERVICE TOOLS - OTHER SUPPLIER

Description Part Number Page
FLUKE RIGID BACK PROBE TP88 258

tmr2011-023 249
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUE
L PUMP)

CE Model
6

= Component must be replac

ed when removed.

250
tmr2011-023
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

GENERAL SYSTEM DESCRIPTION

A WARNING Fuel Tank Vent System
Fuel is flammable and explosive under cer- The fuel tank is equipped with a vent system that
tain conditions. Ensure work area is well ven- ensures the fuel tank remains at ambient pres-
tilated. Do not smoke or allow open flames or sure.
sparks in the vicinity. Air can enter the fuel tank at all times through the
fuel tank vent valve. This prevents negative pres-
A WARNING sure within the fuel tank which could cause fuel
Always disconnect battery prior to working starvation.
on the fuel system.

A WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices must be replaced (e.g.:
locking tabs, elastic stop nuts, self-locking
fasteners, cotter pins, etc.).

A WARNING
Always proceed with care and use appropri-
ate safety equipment when working on pres-
surized fuel system. Wear safety glasses.

A WARNING 1. Vent valve

2. Air inlet hose
Do not allow fuel to spill on hot engine parts
and/or on electrical connectors. The vent valve also prevents fuel from flowing out
through the inlet of the vent system should the
When the repair is completed, ensure that all vehicle be overturned.
hoses are connected and secured. Perform the
Fuel Tank Vent Breather Filter
FUEL PRESSURE TESTand the FUEL TANK LEAK
TEST as explained in this subsection. The air inlet hose of the vent system is equipped
with an in-line breather filter that prevents entry
Fuel lines remain under pressure at all times.
of particles such as dust or small insects. It is
Proceed with care when removing/installing high
located behind the air filter housing next to the
pressure test equipment.
coolant reservoir. To access the breather filter, re-
Use the B.U.D.S. software or disconnect the fuel move the service cover.
pump electrical connector to disable fuel pump
and crank engine to release fuel pressure prior to
disconnecting any fuel hose.
Cover the fuel hose connections with an ab-
sorbent shop rag and carefully disconnect them
to minimize spilling.
Wipe off any fuel spillage.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan-
dards.

1. Fuel tank vent breather filter

2. Cooling system expansion tank

tmr2011-023 251
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

Fuel Pump Module

The fuel pump module is inserted in the fuel tank.
It provides fuel delivery for the EFI system and en-
compasses the following components:
— Electric fuel pump
— Fuel pre-filter (replaceable)
— Fuel pressure regulator
— Fuel level sender.

Fuel Filters
The system comprises two levels of filtration.
A replaceable prefilter element attached to the
bottom of the pump, and a non-replaceable fine
filter element that is integral to the fuel pump
1. Fuel tank vent valve
module. 2. Vent hose to vacuum/pressure pump

Fuel Pump Pressure Regulator PRESSURE

TIME WITHOUT
PRESSURE DROP
The fuel pressure regulator is integral to the fuel
pump module. The pressure regulator maintains 14 kPa (2 PSI) 3 minutes
proper fuel pressure for the EFI system.
If pressure drops, locate fuel leak(s) and repair or
INSPECTION replace leaking component(s).
To locate a leak, check for a fuel smell or leaking
FUEL TANK LEAK TEST fuel.
To ease locating leak(s), spray soapy water on all
A WARNING hose connections and components; bubbles will
Always carry out a fuel tank leak test when- indicate the leak location(s).
ever the fuel tank shows signs of wear or
damage which may cause a leak, or when the FUEL PUMP PRESSURE TEST
fuel pump has been removed or replaced,
or if you suspect a leak. If the fuel tank is The pressure test will show the available pressure
damaged, the fuel tank should be replaced at the fuel pump outlet. It validates the pressure
even if no leak is present. Do not attempt to regulator, the fuel pump and tests for leaks in the
repair the fuel tank. system.
NOTE: Refer to the FUEL SYSTEM DIAGNOSTIC
1. Refill fuel tank and ensure fuel tank cap is in FLOW CHARTto help diagnose a fuel system re-
good condition and properly installed. lated problem.
2. Refer to BODYsubsection and remove the fol- 1. Ensure there are no leaks from hoses and fit-
lowing: tings. Repair any leak.
— RH passenger seat 2. Ensure the fuel level in the tank is sufficient.
— RH lateral console panel
3. Before proceeding with the pressure test en-
— Fuel tank cover panel. sure the battery is fully charged. Battery volt-
3. Remove the vent hose from the fuel tank vent age must be over 12 volts.
valve. 4. Connect vehicle to the applicable B.U.D.S. soft-
4. Using the VACUUM/PRESSURE PUMP (P/N 529 ware version and select the following:
021 800) and a short piece of hose, pressurize — Read Data button
the fuel tank through the vent valve. — Activation page tab
— ECM page tab
— Fuel pump Disabled.

252 tmr2011-023
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

Fuel Pump

Enabled

Activate

Fuel Pump

ooling Fan

Accessory Relay
T-FITTING

brr2011-011 017_b
9. Using B.U.D.S., reactivate fuel pump by select-
1. Click here to disable the fuel pump ing Enabled.
5. Release fuel pressure by running engine until it
runs out of gas. Fuel Pump
1
6. Remove the following items, refer to the BODY )1(
subsection Enabled .Disabled
7 Passenger seat
Activate
— Fuel tank cover
— RH lateral console panel.
7. Carefully disconnect the fuel pump outlet hose Fuel Pump
by pressing on the release tab of the quick dis-
connect fitting. ooling Fan
8. Install fuel PRESSURE GAUGE (P/N 529 035 709)
and FUEL HOSE ADAPTER (P/N 529 036 023) be- Accessory Relay
tween disconnected hose and fuel rail (in-line
installation). 0,- 20'1 011-017,

1. Click here to disable the fuel pump

10. Turn ignition key ON and observe fuel pres-

sure.
FUEL PRESSURE I 350 kPa (51 PSI)

11. Start engine and observe fuel pressure.

12. Stop engine.
13. In B.U.D.S., select the fuel pump Disabled
function.
14. Release fuel pressure by running engine until
PRESSURE GAUGE it runs out of gas.
15. Remove tool and connect hose on fuel rail.

Test Conclusion
The fuel pressure should be within specification in
static or dynamic tests.
A rapid pressure drop after the engine is stopped
indicates leakage either from a fuel hose, fuel rail,
or from the fuel pump check valve.
— Check fuel hoses, fuel rail and fittings for leaks.
If not leaking, replace fuel pump.

tmr2011-023
253
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

A slow pressure drop after the engine is stopped

indicates leakage either from a fuel injector or
from the fuel pressure regulator.
— Check fuel injectors for leaks. If not leaking, re-
place fuel pump.

254
tmr2011-023
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

TROUBLESHOOTING
FUEL SYSTEM DIAGNOSTIC FLOW CHART

Fuel pump does not run

I -4 1 Activate electric system to enable fuel pump
- Fuel pump runs
for 2 sec. then stops

Check fuse. Install fuel pressure gauge

Check fuel pump operation. on fuel pressure line
Repair or replace if necessary.

Replace fuel
Activate electric system to enable fuel pump
pump module

Fuel pump runs

Repair or Fuel pressure less Fuel pressure within Fuel pressure more
replace than specifications specifications than specifications
A
Fails
Check fuel line/
A rail for leaks

Fails * OK Crank or start

Perform fuel pump test engine

Fast Fuel pressure less Fuel pressure more Fuel pressure within
pressure drop than specifications than specifications specifications

Yes
Check
OK
Verify fuel fuel line/
pump check rail for leaks Repair or
valve replace FUEL SYSTEM OK

Fails OK
Fails

OK
Check fuel Perform fuel Replace fuel
injector pump test ->" pump module Retest
OK

1,1,02010 07.300n n

tmr2011-023 255
Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

PROCEDURES
FUEL HOSE AND OETIKER
CLAMPS
Fuel Hose Replacement
When replacing fuel hoses, be sure to use hoses
and clamps as available from BRP parts depart-
ment. This will ensure continued proper and safe
operation.

A WARNING
Use of fuel lines other than those recom- 1. Securing clamp in limited access
mended by BRP may compromise fuel sys-
tem integrity.
FUEL TANK
A WARNING Fuel Tank Draining
Whenever removing a hose in the fuel sys- Remove fuel tank cap and siphon gas into an ap-
tem, always use new Oetiker clamps at as- proved fuel container.
sembly. Then validate fuel system tightness
by performing a fuel pressure test. Fuel Tank Removal
1. Drain fuel tank. Refer to FUEL TANK DRAINING
Oetiker Clamp Replacement above in this subsection.
To secure or cut Oetiker clamps on fuel lines, use 2. Connect the vehicle to the applicable B.U.D.S.
OETIKER PLIERS (P/N 295 000 070). software version.
3. In B.U.D.S., select the following to disable the
fuel pump:
— Read Data button
— Activation page tab
— ECM page tab
— Fuel pump Disabled

Fuel Pump

r' Enabled Disabled

Activate

1. Cutting clamp

Fuel Pump

Cooling Fan

Accessory Relay

17.2011 011-017 b

1. Click here to disable the fuel pump

4. Release fuel pressure by running engine until it

runs out of gas.
1. Securing clamp
5. Disconnect battery, refer to CHARGING SYS-
TEM subsection.

256 tmr2011-023
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

6. Remove RH passenger seat, refer to the BODY

subsection.
7. Refer to BODY subsection and remove the
body parts indicated in the following illustra-
tion.

1. Fuel tank mounting screws (2)

12. Pull fuel tank out from the RH side of vehicle.

Fuel Tank Inspection

Inspect fuel tank for any damages or cracks which
TYPICAL may result in fuel leaks.
1. RH Lateral body panel
2. RH side panel on the console Inspect tank and protector attachment points for
3. Fuel tank cover panel
damages.
8. Disconnect the fuel pump connector. Inspect protector for damages.
9. Remove the vent hose from the fuel tank valve. If cracks, gouges or other damages which may
10. Disconnect the high pressure fuel hose at the lead to a fuel leak, or damages to attachment
fuel injectors. points that could prevent the tank from being
secure are found, replace fuel tank.

Fuel Tank Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Be sure to reinstall the 2 rubber washers between
the fuel tank and the frame.
Be sure to properly connect and route:
— Fuel tank vent tube
— Fuel pump pressure hose
— Electrical connector.
Using B.U.D.S., reactivate fuel pump by selecting
Enabled.

1. Fuel pump connector

2. Vent hose
3. High pressure fuel hose

11. Remove fuel tank retaining screws (2).

tmr2011-023 257
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

Fuel Pump

ri Enabled - Disabled

Activate

Fuel Pump

Cooling Fan

Accessory Relay

tmr2011 011 017 c

1. Click here to enable fuel pump

Refuel tank and ensure there are no leaks by

performing a FUEL TANK LEAK TESTand a FUEL 1. Fuel pump fuse
PRESSURE TESTas described in this subsection.
Fuel Pump Input Voltage Test
FUEL PUMP 1. Remove RH passenger seat and fuel tank
Fuel Pump Pressure Test cover, refer to BODYsubsection.
Refer to INSPECTION in this subsection. Disconnect the fuel pump connector.
2. Use the FLUKE 115 MULTIMETER (P/N 529
Fuel Pump Quick Test 035 868) with the FLUKE RIGID BACK PROBE
1. Turn ignition key to ON. (P/N TP88).

2. Listen for fuel pump operation. Set multimeter to Vdc.

3. Fuel pump should come ON for a few seconds,
then stop.
If fuel pump does operate as in previous steps,
carry out the following:
— Check fuel pump fuse.
— Check in B.U.D.S. for applicable fault codes.
Refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
— Carry out a fuel pump input voltage test.

FLUKE 115 MULTIMETER

FLUKE RIGID BACK PROBE

3. Set multimeter to Vdc.

4. Turn ignition key ON.
5. Read voltage as follows.
258 tmr2011-023
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

FUEL PUMP INPUT VOLTAGE TEST If resistance test failed, disconnect fuel pump
connector and measure resistance at fuel pump
TEST PROBES VOLTAGE READING connector.
Fuel pump Fuel pump FUEL PUMP RESISTANCE TEST
connector connector Battery voltage (AT FUEL PUMP CONNECTOR)
Pin 3 Pin 4
Pins 1 and 2 I Approximately 2 Q
If battery voltage is read, carry out a fuel pump
resistance test. If test failed at pump connector, replace fuel
pump.
If battery voltage is not read, test fuel pump
power input as follows. If test succeeded at pump connector, check
wiring and connectors from fuse box to ECM
FUEL PUMP POWER WIRE TEST connector. Repair or replace as necessary.
TEST PROBES VOLTAGE READING
Fuel Pump Removal
Fuel pump
Battery 1. Using B.U.D.S., select the following to disable
connector Battery voltage
ground the fuel pump:
Pin 3
— Read Data button
If battery voltage is now read, check fuel pump — Activation page tab
ground circuit between fuel pump connector — ECM page tab
5-FP-4 and ECM connector 3-B-M1.
— Fuel pump Disabled
If battery voltage is still not read, check fuel pump:
— Fuse (F15)
— Power circuit
Fuel Pump
il l-- 1
— Wiring and connectors. Enabled 4 Disabled

Fuel Pump Resistance Test

Activate
1. Remove the fuel pump fuse.
2. Remove connector B from the ECM and con-
nect it to the ECM ADAPTER TOOL (P/N 529 036 Riel Pump
166).
aoohng Fan

000000 03 Accessory Relay

0 f!! 0
ft) 0 zr 2 a
't

tr,12011 011 017 h

1. Click here to disable the fuel pump

2. Release fuel pressure by running engine until it

runs out of gas.
3. Refer to BODY subsection and remove the
body parts indicated in the following illustra-
tion.
3. Set multimeter to Q.
4. Measure fuel pump resistance as follows.
FUEL PUMP RESISTANCE TEST
(AT ECM AND FUSE)
RESISTANCE C2
TEST PROBES @ 20°C (68°F)
Fuse box Approximately 2 S2
ECM B-M1
contact 5D

259
tmr2011-023
Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

6. Using a soft face hammer and a brass drift in

the notched portion of the locking ring, remove
fuel pump locking ring.

A WARNING
Fuel vapors are flammable and explosive un-
der certain conditions. Use only non-spark-
ing tools.

TYPICAL
1. RH Lateral body panel
2. RH side panel on the console
3. Fuel tank cover panel

4. Disconnect fuel pump electric connector.

FUEL PUMP LOCKING RING REMOVAL

1. Notch in fuel pump locking ring

7. Carefully pull out fuel pump.

A CAUTION While pulling out the fuel

pump, pay attention to fuel sender float arm.
Float arm can get stuck and bend reducing fuel
1. Fuel pump connector sender accuracy.

5. Disconnect high pressure fuel hose at fuel rails 8. Discard gasket ring.
(2 disconnects).
Fuel Pump Installation
For installation, reverse the removal procedure.
However, pay attention to the following.

A CAUTION Manipulate fuel pump with

care.
1. Install a NEW gasket ring.
2. Place gasket so that it is located between pump
and tank mounting surface.

1. Fuel rail (1 each cylinder)

2. High pressure fuel hose disconnect ((1 each cylinder)

260 tmr2011-023
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

1. Gasket ring here FUEL PUMP LOCKING RING INSTALLATION

2. Fuel pump flange 1. Notch in locking ring
3. Pump locking ring 2. Raised portion in locking ring (5 places)
3. Lock position on tank flange (5 places)

3. Pay attention to pump orientation as in follow- 7. Using B.U.D.S., enable the fuel pump.
ing illustration.

Fuel Pump
1
Enabled r- Disabled

Activate

Fuel Pump

fooling Fan

Accessory Relay

1,11,2011-011 017 2 C

1. Click here to enable the fuel pump

8. Refuel tank and ensure there are no leaks by

performing a FUEL TANK LEAK TEST and a
1. Fuel pump index
2. Fuel tank pump index FUEL PRESSURE TEST as described in this
subsection.
4. Insert fuel pump locking ring over the fuel pres-
9. Check fuel level sender operation.
sure hose and electrical wiring connector.
5. While firmly holding pump against tank, engage Fuel Pump Strainer Replacement
fuel pump locking ring on fuel tank flange.
1. Remove FUEL PUMP, see FUEL PUMP RE-
6. Using a soft face hammer and a brass drift in MOVAL procedure in this subsection.
the notched portion of the locking ring, turn
2. Unlock 3 tabs on plastic ring.
locking ring until it is fully engaged.

A WARNING
Fuel vapors are flammable and explosive un-
der certain conditions. Use only non-spark-
ing tools. Ensure pump locking ring is fully
engaged.

tmr2011-023
261
 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

Step 1: Lift these tabs to unlock ring NOTE: A non serviceable filter is located in fuel
Step 2: Pull ring off pump inlet
pump. If it is clogged, replace fuel pump.
3. Remove rubber pad. 6. Insert the new strainer on fuel pump making
sure to press it in tightly against pump face.
7. Press in a NEW push nut to secure strainer.
8. Reinstall remaining removed parts.

FUEL LEVEL SENDER

The fuel level sender is a float actuated variable
resistance type that is part of the fuel pump.

4. Remove push nut securing strainer to fuel

pump. Be careful not to break the plastic pin.

TYPICAL - FUEL PUMP

1. Fuel level sender

Fuel Level Sender Resistance Test

1. Remove and disconnect multifunction gauge,
refer to the LIGHTS/GAUGE/ACCESSORIES
subsection.
2. Use a multimeter and select a
3. Measure the resistance of the sender as fol-
lows.

5. Pull strainer off fuel pump.

262 tmr2011-023
 Section 04 FUEL SYSTEM
Subsection03 (FUEL TANK AND FUEL PUMP)

FUEL LEVEL SENDER RESISTANCE TEST Fuel Level Sender Replacement

GAUGE RESISTANCE 52 Replace fuel pump. See fuel pump removal and
FUEL LEVEL installation procedures in this subsection.
CONNECTOR @ 20°C (68°F)
Full 5 St ± 1
Pins 4 and 21 FUEL TANK VENT VALVE
Empty 100 12 ± 5
Fuel Tank Vent Valve Test
Test for Normal Operation
1. Disconnect vent hose from fuel tank vent valve.
2. Connect the VACUUM/PRESSURE PUMP (P/N 529
021 800) and a short piece of hose to the fuel
tank vent valve.

If readings are out of specification, repeat test

at fuel pump connector. If resistance test at fuel
pump connector is not good, replace fuel level 7. Fuel tank vent valve
2. Vent hose to vacuum/pressure pump
sender.
If readings are as specified, carry out a FUEL 3. Remove fuel tank cap.
LEVEL SENDER INPUT VOLTAGE TEST 4. Set vacuum/pressure pump to PRESSURE and
activate pump. The gauge on the pump should
Fuel Level Sender Input Voltage Test not change in reading; air should flow through
1. Set ignition switch to ON. the vent valve and fuel tank freely.
2. Disconnect fuel pump connector.
3. Use a multimeter and select Vdc.
4. Measure the input voltage as follows.
FUEL LEVEL SENDER INPUT VOLTAGE TEST
FUEL PUMP VOLTAGE
BATTERY
CONNECTOR
Negative
Pin 1 Battery voltage
terminal

If battery voltage is not read, test wiring continuity

between sender and multifunction gauge.
If wiring continuity is good, replace multifunction
gauge.
If continuity is not obtained, repair or replace
1. Air flows freely in through vent valve
wiring. 2. Air flows out of fuel tank

tmr201 1-023 263

 Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

5. Set vacuum/pressure pump to VACUUM and Fuel Tank Vent Valve Removal and
activate pump. The gauge should not change Installation
in reading; air should flow through the vent
1. When removing or installing the fuel tank vent
valve and fuel tank freely.
valve, pay attention to the following:
— Valve lock position index (dual)
— Valve unlock position index.

1. Air is drawn out freely through vent valve

2. Air flows in fuel tank

Test for Rollover Protection

1. Lock position index (dual)
1. Remove the fuel tank valve, refer to FUEL 2. Unlock position index
TANK VALVE REMOVAL AND INSTALLATION
in this subsection. 2. Remove the vent hose from the valve.
2. Turn the valve upside down. 3. Use an open end wrench of the appropriate size
on the rectangular portion of the valve to rotate
3. Set vacuum/pressure pump to VACUUM and
it to the unlock position for removal.
activate pump. The vacuum gauge reading
should increase; air should not flow through 4. Ensure the wave spring and 0-ring seal on the
the valve. valve to be installed are in good condition.

1. 0-ring seal
VALVE DOES NOT LET AIR PASS OUT UPSIDE DOWN 2. Wave spring

The fuel tank vent valve is defective if air flows 5. Insert the valve in the tank.
freely through the valve when upside down and 6. Press down on the valve and rotate it so that
the vacuum indication does not increase on the its stem rests between the dual valve locking
pump gauge. position index (see first illustration).
7. Reconnect the vent hose to the valve stem.

264 tmr2011-023
 Section 05 ELECTRICAL SYSTEM
Subsection 01 (POWER DISTRIBUTION)

POWER DISTRIBUTION
GENERAL
POWER DISTRIBUTION DIAGRAM

FUSE BOX 1

MAIN
■•■
RELAY (R2)
BAT BRAKE LIGHTS]
SWITCH
• • F4 10A
000000
FUSE BOX 2 GAUGE
IGNITION COIL
• • MF1 30A
TAILLIGHTS
F5 7.5A • FUEL INJECTORS
6
MF2 40A
SPEED SENSOR BRAKE RELAY (R8)

OH F6 5A
ECM

ACCESSORIES
VOLTAGE RELAY (R3)
REGULATOR/ SWITCHES ILLUMINATION
RECTIFIER
F7 5A 2WD/4WD SWITCH
0 0 0 0 0 52
WINCH SWITCH

STARTER RELAY

GAUGE
F8 5A
IGNITION SWITCH
WINCH RELAY

FAN RELAY (R1)

COMMUNICATION
CONNECTOR 000000

F9 30A • FAN MOTOR

F10

F11
5A

30A
EURO CONTROLS

LIGHTS RELAY
H CONSOLE ACCESSORY
CONNECTOR 1 (DC3)

• —I 12-VOLT POWER OUTLET

F12 15A UNDER DASH ACCESSORY

CONNECTOR (DC4)

OH F13 5A •
•-I COMMUNICATION
CONNECTOR

CONSOLE ACCESSORY
F14 15A
CONNECTOR 2 (DC6)

--I F15 5A FUEL PUMP

tmi ee 1 -0 2 4 00 1 er

tmr2011-024 265
 Section 05 ELECTRICAL SYSTEM
Subsection 01 (POWER DISTRIBUTION)

FUSE BOX 1 RELAY IDENTIFICATION

1 Cooling fan
2 Main
Relays 3 Accessories
4 Headlights
8 Brake lights

FUSE BOX 2

FUSE IDENTIFICATION
4 10 A
5 7.5 A
6 5A
7 5A
8 5A
9 30 A
Fuse
10 5A
11 30 A
12 15 A
13 5A
14 15 A FUSE IDENTIFICATION
15 5A 1 Main 30 A
Fuse
2 Fan/accessories 40 A

266 tmr2011-024
 Section 05 ELECTRICAL SYSTEM
Subsection 02 (CONTROLLER AREA NETWORK (CAN))

CONTROLLER AREA NETWORK (CAN)

GENERAL
SYSTEM DESCRIPTION
The CAN (Controller Area Network) protocol is an
ISO standard for serial data communication. The
CAN bus links the ECM and multifunction gauge
together so that they communicate to interact
as required. The components are connected
together by 2 wires and they are in constant
communication with each other at a rate of about
every 20 milliseconds. CAN lines consist of a pair
of wires (WHITE/BEIGE and BEIGE/GREEN).
If a component or system malfunction is detected,
a module (ECM or multifunction gauge) may gen-
erate a fault code, which it transmits through the
CAN bus as a signal. The fault signal may be used
for various functions such as triggering the display
of an error message in the multifunction gauge
cluster, turning on a fault indicator light, limiting or
inhibiting vehicle or engine operation, or viewed
using the B.U.D.S. software for troubleshooting.

CAN-HI
WHITE/BEIGE

B-C1 DB-2 • CI-4

ECM DB

B-C2 DB-1 CI-18

BEIGE/GREEN
CAN-LO
tmr701 '41125 001_,

CLUSTER: Multifunction Gauge

DB: Diagnostic Connector
ECM: Engine Control Module
WH/BE: White/Beige
BE/GN: Beige/Green

tmr2011-025 267
 Section 05 ELECTRICAL SYSTEM
Subsection 03 (IGNITION SYSTEM)

IGNITION SYSTEM
SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL 529 036 166 271
FLUKE 115 MULTIMETER 529 035 868 271

GENERAL ENGINE WILL NOT START (ENGINE

TURNS OVER)
A WARNING 1. Fouled or defective spark plug
Torque wrench tightening specifications
must be strictly adhered to. - Replace.
Locking devices when removed (e.g.: locking 2. Defective CPS
tabs, elastic stop nuts, self-locking fasteners, - Check operation of CPS and replace if necessary.
cotter pins, etc.) must be replaced. Refer to ELECTRONIC FUEL INJECTION section.
3. Defective trigger wheel
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan- - Check. Refer to PTO HOUSING/MAGNETO.
dards. 4. Defective ignition circuit
- Check fuse 5 of fuse box 1, ignition coil and wiring
SYSTEM DESCRIPTION condition.

The battery supplies the primary side of ignition 5. Defective fuel pump
coil through the main relay (R2) while the ECM - Check fuel pump, refer to FUEL SYSTEM.
completes the circuit for each cylinder by switch-
6. Defective fuel injectors or circuit
ing it to the ground at the right moment. The ECM
can detect open and short circuit in the primary - Check fuel injectors, refer to ENGINE MANAGE-
MENT.
winding but it does not check the secondary wind-
ing. ENGINE HARD TO START
The EMS controls the ignition system. For more
1. Spark plug faulty, fouled or worn out
information, refer to ENGINE MANAGEMENT
section. - Check spark plug condition. Replace if necessary

2. Low fuel pressure

Ignition Timing - Test fuel pressure, refer to FUEL SYSTEM.
Ignition timing is not adjustable.
ENGINE MISFIRES, RUNS IRREGULARLY
TROUBLESHOOTING 1. Fouled, defective, worn spark plugs
It is good practice to check for fault codes using - Check/verify heat range/gap/replace.
the B.U.D.S. software as a first troubleshooting 2. Damaged trigger wheel/loose CPS
step. Refer to DIAGNOSTIC SYSTEM AND FAULT
- Check. Refer to PTO HOUSING/MAGNETO.
CODES subsection.
Always refer to the WIRING DIAGRAM when 3. Defective ignition circuit
troubleshooting an electrical circuit. - Check ignition coil, fuse 5, and wiring condition.
Refer to POWER DISTRIBUTION for fuse and re- 4. Poor engine grounds
lay information. - Check/clean/repair.

DIAGNOSTIC GUIDELINES
The following is provided to help in diagnosing the
probable cause of a problem. It is a guideline and
should not be assumed to list all possible causes.

tmr201 1-026 269

Section 05 ELECTRICAL SYSTEM
Subsection 03 (IGNITION SYSTEM)

ENGINE CONTINUALLY BACKFIRES IGNITION COIL

1. Fouled, defective spark plugs
- Clean/replace.
2. Damaged trigger wheel/defective or loose CPS
- Check, refer to ELECTRONIC FUEL INJECTION.

PROCEDURES
IGNITION SWITCH
Ignition Switch Quick Test
Turn ignition switch to ON position.
If multifunction gauge turns on (assuming it
works), the ignition switch is good.
If multifunction gauge does not turn on, check the
following in this order:
— Battery
— Fuses 1 and 2 of fuse box 2 Ignition Coil Access
— Fuse 4 and 8 of fuse box 1 Refer to BODYand remove upper console.
— ECM is properly powered (refer to ENGINE
MANAGEMEN7) Ignition Coil Installation
— Ignition switch. Install a new elastic nut and tighten to the speci-
fied torque.
Ignition Switch Access
IGNITION COIL RETAINING BOLT
Refer to BODYand remove upper console. TIGHTENING TORQUE

Ignition Switch Wire Identification 8 N•m ± 1 N•rn (71 lbf•in ± 9 lbf•in)

FUNCTION PIN WIRE COLOR

Quick Test with B.U.D.S.
12 Vdc output (lights) A YELLOW/BLUE Connect to the latest applicable B.U.D.S. soft-
12 Vdc input B BE IGE/VVHITE ware. Refer to COMMUNICATION TOOLS AND
B.U.D.S. section.
Ground (through
C ORANGENIOLET In B.U.D.S., select the Activation tab and the
ECM)
ECM tab.
Ground signal to D YELLOW/ORANGE
ECM in OFF position You should hear the spark occurring. In doubt, use
an inductive spark tester. If there is no spark, per-
D.E.S.S. signal E ORANGE/RED form the following checks.
12 Vdc output (ECM, NOTE: Keep in mind that even if there is a spark
starter solenoid and F BLACK/YELLOW during this static test, voltage requirement is
start switch) higher to produce a spark in the combustion
chamber when engine is running. Ignition coil
could be not working in real operation. Replacing
ignition coil may be necessary as a test.
NOTE: Ensure spark plug cable is on the appropri-
ate cylinder.

Ignition Coil Input Voltage Test

Disconnect the 3-pin connector from the ignition
coil.

270 tmr2011-026
 Section 05 ELECTRICAL SYSTEM
Subsection 03 (IGNITION SYSTEM)

PIN
PIN
(IGNITION
COMPONENT (ECM
COIL
CONNECTOR)
CONNECTOR)
Cylinder 1 (front) 1 A-M1
Cylinder 2 (rear) 3 A-M2

Ignition Coil Resistance Test

An ignition coil with good resistance measure-
ment can still be faulty. Voltage leak can occur
1. Ignition coil connector at high voltage level which is not detectable with
an ohmmeter. Replacing the ignition coil may be
Turn ignition switch to ON. necessary as a test.
Using a the FLUKE 115 MULTIMETER (P/N 529 035 Disconnect ignition cables from spark plugs.
868), read voltage.
Primary Windings
Disconnect ECM "A" connector and connect it to
the ECM ADAPTER TOOL (P/N 529 036 166).
Using a multimeter, check resistance in primary
windings as follows.
ENGINE ECM
PRIMARY RESISTANCE
CONCTOR
NE CONN ECTOR
CIRCUIT q 0 20°C (68°F)
(HIC)
Cylinder 1
A-M1
(front)
Pin E .3 - .6 C2
Cylinder 2
A-M2
(rear)
IGNITION COIL
VOLTAGE
CONNECTOR
If any resistance is not good, measure resistance
Pin 2 with battery ground Battery voltage directly on coil. If second test is ok, check wiring.

Battery voltage should be read. Secondary Windings

If Battery voltage is NOT read, check continuity of Due to the integrated diode, it is not possible
ignition coil supply circuit. to take any resistance measurement of the sec-
ondary winding.
Ignition Coil Ground Circuit Continuity
Test SPARK PLUG
Disconnect the ECM connector "A" and connect For spark plug replacement procedure, refer to
it to the ECM ADAPTER TOOL (P/N 529 036 166). PERIODIC MAINTENANCE PROCEDURE sub-
section.

Troubleshooting Fouled Spark Plug

Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed
due to misfiring, reduced performance, and in-
creased fuel consumption. This is due to a loss
of compression. Other possible causes are: pro-
longed idling or low-speed riding, a clogged air
filter, incorrect fuel, defective ignition system,
incorrect spark plug gap, lubricating oil entering
the combustion chamber, or too cold spark plug.
Check wiring continuity as per following table. The plug face of a fouled spark plug has either a

tmr2011-026 271
Section 05 ELECTRICAL SYSTEM
Subsection 03 (IGNITION SYSTEM)

wet black deposit or a black carbon fouling. Such

coatings form a conductive connection between
the center electrode and ground.

Spark Plug Analysis

TYPICAL
1. Overheated (light grey, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, grey, melted coating)

The plug face reveals the condition of the engine,

operating condition, method of driving and fuel
mixture. For this reason it is advisable to inspect
the spark plug at regular intervals, examining the
plug face (i.e. the part of the plug projecting into
the combustion chamber).

272
 Section 05 ELECTRICAL SYSTEM
Subsection 04 (CHARGING SYSTEM)

CHARGING SYSTEM
SERVICE TOOLS - OTHER SUPPLIER
Description Part Number Page
NAPA ULTRA PRO BATTERY LOAD TESTER 95260 275

SERVICE PRODUCTS
Description Part Number Page
DIELECTRIC GREASE 293 550 004 275

GENERAL
SYSTEM DESCRIPTION
The purpose of the charging system is to keep
the battery at a full state of charge and to provide
the electrical system with the required electrical
power for normal vehicle operation.

Magneto
The magneto is the primary source of electrical
energy. It transforms magnetic field into electric TYPICAL - VOLTAGE REGULATOR/RECTIFIER
current (AC).
The magneto has a 3 phase series stator. Battery
The battery supplies DC power to the electric
starter for cranking the engine. During engine
starting, it also supplies DC power to the entire
electrical system.
At low engine RPM operation and high current
load conditions, it supplements the magneto
output and helps to maintain a steady system
voltage.

INSPECTION
CHARGING SYSTEM OUTPUT
First ensure that battery is in good condition prior
to performing the following tests.

Output Voltage Test Using B.U.D.S.

TYPICAL
1. Connect to the latest applicable B.U.D.S. soft-
Voltage Regulator/Rectifier ware. Refer to COMMUNICATION TOOLS
AND B.U.D.S. subsection.
The rectifier receives AC current from the mag-
neto and transforms it into direct current (DC). 2. In B.U.D.S., select the Monitoring tab then the
ECM tab.
The voltage regulator, included in the same unit,
limits voltage to prevent any damage to electrical 3. Start engine.
components.

tmr2011-027 273
 Section 05 ELECTRICAL SYSTEM
Subsection 04 (CHARGING SYSTEM)

4. Increase engine RPM as specified in the follow- BATTERY REGULARLY DISCHARGED OR

ing table and read voltage in the ECM Input WEAK
Voltage box.
1. Loose or corroded battery cables connections.
OUTPUT VOLTAGE TEST USING B.U.D.S. - Tighten or repair battery cables connections.
ENGINE SPEED VOLTAGE (DC) 2. Worn or defective battery.
4000 RPM 14.8 ± .4 Vdc - Charge and test battery.

3. Defective magneto stator.

- Test stator.

4. Defective regulator/rectifier.
Pe4'
uanc
- Test system voltage.
10,1 Int•■::4r Mardr,0 aRs pas% r.51 ,

5. Damaged magneto rotor or Woodruff key.

1
- Replace magneto rotor or Woodruff key.

PROCEDURES
imr2011 - 027 002_3

1. ECM Input Voltage box

VOLTAGE REGULATOR/
RECTIFIER
If voltage is above specification, replace voltage
regulator/rectifier. Voltage Regulator/Rectifier Static Test
If voltage is below specification, check stator Due to internal circuitry, there is no static test
output and wiring harness prior to concluding that available.
voltage regulator/rectifier is defective. Refer to
MAGNETO SYSTEM subsection. Voltage Regulator/Rectifier Access
The voltage regulator/rectifier is located on the LH
Output Voltage Test Using a side, underneath dashboard, on the RH side of the
Multimeter battery rack.
1. Set multimeter to Vdc.
Voltage Regulator/Rectifier Wire
2. Connect multimeter to battery posts.
Identification
3. Start engine.
FUNCTION PIN COLOR
4. Increase engine RPM as specified in the follow-
ing table and read voltage with the multimeter. 12 Vdc output RD1-1 RED

OUTPUT VOLTAGE TEST USING A MULTIMETER 12 Vdc ground RD1-3 BLACK

TEST ENGINE SPEED VOLTAGE (DC) 12 Vac input RD2-1 YELLOW

4000 RPM 14.8 ± .4 Vdc 12 Vac input RD2-2 YELLOW

12 Vac input RD2-3 YELLOW
If voltage is above specification, replace voltage
regulator/rectifier.
If voltage is below specification, check stator and BATTERY
wiring harness prior to concluding that voltage Battery Information
regulator/rectifier is defective. Refer to MAG-
NETO SYSTEM subsection. These vehicles are equipped with a VRLA battery
(Valve Regulated Lead Acid). It is a maintenance-
free type battery.
TROUBLESHOOTING
Refer to battery manufacturer's instructions for
It is good practice to check for fault codes using proper filling, activation and routine charging pro-
the B.U.D.S. software as a first troubleshooting cedures.
step. Refer to DIAGNOSTIC SYSTEM AND FAULT
CODES subsection.

274 tmr2011-027
 Section 05 ELECTRICAL SYSTEM
Subsection 04 (CHARGING SYSTEM)

Battery Voltage Test (No Load Applied)

NOTE: A voltage test is carried out on a battery
without discharging current. It is the simplest and
most commonly used. However, be aware that
the voltage test can be good, while the battery
does not have enough power to crank the engine.
A load test gives a more accurate condition of the
battery.
A voltage reading provides an instant indication of
the state of charge of the battery, not of it's cur-
rent output capacity. A load test gives a more ac-
curate indication of the battery's condition.
1. Battery strap
If the battery has just received a charge, allow it to 2. Battery strap retaining nut
rest for 1 - 2 hours before taking a voltage reading.
3. Unhook the top of battery strap.
Set multimeter to Vdc and connect to battery ter-
minals. Always respect polarity. 4. Remove battery.

FULLY CHARGED BATTERY VOLTAGE Battery Cleaning

12.6 Vdc minimum Clean the battery rack, cableS and battery posts
using a solution of baking soda and water.
NOTE: A battery that shows a voltage of 12.0 Vdc
Remove corrosion (if so) from battery cable ter-
is considered completely discharged and need to
minals and battery posts using a firm wire brush.
be recharged.
Rinse with clear water and dry well.
Battery Load Test Battery Storage
This is the best test to indicate a battery condition.
If the battery is in storage or used infrequently,
Use a load testing device such as the NAPA ULTRA
disconnect the battery cables to eliminate drain
PRO BATTERY LOAD TESTER (P/N 95260). It has a
from electrical equipment.
500 Amp adjustable load.
For extended storage, remove the battery from
Apply a load of 3 times the ampere-hour rating of
vehicle.
the battery. At 14 seconds into the test, check
battery voltage. Clean battery terminals and cable connections us-
ing a wire brush. Apply a light coat of DIELECTRIC
TIME TO MEASURE GREASE (P/N 293 550 004) on terminals.
VOLTAGE
INTO TEST
Clean battery casing using a solution of baking
Min. 10.5 Vdc @ soda and water. Rinse battery with clear water
14 seconds
20°C (68°F) and dry well using a clean cloth.
Regularly charge battery as per manufacturer's
Battery Removal recommendations.
1. Disconnect BLACK (-) cable first, then the RED For other recommendations during storage, refer
(+) cable. to battery manufacturer's instructions.
NOTICE Always respect this order for re-
moval; disconnect BLACK (-) cable first.
a WARNING
Ensure to store battery in a safe place, out of
2. Remove battery strap retaining nut. reach for children.

Battery Installation
NOTICE Always connect RED (+) cable first
then BLACK (-) cable.

tmr2011-027 275
 Section 05 ELECTRICAL SYSTEM
Subsection 04 (CHARGING SYSTEM)

Installation is the reverse of removal procedure,

however pay attention to the following:
— Install the battery with the positive post down.
— Tighten battery strap retaining nut to the speci-
fied torque.
BATTERY STRAP RETAINING NUT
TIGHTENING TORQUE
3.4 N•m ± 0.3 N•m (30 lbf•in ± 31bfoin)

276
tmr2011-027
 Section 05 ELECTRICAL SYSTEM
Subsection 05 (STARTING SYSTEM)

STARTING SYSTEM
SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL 529 036 166 278
FLUKE 115 MULTIMETER 529 035 868 279

SERVICE PRODUCTS
Description Part Number Page
DIELECTRIC GREASE 293 550 004 281

GENERAL Always refer to the WIRING DIAGRAM when

a WARNING troubleshooting an electrical circuit.

Refer to POWER DISTRIBUTION for fuse and re-
Torque wrench tightening specifications lay information.
must be strictly adhered to.
Locking devices when removed (e.g.: locking Check all connections, cables and wires. Tighten
tabs, elastic stop nuts, self-locking fasteners, any loose connections. Replace any chafed or cor-
cotter pins, etc.) must be replaced. roded wires/cables.

Hoses, cables or locking ties removed during a DIAGNOSTIC GUIDELINES

procedure must be reinstalled as per factory stan- FUSE 8 INFUSE BOX 1 BURNS WHILE
dards. ATTEMPTING TO CRANK ENGINE
SYSTEM DESCRIPTION 1. Defective D2 Diode
- Test diode, see procedure in this subsection.
The starting system is composed of an electric
starter supplied in current by the battery through 2. Defective starter solenoid
a solenoid. - Test starter solenoid, see procedure in this sub-
section.
The starter solenoid receives a 12 volt input from
the ignition switch and the ground signal is pro- 3. Wiring short to ground
vided by the ECM when the following engine - Check wiring.
cranking conditions are met.
— Ignition switch ON. ENGINE DOES NOT CRANK AND GAUGE
— Transmission in Park or Neutral position and/or
DOES NOT TURN ON
brake pedal held. 1. Burnt main fuse (F1) in fuse box 2
— Start button held. - Check fuse.
NOTE: If the ignition switch is left ON for more 2. Burnt fuse F8 in fuse box 1
than 15 minutes, engine will not start unless igni-
- Check fuse.
tion switch is turned OFF, then ON again.
3. Defective or discharged battery
TROUBLESHOOTING - Test battery, refer to CHARGING SYSTEM.

It is good practice to check for fault codes using 4. Defective ignition switch or circuit
the B.U.D.S. software as a first troubleshooting - Check ignition switch, refer to IGNITION SYS-
step. Refer to DIAGNOSTIC SYSTEM AND FAULT TEM.
CODES subsection.
NOTE: Clear any fault code after solving a prob-
lem.

tmr2011-028
277
Section 05 ELECTRICAL SYSTEM
Subsection 05 (STARTING SYSTEM)

ENGINE DOES NOT CRANK BUT GAUGE

TURNS ON
1. Defective brake switch
- Check brake switch, refer to BRAKES section.

2. Defective gearbox position sensor (GPBS)

- Check GPBS, refer to GEARBOX AND 4X4 COU-
PLING UNIT subsection.

3. Defective start button or circuit

- Test start button, see procedure in this subsec-
tion.

4. Defective starter solenoid or circuit

- Test starter solenoid, see procedure in this sub-
section.

5. Defective starter motor

- Check starter motor, see procedure in this sub-
section. 6. Test diode as per following table.
D2 DIODE TEST
PROCEDURES
MULTIMETER MULTIMETER
POSITIVE NEGATIVE RESULT
D2 DIODE (STARTER SOLENOID) PROBE PROBE
Diode Location ECM-B pin A2 ECM-B pin L4 Overload (open)
The diode is located in the main harness, near
starter solenoid. Approximately
ECM-B pin L4 ECM-B pin A2
0.5 volts
Diode Test
If diode fail any test, replace it.
1. Make sure ignition switch is OFF.
2. Disconnect pins SS1 and SS2 from starter sole- START BUTTON
noid.
3. Disconnect ECM connector B. Start Button Access
Remove upper console.
4. Connect ECM ADAPTER TOOL (P/N 529 036 166)
to the ECM connector B.
Start Button Wire Identification
FUNCTION PIN COLOR

12 volt input from ignition

1 BLACK/YELLOW
switch
12 volt output to ECM B-
2 YELLOW/RED
pin D1

Start Button Test with B.U.D.S.

Connect to the latest applicable B.U.D.S. soft-
ware. Refer to COMMUNICATION TOOLS AND
B.U.D.S. section.
5. Set multimeter to "diode check". In B.U.D.S., select the Monitoring and ECM tabs.
Press the vehicle's start button and look at the
Start Button LED.

278 tmr2011-028
 Section 05 ELECTRICAL SYSTEM
Subsection 05 (STARTING SYSTEM)

If starter does not run, carry out the STARTER SO-

LENOID WINDING RESISTANCE TEST
Start Button Starter Solenoid Input Voltage Test
1. Disconnect connector with BLACK/YELLOW
It should turn on, indicating the start signa wire.
reaches the ECM. 2. Turn ignition switch ON.
If it does not turn on, check the start button and 3. Measure voltage as per following table.
wiring.
STARTER SOLENOID INPUT VOLTAGE TEST
Start Button Resistance Test RESULT
Disconnect start button connector. TEST PROBES (START BUTTON
RELEASED)
Using the FLUKE 115 MULTIMETER (P/N 529 035
868), measure resistance as per the following BLACK/
YELLOW Battery ground Battery voltage
table.
wire
START BUTTON
POSITION RESISTANCE
CONNECTOR PIN
Starter Solenoid Ground Signal Test
Switch 1. Disconnect SS2 (ORANGE/BROWN) from sole-
Infinite (OL)
released noid.
Switch 1 2
2. Turn ignition switch ON.
depressed 0.6 52 max.
and held 3. Measure voltage as per following table.
STARTER SOLENOID GROUND SIGNAL TEST
Replace start button if defective.
RESULT
TEST PROBES (START BUTTON
STARTER SOLENOID DEPRESSED)
Starter Solenoid Access ORANGE/
Battery
The starter solenoid is located on the LH side, un- BROWN Battery voltage
positive post
derneath dashboard, on top of battery rack. wire

To access starter solenoid, remove the CVT vent

inlet tube. Starter Solenoid Winding Resistance
Test.
Starter Solenoid Wire Identification Disconnect terminals from solenoid.
WIRE With a multimeter, check primary winding resis-
FUNCTION PIN
COLOR tance as follows.
12 volt input from BLACK/ STARTER SOLENOID WINDING
SS1
ignition switch YELLOW RESISTANCE TEST
Ground from ECM-B ORANGE/ RESULT @ 20°C
SS2 TEST PROBES
pin L4 BROWN (68°F)
Starter Starter
Starter Solenoid Operational Test solenoid solenoid SS2 Approximately 552
1. Disconnect both terminals (SS1 and SS2) from SS1 pin pin
the starter solenoid.
If measurement is out of specification, replace so-
2. Connect SS1 to the positive battery terminal. lenoid.
3. Momentarily connect SS2 to the chassis
ground. Starter Solenoid Voltage Drop Test
If starter runs, carry out the STARTER SOLENOID Turn ignition key ON.
INPUT VOLTAGE TEST

tmr201 1-028 279

Section 05 ELECTRICAL SYSTEM
Subsection 05 (STARTING SYSTEM)

Measure voltage as per following table while Disconnect BLACK (-) cable from battery.
cranking engine in drowned mode (to prevent
engine starting). A WARNING
NOTE: For drowned mode, refer to ENGINE Always disconnect BLACK (-) cable first and
MANAGEMENT subsection. reconnect last.
STARTER SOLENOID VOLTAGE DROP TEST Disconnect RED (+) cable from starter.
RESULT (WHILE Clean starter area.
TEST PROBES
CRANKING)
Remove starter retaining screw.
Post coming Post going to
0.2 Vdc max.
from battery starter

TYPICAL - SOME PARTS REMOVED FOR CLARITY PURPOSE

ONLY

Carefully pry starter out of the engine crankcase.

Starter Installation
If voltage is out of specification, replace solenoid. Installation is the reverse of removal procedure.
However, pay particular attention to the following.
ELECTRIC STARTER Make sure that starter and engine mating surfaces
Starter Access are free of debris. Serious problem may arise if
the starter is not properly aligned.
To access starter electrical terminal, refer to
BODY and remove LH seat and LH lateral con- Bring starter close to its location. Rotate it so
sole panel. that its mounting ear allows installation in engine
crankcase.
To access starter for removal, remove drive pul-
ley, driven pulley and CVT back cover, refer to Push starter in place and align mounting ear to in-
CONTINUOUSLY VARIABLE TRANSMISSION stall screw. Tighten to the specified torque.
(CVT) subsection. STARTER MOUNTING SCREW TIGHTENING
TORQUE
Starter Operation Test
Starter mounting screw I 25 Nom (18Ibf•ft)
Using booster cables, carefully supply current
from a 12 volt battery directly to the starter. Con- Connect the RED (+) cable to the starter and
nect the BLACK (-) cable first. Then connect the tighten nut and apply specified product.
remaining jumper cable from the battery then to
the starter.
If starter turns, test other starting system compo-
A CAUTION When connecting the RED (+)
cable to the starter motor, make sure the bat-
nents. tery cables are disconnected.

Starter Removal
Turn OFF ignition switch.

280 tmr2011-028
 Section 05 ELECTRICAL SYSTEM
Subsection 05 (STARTING SYSTEM)

STARTER CABLE NUT

TIGHTENING TORQUE PRODUCT
DIELECTRIC GREASE
6 Nom (53Ibfoin)
(P/N 293 550 004)

First connect RED (+) cable to battery then con-

nect the BLACK (-) cable.
Connect battery cables.

A WARNING
Always connect RED (+) cable first then
BLACK (-) cable last.

Test starter operation.

Imr2011-028 281
 Section 05 ELECTRICAL SYSTEM
Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

DIGITALLY ENCODED SECURITY

SYSTEM (D.E.S.S.)
GENERAL The B.U.D.S. software is designed to allow,
among other things, the programming of ignition
SYSTEM DESCRIPTION key(s) and entering customer information.
For more information pertaining to the use of the
The ignition key contains a ROM chip with a
software B.U.D.S., use its help which contains de-
unique digital code that is the equivalent of a
tailed information on its functions.
unique teeth pattern on a conventional key.
When the ignition key is turned ON, the ECM A WARNING
reads the ignition key and, if it is not recognized, If the computer you are using is connected
no engine starting will be possible. to the 110 Vac power outlet, there is a poten-
NOTE: When a key is not recognized by the ECM, tial risk of electrocution when working in con-
INVALID KEY will be displayed in the multifunction tact with water. Be careful not to touch water
speedometer. while working with the VCK.
NOTE: All ignition keys have the same teeth
pattern. Therefore, they can be used and turned 1. Turn ignition switch to ON using any of the key
in the switch of any D.E.S.S.-equipped vehicle. provided with the vehicle. DO NOT start the
However, unless the D.E.S.S. system recognizes engine.
(in the ECM) a valid programmed key, the engine 2. Start B.U.D.S. and logon.
starting will not be allowed.
3. Wait during detection setup.
NOTE: Actually, it is the memory of the ECM that
4. Ensure the status bar shows the Kw2000 pro-
is programmed to recognize the digital code of the tocol and the appropriate number of modules to
ignition key. its right according to the vehicle model.
Up to 10 ignition keys may be programmed in the
memory of the ECM. They can also be erased in-
dividually or all at once.
Note that the D.E.S.S. circuitry is already activated
on all new ECM.

TROUBLESHOOTING
TYPICAL - SUCCESSFUL CONNECTION
DIAGNOSTIC TIPS 1. Connection protocol
2. Number of modules
NOTE: It is a good practice to check for fault
codes using B.U.D.S. software as a first trou- 5. Click the Read Data button.
bleshooting step.
If D.E.S.S. key is not recognized by the ECM, key File View MP Module Tools Help
is defective or there is a wiring problem, CHECK
ENGINE light will turn on and a message will be
displayed in the multifunction speedometer. ri

PROCEDURES IIP A

Write Data
A

Read Data
KEY PROGRAMMING
Use the appropriate B.U.D.S. software version
available from BOSSWeb. Refer to COMMU- 6. Click on Keys tab.
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection for proper connection instructions.

tmr2011-029 283
 Section 05 ELECTRICAL SYSTEM
Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

14. Program the other key by selecting the right

type according to above chart.
15. Repeat previous steps to program other keys.
16. Click on Write Data button to transfer new
settings and information to the ECM.

:at* Type
Modtie Tools Help

•K

5m2011 079 - 001

KEYS TAB

7. Click on Erase All Keys button.

vrer 2006-012-100_50r.
Free WRITE DATA BUTTON
Free

Free
17. Click on EXIT button to end session.
Free 18. Disconnect all cables and hardware from vehi-
Free cle.
1
htese Key 19. Ensure to reinstall the connector into its hous-
Erase An Keys Add Performance Key Add hdrmai Kef
ing.
1913011-001 052_ a

1. Click here to erase all keys

8. Click "YES" to confirm the action.

9. Confirm key color in ignition switch.
10. Program the key by selecting the right type
according to chart.
KEY KEY TYPE
BLACK key Performance key
GRAY key Normal key

NOTE: The work key (ORANGE key) is optional.

.0 Grime

ea Ft*.

Free

r7 roe
1
rll frce 2

Add Ereemence Key J iekiNretetelKey

11,17011-001-053 tl

1. Add Performance Key button

2. Add Normal Key button

11. Turn ignition switch to OFF. Remove the key.

12. Install the other key.
13. Turn ignition key to ON position.

284 tmr2011-029
 Section 05 ELECTRICAL SYSTEM
Subsection07 (LIGHTS, GAUGE AND ACCESSORIES)

LIGHTS, GAUGE AND ACCESSORIES

SERVICE PRODUCTS
Description Part Number Page
DIELECTRIC GREASE 293 550 004 285

GENERAL Pay attention to ground wires.

NOTICE It is recommended to always discon-
nect the battery when replacing any electric
PROCEDURES
or electronic parts. Always disconnect battery
exactly in the specified order, BLACK (-) cable CONSOLE SWITCHES
first.
Switches Access
Refer to BODYand remove upper console.
TROUBLESHOOTING
Switches Removal and Installation
DIAGNOSTIC TIPS Disconnect electrical connector.
NOTE: It is a good practice to check for fault Release retaining clips, then push switch out of
codes using B.U.D.S. software as a first trou- the console.
bleshooting step. Refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection.
IMPORTANT: When troubleshooting an electrical
system fault, check battery condition, cables and
connections first.

Circuit Testing
Check the related-circuit fuse condition with a
fuse tester or test lamp (a visual inspection could
lead to a wrong conclusion).
NOTE: If the ignition switch is left ON for more
than 30 minutes, the accessory relay will shut
down.

Electrical Connection Inspection 1. Retaining clips

When replacing an electric or electronic compo- For installation, reverse removal procedure.
nent, always check electrical connections. Make
sure they are tight, make good contact, and are Switches Illumination Wire
corrosion-free. Dirty, loose or corroded contacts Identification
are poor conductors and are often the source of a
system or component malfunction. FUNCTION PIN COLOR

Pay particular attention to ensure that pins are not See

12 volt input from fuse F7 RED/BLACK
bent or pushed out of their connectors. note

Ensure all wire terminals are properly crimped on NOTE: The illumination circuit of all console
wires, and connector housings are properly fas- switches is supplied by the RED/BLACK wire
tened. (except hazard switch if equipped) but the pin
Check for signs of moisture, corrosion or dullness. location differ from one to another.
Clean pins properly and coat them with DIELEC-
TRIC GREASE (P/N 293 550 004) or other appropriate
lubricant when reassembling them, except if oth-
erwise specified such as for the ECM connectors.

Imr2011-030 285
Section 05 ELECTRICAL SYSTEM
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Switches Illumination Circuit

Protection
CONDITION CIRCUIT PROTECTION
Supplied with
Fuse 7 of fuse block 1 (from
accessories relay
accessories relay R3)
activated

MULTIFUNCTION GAUGE (LCD

AND ANALOG/DIGITAL)
Multifunction Gauge Wire
Identification
ANALOG/DIGITAL GAUGE SHOWN
FUNCTION PIN COLOR 1. Retaining clips

12 volt input from fuse F4 17 ORANGE/GREEN 4. Tilt top of gauge rearward, then pull it up to re-
12 volt input from fuse F8 16 BEIGE/WHITE move it from its support.
Ground 20 BLACK Multifunction Gauge Installation
CAN LO 18 BEIGE/GREEN For the installation, reverse the removal proce-
CAN HI 19 WHITE/BEIGE dure, however pay attention to the following.
4 BROWN/PINK
Align gauge support top in the gauge cover slots
Fuel level gauge supply
on each side.
Fuel level gauge ground 21 VIOLET/PINK
2WD/4WD switch signal (-) 7 BLACK/BEIGE
HI beam signal (+) 5 BLUE

Multifunction Gauge Circuit Protection

CONDITION CIRCUIT PROTECTION
Fuse 8 of fuse block 1
Supplied at all times (from fuse 1 of fuse
block 2)
Supplied with main Fuse 4 of fuse block 1
relay activated (from main relay R2)

Multifunction Gauge Removal

1. Remove gauge cover. ANALOG/DIGITAL GAUGE SHOWN
1. Gauge support top
2. Disconnect gauge connector. 2. Gauge cover slot
3. Release retaining clips at the top of gauge.
Maintenance Soon Message
Maintenance Soon Message Manual Reset
With the ignition switch ON, alternately depress
the override button and brake pedal 3 times.
Maintenance Soon Message Reset Using
B.U.D.S.
Connect to the applicable B.U.D.S. software. Re-
fer to COMMUNICATION TOOLS AND B.U.D.S.
subsection.
Select Vehicle tab.

286 tmr2011-030
 Section 05 ELECTRICAL SYSTEM
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Click on the Reset Service button. Scroll and select the appropriate tire diameter (see
inscriptions on the tires) in the Tire Size box.
I

Liyn, La

CCM first initiazation Tare Size

120

Hours Reset

ECM !COATI
11,12011 -030-008_a

1. Tire Size box

Clock Setting

ra' , 2011 03(-014a

Select Setting and Cluster tabs.
7. Reset Service button To set clock to the 24-hour format, check the 24 H
box. To set it to the 12-hour format, leave the box
Multifunction Gauge Set-Up Using empty.
B.U.D.S. If 12-hour format was selected, check the PM box
Connect to the applicable B.U.D.S. software. Re- if required.
fer to COMMUNICATION TOOLS AND B.UD.S Set hour and minutes using the up or down ar-
subsection. rows.
Language Selection
Select Setting and Cluster tabs. 3
Scroll and select the desired display language in
the Cluster Language box.
Real Time Clock

Ce4ter Language Cluster Country i,80- 24 H

r■ NA
lEnghsh Hour:
r CE
Minute:
Stuler Wes CluVer Comity
R NA
tmr2011-030-007_a
r• Metric r GI
1. 24 H box
2. PM box
am2011-030-006_a
3. Arrows
1 Cluster Language box
Country Selection
Units Selection To enable flasher pilot lamp on European Commu-
Select Setting and Cluster tabs. nity (CE) models, select Cluster and Setting tabs.
Select Imperial or Metric in the Cluster Units Select CE in the Cluster Country box.
box.
Custer Language

Geiger Language
lEnglistt

iEnejksh

CritiStOt Unit Cloter Coun

a NA
Metric
1m12011 030-006_c

Imr2011-030-006_b I. Cluster Country box

1. Cluster Units box
Outside Europe, select NA.
Tire Size Selection
Select Setting and ECM tabs.

tmr2011-030 287
 Section 05 ELECTRICAL SYSTEM
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

New Multifunction Gauge Registration Cluster Lamp Active

(coding) Oil Pressure switch: Engine Hi Temp:
Whenever multifunction gauge is replaced, it is Low Fuel: Engine Warning:
required to use B.U.D.S. to register it in ECM. Low Batt:
Simply click Yes when the following message
High bat:
appears.
ECM Cluster (
c nC2011-030 010

The cluster codina does not match with CLUSTER LAMP ACTIVE BOX
the ECM connected. Do you want to change it?
This function confirms that the signals are broad-
casting and the indicator lights should be ON in
the multifunction gauge.
Switches Input Monitoring
Select Monitoring and Cluster tabs.
MPORTANT: If a multifunction gauge from an-
Use the Switch Inputs box to monitor different
other vehicle model is installed and is not regis-
switch inputs as you activates the switches.
tered in ECM through B.U.D.S., engine starting
will not be allowed until gauge is registered
with proper coding.
Neal l ime:
Switch inputs
Multifunction Gauge Test with B.U.D.S. Flasher L. Mode Button:
Connect to the applicable B.U.D.S. software. Re-
fer to COMMUNICATION TOOLS AND B.U.D.S. 4WD: Set Button:
subsection.
High Beam:
Wow Test
Park Brake.
This function is used to check if the indicator
lights, display and analog indicators (if applicable)
are functional. m, 2011-030011

SWITCH INPUTS BOX

NOTE: This function does not test the signals or
external circuits. This function confirms that the ECM receives the
Select the Activation and Cluster tabs. inputs.
Click on the WOW Test button. Vehicle Parameters Monitoring
Select Monitoring and Cluster tabs.
In the upper area, the fuel level, engine speed
(RPM), vehicle speed and engine coolant temper-
ature are displayed.
This function confirms that the signals are broad-
casting and the information should be displayed
on the multifunction gauge.

12 VOLT POWER OUTLET

q2011 030 009,
12 Volt Power Outlet Removal and
TYPICAL Installation
1. WOW Test button
Refer to BODYand remove upper console.
Indicator Lights Monitoring Unplug the connectors of the power outlet.
Select Monitoring and Cluster tabs. Unscrew the retaining nut.
Use the Cluster Lamp Active box to monitor dif- Reverse procedure for installation.
ferent indicator lights outputs.

288 tmr2011-030
 Section 05 ELECTRICAL SYSTEM
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

12 Volt Power Outlet Wire HEADLIGHT LOW/HIGH BEAM SWITCH

Identification (EUROPE - IN MULTIFUNCTION SWITCH)
FUNCTION PIN COLOR FUNCTION PIN COLOR

12 volt input from 12 volt input from

2 RED/BROWN MGC-4 GREEN
fuse F12 headlights relay

Ground (to ground 12 volt output to

1 BLACK BLUE
terminal BK3) high beam headlights MGC-5
(HI position)
12 Volt Power Outlet Circuit Protection 12 volt output to
high beam headlights MGC-2 BLUE
CONDITION CIRCUIT PROTECTION (PASS position)
Supplied with Fuse 12 of fuse block
accessories relay 1 (from accessories Headlights Circuit Protection
activated relay R3)
CONDITION CIRCUIT PROTECTION
Fuse 11 of fuse block 1
HEADLIGHTS Supplied at all times
(from fuse 2 of fuse block 2)
Headlight Wire Identification
HEADLIGHTS RELAY (R4)
Headlight Test
Disconnect headlight connector. Refer to BULB
FUNCTION PIN COLOR
REPLACEMENT.
12 volt input from fuse F11
7D YELLOW/BLACK Using a multimeter, measure the voltage on head-
(headlights power)
light connector as follows.
12 volt input from ignition
switch pin A (relay 6D YELLOW/BLUE SWITCH
WIRE COLOR VOLTAGE
winding input) POSITION

12 volt output to headlights GREEN

LO beam/
low beam and low/high 6C GREEN (Low beam BLACK
HI beam
beam switch bulb) Battery
BLUE voltage
Relay winding ground
7C ORANGE/BLACK HI beam (Hi beam BLACK
(from ECM-B G1)
bulb)
HEADLIGHT LOW/HIGH BEAM SWITCH
(EXCEPT EUROPE) Headlight Bulb Replacement
FUNCTION PIN COLOR NOTICE Never touch glass portion of an
12 volt input from halogen bulb with bare fingers, it shortens its
2 GREEN
headlights relay operating life. If glass is touched, clean it with
isopropyl alcohol which will not leave a film
12 volt output to high 3
BLUE on the bulb.
beam headlights
NOTE: The same bulb type is used for LO and HI
beams on both sides of vehicle.
Unplug connector from bulb.

tmr201 1-030 289

Section 05 ELECTRICAL SYSTEM
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Headlamp Beam Aiming

Select high beam.
Beam aiming is correct when center of high beam
is 130 mm (5 in) below the headlight horizontal
center line, scribed on a test surface, 5m (16 ft)
away.
NOTE: Load vehicle as per normal use.
Measure headlight center distance from the
ground. Scribe a line at this height on test sur-
face (wall or screen). Light beam center should
be 130 mm (5 in) below scribed line.

vn O! , 0-202, _a

Rotate bulb.
90 0,
A

1nr2011 030002 d

1. Light beam center

A. 5 m (17 ft)
B. 131 mm (5 in)

Pull bulb out.

1. Headlight center lines

2. Light beam center

Beam Aiming Adjustment

Turn adjustment screws to adjust beam height
and side orientation as described below. Adjust
both headlight evenly.

Properly reinstall removed parts in the reverse or-

der of their removal.
Validate headlight operation.

290 trnr2011-030
 Section 05 ELECTRICAL SYSTEM
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

BRAKE LIGHT SWITCH

FUNCTION PIN COLOR
12 volt input from fuse F4 2 ORANGE/GREEN
12 volt output to RH brake 1 RED/ORANGE
light and R8 relay winding

Taillight/Brake Light Circuit Protection

CONDITION CIRCUIT PROTECTION
Supplied with main Fuse 4 of fuse block 1
relay activated (from main relay R2)

Taillight/Brake Light Bulb Replacement

1. Adjustment screws Open upper tail gate.
Remove both taillight retaining screws.
TAILLIGHTS/BRAKE LIGHTS
Taillight/Brake Light Switch Access
The taillight/brake light switch is located on the
brake master cylinder.

0410kPit,t , 1414*
PI1Piop1oppple)+14)111,11,
4thl.) # 1
imp r. 04

1. Tail gate cable

2. Taillight
3. Retaining screws

1. Master cylinder
2. Taillight/brake light switch Pull taillight out of its location.
Remove bulb socket from taillight.
Taillight/Brake Light Wire Identification
BRAKE LIGHT RELAY (R8)
FUNCTION PIN COLOR
12 volt input from fuse F4 12B ORANGE/GREEN
(LH brake light power)
12 volt input from
brake light switch (relay 1 1B RED/ORANGE
winding input)
12 volt output to LH 11A WHITE/ORANGE
brake light
Relay winding ground (to BLACK
12A
ground terminal BK2)

291
tmr2011-030
 Section 05 ELECTRICAL SYSTEM
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

WINCH SWITCH
FUNCTION PIN COLOR
12 volt input from fuse 7 2 RED/BLACK
12 volt output to relay
1 GREEN/BLUE
winding ("IN")
12 volt output to relay
3 LIGHT BLUE
winding ("OUT")

A WARNING
Before testing, make sure the winch is in
FREESPOOL mode (Freespool clutch disen-
gaged).

1. Taillight
2. Light bulb and socket

Push the bulb in and hold while turning counter-

clockwise to release.
Installation is the reverse of the removal proce-
dure.

WINCH
XT Models Only

Winch Wire Identification

WINCH RELAY
FUNCTION PIN COLOR
12 volt input from battery SIMPLIFIED WINCH WIRING DIAGRAM
BP4 RED
(winch power) 1. Winch motor
2. Winch relay
Ground BN4 BLACK 3. Winch remote control
4. Winch switch
12 volt input from 5. Battery
SW1 GREEN/BLUE 6. 12 volt input to switch (switch pin 2 - from fuse 7)
switch ("IN") 7. Winch motor power (SW3)
8. Winch motor power (SW5)
12 volt input from switch 9. 12 volt input to relay winding ("iN" - SW1)
SW2 LIGHT BLUE 10.12 volt input to relay winding ("OUT"- SW2)
("OUT")
Motor power (switches Winch Switch Circuit Protection
RED (with blue
polarity depending on SW3
sleeve)
rotation direction) CONDITION CIRCUIT PROTECTION
Motor power (switches Supplied with Fuse 7 of fuse block
RED (with
polarity depending on SW5 accessories relay 1 (from accessories
Yellow sleeve)
rotation direction) activated relay R3)

NOTE: The small black w're at terminal BN4 is

Winch Removal
connected to the diodes used to prevent electric
arcs in the switch. 1. Disconnect, the battery BLACK (-) cable first,
then the RED (+) cable.

292 tmr2011-030
 Section 05 ELECTRICAL SYSTEM
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

a WARNING TURN SIGNALS/HAZARD

Always respect this order for disassembly; (EC MODELS ONLY)
disconnect BLACK (-) cable first. Electrolyte Turn Signal Wire Identification
or fuel vapors can be present in engine com-
partment and a spark may ignite them and FLASHER MODULE
possibly cause personal injuries. FUNCTION PIN COLOR

2. Remove the hook. 12 volt input from

MC2-1 RED/WHITE
fuse F10
2.1 Remove and discard the cotter pin.
12 volt input from
2.2 Remove the hook pin. MC1-5 ORANGE/GREEN
fuse F4
RH turn 12 volt input
from turn signal MC1-1 BEIGE/ORANGE
switch
LH turn 12 volt input
from turn signal MC1-2 BEIGE/GREY
switch

Output to RH turn
MC2-2 BROWN
signal lights
Output to LH turn
MC2-3 GREY
signal lights
Output to
multifunction gauge MC2-4 ORANGE
(turn signal indicator)
Ground MC1-4 BLACK

Hazard 12 volt input

1. Hook MC1-6 GREEN/ORANGE
from hazard switch
2. Hook pin
3. Cotter pin
TURN SIGNAL SWITCH
3. Remove the four retaining screws from under- (IN MULTIFUNCTION SWITCH)
neath the winch motor.
FUNCTION PIN COLOR
4. Disconnect both winch power cables.
12 volt input from
NOTE: Note the position of the power cables for MGB-3 ORANGE/GREEN
fuse F4
reinstallation.
RH turn 12 volt output
5. Protect radiator using strong cardboard. MGB-4 BEIGE/ORANGE
to flasher module
6. Pass the cable through the roller fairlead. LH turn 12 volt output
MGB-2 BEIGE/GREY
7. Remove winch. to flasher module

NOTICE Be careful not to lean on the radiator HAZARD SWITCH

while removing winch.
FUNCTION PIN COLOR
Winch Installation 12 volt input from
2 RED/WHITE
For the installation, reverse the removal proce- fuse F10
dure, however pay attention to the following. 12 volt output to
3 GREEN/ORANGE
Tighten winch retaining screws to flasher module
24.5 N•rn ± 3.5 N•m (18 lbf•ft ± 3 lbf•ft). Hazard indicator
Connect wires the yellow wire at rear and the blue 12 volt input from 8 ORANGE/BROWN
one at front. fuse F4

Install a new cotter pin on the hook pin. Hazard indicator

ground 7 BLACK/ORANGE
(through bulbs)

tm , 2011-030 293
 Section 05 ELECTRICAL SYSTEM
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Turn Signal/Hazard Circuit Protection

CONDITION CIRCUIT PROTECTION
Supplied with main Fuse 4 of fuse block 1
relay (R2) activated (from main relay R2)
Fuse 10 of fuse block 1
Supplied at all times
(from fuse 2 of fuse box 2)

HORN (EC MODELS ONLY)

Horn Wire Identification
HORN SWITCH (IN MULTIFUNCTION SWITCH)
FUNCTION PIN COLOR
12 volt input from
MGB-1 ORANGE/GREEN
fuse F10
12 volt output to horn MGB-6 BEIGE/BLUE

HORN
FUNCTION PIN COLOR
12 volt input from
2 BEIGE/BLUE
horn switch
Ground 1 BLACK

Horn Circuit Protection

CONDITION CIRCUIT PROTECTION
Supplied with main relay Fuse 4 of fuse block 1
(R2) activated (from main relay R2)

294 tmr2011-030
 Section 06 DRIVE SYSTEM
Subsection 01 (FRONT DRIVE)

FRONT DRIVE
SERVICE TOOLS
Description Part Number Page

BACKLASH MEASUREMENT TOOL 529 035 665 301

CV JOINT EXTRACTOR 529 036 005 299
OETIKER PLIERS 295 000 069 299
OETIKER PLIERS 295 000 070 299
SPANNER SOCKET 529 035 649 301

SERVICE PRODUCTS
Description Part Number Page

LOCTITE 271 (RED) 293 800 005 303

LOCTITE 277 293 800 073 302
XPS SYNTHETIC GREASE 293 550 010 299, 303

295
tmr2011-031
 Section 06 DRIVE SYSTEM
Subsection 01 (FRONT DRIVE)

7221 225 ± 15 N•rn

(166 ± 11 Ib•t)

XPS
Synthetic
grease
See
BRAKES

See
STEERING
SYSTEM

22.5 ± 2.5 N•rn

(17 ± 2 lbf•ft)

70 ± 5 N•rn
(52 ± 4 lbf•in)
XPS
Synthetic
grease

75 ± 5 N•rn
2_41..----- (55 ± 4 lbf•in)

To
Engine
Loctite See
271
STEERING
SYSTEM

See
BRAKES
PROPELLER SHAFT 225 ± 15 N•rn
(166± 11 lbf•ft)

^ e. 111WAA 00 (a MD
"

XPS XPS
Hi-temp bearing grease
Synthetic Synthetic Component must be replaced
NLGI-2 or equivalent
grease grease when removed
:nlri011 031-001

296
tmr2011-031
 Section 06 DRIVE SYSTEM
Subsection 01 (FRONT DRIVE)

33 ± 3 N•rn
(24 ± 2 lbf•ft)

12

11
1
33 ± 3 N•m
(24 ± 2 lbf•ft)

10

11

12

8
0 4I !Mira
7.5 ± 0.5 N • rn
rr,-T %
13 14,_J
(66 ± 4 lbf•in)

NEW

180 ± 15 N•rn
(133 ± 11 lbf•ft)
Loctite LEFT HAND
277 THREADED
XPS
Synthetic
grease
MEI = Component must be replaced when removed

r 2011 031.002a

297
tmr2011-031
 Section 06 DRIVE SYSTEM
Subsection 01 (FRONT DRIVE)

GENERAL Select the 4WD position and place the transmis-

sion lever on P.
The procedure explained below is the same for
the RH and LH sides unless otherwise instructed. Remove caliper from knuckle. Refer to BRAKES
subsection.
During assembly/installation, use torque values
and service products as in the exploded views. Remove the following parts:
Clean threads before applying threadlocker. Re- — Wheel
fer to SELF-LOCKING FASTENERS and LOCTITE — Cotter pin
APPLICATION at the beginning of this manual for — Castellated nut
complete procedure. — Belleville washer.

A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.

Hoses, cables or locking ties removed during a

procedure must be reinstalled as per factory stan-
dards.

SYSTEM DESCRIPTION
The Visco-Loke system constantly monitors front
TYPICAL
wheel speed and, if it detects one wheel spinning 1. Cotter pin
faster than its mate, it progressively sends more 2. Castellated nut
3. Belleville washer
power to the wheel with the better traction.
The Visco-Lok system is comprised of two princi- Remove wheel hub.
pal components, a shear pump and the controlled
multi-plate clutch. Wheel Hub Inspection
A unique feature of the shear pump is that it Check wheel hub for cracks or other damages.
is self-contained and independent. It does not Check inner splines for wear or other damages.
require an external source of hydraulic fluid. The
If any damage is detected on wheel hub, replace
self-contained viscous shear pump generates a it with a new one.
pressure proportional to wheel speed differential
- meaning the difference in rotational speed be- Wheel Hub Installation
tween the two wheels. This pressure engages
the friction clutch via a piston to transmit the The installation is the reverse of removal proce-
torque. dure. However, pay attention to the following.
In the event of a failure, the entire Visco-Lok pump Install Belleville washer with its concave side to-
and its carrier will have to be replaced. The Visco- wards outward.
Lok pump itself is a non-serviceable item. If the PART TORQUE
pump is disassembled, the viscous fluid contained
inside will be lost and it cannot be replaced. Castellated nut 225 N•m ± 15 N•m
(166 lbf•ft ± 11 lbf•ft)
PROCEDURES NOTE: Tighten further castellated nut if required
to align grooves with drive shaft hole.
WHEEL HUB Install a NEW cotter pin.
Wheel Hub Removal
Lift and support vehicle. Refer to INTRODUC-
TION section for proper procedure.

298
tmr2071-031
 Section 06 DRIVE SYSTEM
Subsection 01 (FRONT DRIVE)

Apply XPS SYNTHETIC GREASE (P/N 293 550 010) to

the splines.
The wear ring should be closed to the differential.
Reinstall all removed parts.

DRIVE SHAFT BOOT

Drive Shaft Boot Removal
Remove the drive shaft from the vehicle.
Remove drive shaft boot clamps using the follow-
ing tools:
TOOL

FRONT DRIVE SHAFT OETIKER PLIERS

(P/N 295 000 069)
Front Drive Shaft Removal
Lift and support vehicle. Refer to INTRODUC-
TION section for proper procedure. OETIKER PLIERS
(P/N 295 000 070)
Remove the wheel hub, see procedure in this sub-
section.
Remove the knuckle. Refer to STEERING SYS- Dislodge the large boot end.
TEM subsection. Separate the joint from the shaft. Two procedures
Strongly pull drive shaft out of differential. can be done.
Discard the stop ring at the end of the shaft. Without the Special Tool
Clamp joint housing in a vise.
Front Drive Shaft Inspection
Align shaft with joint.
Inspect the condition of boots. If there is any dam-
age or evidence of leaking lubricant, replace them. Pull hard on shaft to remove from joint.
Refer to DRIVE SHAFT BOOT Remove boot from drive shaft.
Check splines for excessive wear. Replace if nec- Remove and discard the circlip. A new one is in-
essary. cluded in the boot kit.
NOTE: If the splines on plunging joint are worn, a With the Special Tool
check of differential inner splines should be done.
Place drive shaft in vice with the joint downward.
Front Drive Shaft Installation Install the CV JOINT EXTRACTOR (P/N 529 036 005)
The installation is the reverse of the removal pro- on bearing.
cedure. However, pay attention to the following.
Install a NEW stop ring.

1. Stop ring

tmr2011-031 299
Section 06 DRIVE SYSTEM
Subsection 01 (FRONT DRIVE)

TYPICAL — CV JOINT SHOWN

1. Joint extractor tool FROM THE LEFT SIDE OF VEHICLE
1. Front retaining screw
2. Rear retaining nuts
With an hammer, hit on the tool to separate joint
from shaft. Remove the upper differential bolts.
When joint and shaft are separated, remove boot Remove nuts securing the lower bolts. Pull bolts
from drive shaft. to free the left support.
Remove and discard the circlip. A new one is in- NOTE: Differential removal is required to remove
cluded in the boot kit. lower bolts and LH lower differential support.

Drive Shaft Boot Installation Remove the large clamp from the propeller shaft
rubber boot.
For installation, reverse the removal procedure.
Pay attention to the following details. Remove the differential from the front of vehicle.

Install the NEW circlip. Remove yoke if required.

Pack bearing area with grease (included with the Front Differential Inspection
new boot kit).
Check backlash and drag torque, see FRONT DIF-
NOTE: Do not use or add other grease. FERENTIAL ADJUSTMENTin this subsection.
Check if oil seals are brittle, hard or damaged. Re-
FRONT DIFFERENTIAL place if necessary.
Front Differential Removal
Front Differential Disassembly
Drain the differential. Refer to PERIODIC MAIN-
TENANCE PROCEDURES subsection. Visco-Lok Carrier/Ring Gear
Remove both drive shafts. See procedure in this Unscrew the differential housing screws no. 1,
subsection. then separate half housings.
Remove heavy duty front bumper (X and XT
models) with front fascia.
Remove the radiator. Refer to COOLING SYSTEM
subsection.
Remove bolts that attach winch bracket to the
frame (XT models).
Remove front screw and rear nut securing the LH
lower differential support.

TYPICAL

300 tmr2011-031
 Section 06 DRIVE SYSTEM
Subsection 01 (FRONT DRIVE)

NOTE: Be careful to keep track of shims no. 2 on

each end of the Visco-Lok carrier no. 3.
Extract Visco-Lok carrier out of half housing.
Pinion Gear
Remove and discard oil seal no. 4.
Unscrew the pinion nut no. 5. Use the SPANNER
SOCKET (P/N 529 035 649).

1. Backlash side
2. Preload side

Temporarily assemble the front differential. See

procedure in FRONT DIFFERENTIAL ASSEMBLY
NOTE: The pinion nut is left hand threaded. Un- below in this subsection.
screw by turning clockwise.
Backlash
Remove the bearing no. 6 at the same time as
Using a dial indicator and the BACKLASH MEA-
the pinion gear no. 7. Be careful to keep track of
shims no. 8. SUREMENT TOOL (P/N 529 035 665), measure the
backlash. Place the backlash measurement tool
The pinion gear and bearing can be easily removed at the end of pinion gear.
using the following suggested tool:
From center of bolt, measure 25.4 mm (1 in) and
PART QTY scribe a mark on the tab.
Pipe: 89 mm (3-1/2 in) diameter x 127 mm
1
(5 in) in length
Screwed rod: M12 x 1.25, 178 mm (7 in)
1
length
M12 x 1.25 nut 3
Flat bar 1

Remove and discard the needle bearing no. 9.

Front Differential Adjustment

A shimming procedure must be done when
Visco-Lok carrier, pinion gear or housing is (are)
changed.
Install recommended shims accordingly with the
following table. 1. Tab of backlash measurement tool
2. Mark on tab
RECOMMENDED SHIMS A. 25.4 mm (1 in)
1.67 mm ± 0.04 mm
PINION GEAR Position the dial indicator tip against the tab at a
(.066 in ± .002 in)
90° angle and right on the previously scribed mark.
BACKLASH 0.5 mm (.02 in) Gently, move the tab back and forth. Note the re-
PRELOAD (for preliminary adjustment)
sult.

NOTE: The procedure above sets the pinion shim

thickness and should not be modified thereafter.
Any changes should be done on the preload
and/or backlash side(s).

tmr201 1-031 301

Section 06 DRIVE SYSTEM
Subsection 01 (FRONT DRIVE)

TYPICAL

If the drag torque is greater than 0.5 N•m

(51bf•in), reduce preload shim by 0.05 mm
Rotate pinion gear 1/2 turn and check backlash (.002 in) and check drag torque again.
again. Note the result. If the drag torque is less than 0.06 N•rn (.5 lbf•in),
Rotate pinion gear 1 turn and check backlash increase preload shim by 0.05 mm (.002 in) and
again. check drag torque again.

If backlash is below 0.05 mm (.002 in), increase Front Differential Assembly

backlash shim and check the backlash again.
Visco-Lok Carrier/Ring Gear
If backlash is greater than 0.356 mm (.014 in),
decrease backlash shim and check the backlash To assemble, reverse the removal procedure. Pay
again. attention to the following.
Measure preload. Check condition of seal no. 10. Replace if dam-
age.
Preload
Check bearings no. 11. Replace if damage.
Screw the propeller shaft adaptor bolt in pinion
gear. Tighten differential housing screws no. 1.
PART TORQUE
Differential housing 33 N•m ± 3 Nom
screws (24 lbf•ft ± 2 lbf•ft)

Pinion Gear
To install, reverse the removal procedure. Pay at-
tention to the following details.
Replace the 0-ring no. 13.
Install the shim(s) no. 8 then the ball bearing no. 6.
Install a new needle bearing no. 9.
Apply LOCTITE 277 (P/N 293 800 073) to pinion nut
TYPICAL no. 5.
Using a needle torque wrench, measure the drag NOTE: If a new pinion nut is used, a self-locking
torque. product is already applied, do not use Loctite 277.
Install and tighten the pinion nut.
PART TORQUE
Pinion nut 180 N•rn ± 15 N•m
(LEFT HAND
(133 lbfeft ± 11 lbf•ft)
THREADED)

tmr2011-031
302
 Section 06 DRIVE SYSTEM
Subsection 01 (FRONT DRIVE)

Front Differential Installation PARTS TORQUE

The installation is the reverse of the removal pro- Propeller shaft screw 75 N•m ± 15 N•m
cedure. However, pay attention to the following. (differential side) (55 lbf•ft ± 11 lbf•ft)
When inserting the small portion of propeller shaft 75 N•m ± 15 N•m
into propeller shaft boot, make sure both parts of Propeller shaft screw (55 lbf•ft ± 11 lbf•ft) +
propeller shaft are well indexed. (engine side) LOCTITE 271 (RED)
(P/N 293 800 005)
PARTS TORQUE
Differential retaining 70 N•m ± 5 N•m
nuts (52 lbf•ft ± 4 lbfeft) PROPELLER SHAFT U-JOINTS
Differential upper bolts
24.5 N•m ± 3.5 N•m Propeller Shaft U-Joint Removal
(18 lbf•ft ± 3 lbfeft)
Remove internal snap ring from bearing caps.
24.5 N•m ± 3.5 N•m
Differential support nut
(18 lbf•ft ± 3 lbf•ft)
24.5 N•m ± 3.5 N•m
Differential support bolt
(18 lbf•ft ± 3 lbfeft)

Refill the front differential with recommended

oil. Refer to PERIODIC MAINTENANCE PROCE-
DURES subsection.

FRONT PROPELLER SHAFT

Front Propeller Shaft Removal
Remove the RH lateral console panel.
Remove propeller shaft screws (on engine and dif-
ferential).
Remove lower and upper differential bolts. 1. Snap ring

Move the differential forwards. Support inner yoke in vice and drive other yoke
Dislodge the propeller shaft from the engine and down with a soft hammer.
differential.
Remove front propeller shaft.

Front Propeller Shaft Inspection

Inspect if propeller shaft is not bent or twisted.
Check propeller shaft splines for wear or damage.
Check if propeller shaft bellows is pierced or brit-
tle

Front Propeller Shaft Installation

Installation is the reverse of removal procedure.
However, pay attention to the following.
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) to
splines on engine side.
Support U-joint in vice and drive inner yoke down
to remove remaining bearing caps.
Remove U-joint cross.

Propeller Shaft U-Joint Installation

Install new U-joint in inner yoke.

tmr2011-031 303
Section 06 DRIVE SYSTEM
Subsection 01 (FRONT DRIVE)

NOTE: Position propeller shaft U-joint as shown

for proper grease fitting location.

Install bearing caps. Use a vise to insert bearing

caps.

Using a suitable pusher, fully seat bearing cap on

one side.

Install snap ring.

Grease U-joints. Refer to PERIODIC MAINTE-
NANCE PROCEDURES subsection.

tmr2011-031
304
 Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

REAR DRIVE
SERVICE TOOLS
Description Part Number Page
BACKLASH MEASUREMENT TOOL 529 035 665 313
CV JOINT EXTRACTOR 529 036 005 309
OETIKER PLIERS 295 000 069 309
OETIKER PLIERS 295 000 070 309
SPANNER SOCKET 529 035 649 312

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 271 (RED) 293 800 005 310
LOCTITE 277 293 800 073 314
XPS SYNTHETIC GREASE 293 550 010 308, 310

tmr2011-032
305
 Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

NEW DRIVE SHAFT

225 ± 15 Nom
NEW
(166 ± 11 lbf•ft)
emo; KUM
( v im
Plunging
joint
CV joint

See
BRAKES

XPS
Synthetic
grease

70 ± 5 N•rn
(52 ± 4 lb•in)

(79--- 22.5 ± 2.5 N•rn

(17 ± 2 lbf•ft)

70 ± 5 Nom
(52 ± 4 lbf•in) XPS
Synthetic
grease

75 ± 5 Nom
To (55 ± 4 lbf•in)
Engine
Loctite
271

PROPELLER SHAFT
225 ± 15 N • rn
(166 ± 11 lbf4)

XPS Synthetic Iii-temp bearing grease XPS Synthetic = Component must be replaced
grease NLGI-2 or equivalent grease when removed

trn r2011-032-001_a

306 tmr2011-032
 Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

32.5 ± 3.5 N.m

(24 ± 3 lbf•ft)
1

/
12

11
10
1
32.5 ± 3.5 N•rn
(24 ± 3 lbf•ft)

12

Loctite 7.5 ± 0.5 N•rn

277 (66 -± 4 lbf•in)

180 ± 15 N•rn
(133 -± 11 lbf•ft)
LEFT HAND
THREADED

XPS
Synthetic
= Component must be replaced when removed
grease

trra2011-03 2-902 . a

tmr2011-032 307
Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

GENERAL
During assembly/installation, use torque values
and service products as in the exploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATIONat the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced. Remove wheel hub.

Wheel Hub Inspection

Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan- Check wheel hub for cracks or other damages.
dards Check inner splines for wear or other damages.
If any damage is detected on wheel hub, replace
PROCEDURES it with a new one.
Check wear ring. If it is loose on hub or deformed,
WHEEL HUB replace the wear ring.
Wheel Hub Removal
Lift and support vehicle. Refer to INTRODUC-
TION section for proper procedure.
Remove the wheel.
Remove the following parts:
— Cotter pin
— Wheel hub nut
— Belleville washer.

TYPICAL - LH WHEEL HUB SHOWN

1. Wheel hub
2. Wear ring

Wheel Hub Installation

The installation is the reverse of removal proce-
dure. Pay attention to the following.
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on
drive shaft splines.
1. Cotter pin Install Belleville washer with its concave side to-
2. Wheel hub nut wards outward.
3. Belleville washer
PART TORQUE
NOTE: On RH side, remove also the brake caliper.
225 Nom ± 15 N•rn
Wheel hub nut (166 lbf•ft ± 11 lbf•ft)

308 tmr2011-032
 Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

NOTE: Tighten further castellated nut if required

to align grooves with drive shaft hole.
Install a NEW cotter pin.

1. Stop ring

After drive shaft insertion in rear final drive, vali-

date if properly locked.

DRIVE SHAFT BOOT

DRIVE SHAFT
Drive Shaft Boot Removal
Drive Shaft Removal
Remove the drive shaft from vehicle. See proce-
Lift and support vehicle. Refer to INTRODUC- dure in this subsection.
TION section for proper procedure.
Remove drive shaft boot clamps using the follow-
Remove the wheel hub. See procedure in this ing tools:
subsection.
TOOL
Remove trailing arm. Refer to REAR SUSPEN-
SION. OETIKER PLIERS
Strongly pull drive shaft out of final drive. (P/N 295 000 069)

Drive Shaft Inspection

OETIKER PLIERS
Inspect the condition of boots. If there is any dam- (P/N 295 000 070)
age or evidence of leaking lubricant, replace them.
Refer to DRIVE SHAFT BOOT
Check shaft splines. Replace drive shaft if neces- Dislodge the large boot end.
sary. Separate the joint from the shaft. Two procedures
Check dust shield on drive shaft end. Replace if can be done.
necessary. Without the Special Tool
Drive Shaft Installation Clamp joint housing in a vise.
The installation is the reverse of the removal pro- Align shaft with joint.
cedure. However, pay attention to the following. Pull hard on shaft to remove from joint.
Install a NEW stop ring. Remove boot from drive shaft.
Remove and discard the circlip. A new one is in-
cluded in the boot kit.
With the Special Tool
Place drive shaft in vice with the joint downward.
Install the CV JOINT EXTRACTOR (P/N 529 036 005)
on bearing.

tmr2011-032 309
Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

8. Remove the propeller shaft.

Propeller Shaft Inspection

Inspect if propeller shaft is not bent or twisted.
Check propeller shaft splines for wear or damage.
Check if propeller shaft bellows is pierced or brit-
tle.

Propeller Shaft Installation

Installation is essentially the reverse of removal
procedure. Pay attention to the following details.
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) to
splines.
PARTS TORQUE
Propeller shaft screw 75 N•m ± 5 N•m
(final drive side) (55 lbf•ft ± 4 lbf•ft)
TYPICAL — CV JOINT SHOWN
1. Joint extractor tool 75 N•m ± 5 N•m
Propeller shaft screw (55 lbf•ft ± 4 lbf•ft) +
With an hammer, hit on the tool to separate joint (engine side) LOCTITE 271 (RED)
from shaft. (P/N 293 800 005)
When joint and shaft are separated, remove boot
from drive shaft. PROPELLER SHAFT U-JOINTS
Remove and discard the circlip. A new one is in-
cluded in the boot kit. Propeller Shaft U-Joint Removal
Remove drive shaft boot. Remove internal snap ring from bearing caps.

Drive Shaft Boot Installation

For installation, reverse the removal procedure.
Pay attention to the following.
Pack bearing area with grease (included with the
new boot kit).
NOTE: Do not use any other grease.

PROPELLER SHAFT
Propeller Shaft Removal
1. Remove the fuel tank. Refer to FUEL TANK
subsection.
2. Remove propeller shaft screw from gearbox
output shaft. 1. Snap ring

3. Lift and support vehicle. Refer to INTRODUC- Support inner yoke in vice and drive other yoke
TION section for proper procedure. down with a soft hammer.
4. Remove propeller shaft screw from rear final
drive yoke.
5. Remove rear final drive bolts. Refer to REAR
FINAL DRIVE in this subsection.
6. Move the rear final drive rearward to dislodge
the propeller shaft.
7. Dislodge the propeller shaft from the engine.

310 tmr2011-032
 Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

Using a suitable pusher, fully seat bearing cap on

one side.

Support U-joint in vice and drive inner yoke down

to remove remaining bearing caps.
Remove U-joint cross. nstall snap ring.
Complete installation for the other bearing caps.
Propeller Shaft U-Joint Installation
Grease U-joint. Refer to PERIODIC MAINTE-
Install new U-joint in inner yoke. NANCE PROCEDURES subsection.
NOTE: Position propeller shaft U-joint as shown
for proper grease fitting location. REAR FINAL DRIVE
Rear Final Drive Removal
Drain oil. Refer to PERIODIC MAINTENANCE
PROCEDURES subsection.
Remove drive shafts. See procedure in this sub-
section.
Remove the rear skid plate.
Remove the propeller shaft screw from the rear
final drive yoke.
Remove final drive lower bolts.

Install bearing caps. Use a vise to push bearing

caps.

1. Lower final drive bolts

Remove final drive upper bolts and the front bolts

of the final drive support.

tmr2011-032 311
Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

Pinion Gear
Remove and discard oil seal no.4.
Unscrew the pinion nut no. 5. Use the SPANNER
SOCKET (P/N 529 035 649).

1. Upper final drive bolts

2. Final drive support front bolts NOTE: The pinion nut is left hand threaded. Un-
screw by turning clockwise.
Unplug the vent hose from final drive.
Remove the bearing no.6 at the same time as
Loosen rear bolts of the final drive support and tilt the pinion gear no.7. Be careful to keep track of
the support rearward to make room. shims no. 8.
Remove the final drive. The pinion gear and bearing can be easily removed
using the following suggested tool:
Rear Final Drive Inspection
(Assembled) PART QTY
Turn rear final drive gear with a finger; it should Pipe: 89 mm (3-1/2 in) diameter x 127 mm
1
turn smoothly. Replace if necessary. (5 in) in length
Check backlash and drag torque, see REAR FINAL Screwed rod: M12 x 1.25, 178 mm (7 in)
1
DRIVE ADJUSTMENTin this subsection. length
Check if oil seals are brittle, hard or damaged. Re- M12 x 1.25 nut 3
place if necessary. 1
Flat bar
Rear Final Drive Disassembly Remove and discard the needle bearing no.9.
Ring Gear
Rear Final Drive Adjustment
Unscrew the final drive housing screws no.1.
A shimming procedure must be done when pinion
gear, ring gear or housing is (are) changed.
Install recommended shims accordingly with the
following table.
RECOMMENDED SHIMS
1.67 mm ± 0.04 mm
PINION GEAR
(.066 in ± .002 in)
BACKLASH 0.5 mm (.02 in)
PRELOAD (for preliminary adjustment)

NOTE: The procedure above sets the pinion shim

thickness and should not be modified thereafter.
Any changes should be done on preload and/or
backlash side(s).
1. Housing screws

Split final drive housings.

NOTE: Be careful to keep track of shims no. 2 on
ring gear no.3.
Extract ring gear out of half housing.
312 tmr2011-032
 Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

Rotate pinion gear 1/2 turn and check backlash

1. Backlash side again. Note the result.
2. Preload side
Rotate pinion gear 1 turn and check backlash
Temporarily assemble the final drive. See proce- again.
dure in REAR FINAL DRIVE ASSEMBLYbelow in
If backlash is below 0.05 mm (.002 in), increase
this subsection.
backlash shim and check the backlash again.
Backlash If backlash is greater than 0.356 mm (.014 in),
Using a dial indicator and the BACKLASH MEA- decrease backlash shim and check the backlash
SUREMENT TOOL (P/N 529 035 665), measure the again.
backlash. Place the backlash measurement tool Measure preload.
at the end of pinion gear.
Preload
From center of bolt, measure 25.4 mm (1 in) and
scribe a mark on the tab. Screw the propeller shaft adaptor bolt in pinion
gear.

TYPICAL — FRONT DIFFERENTIAL SHOWN

Using a needle torque wrench, measure the drag

1. Tab of backlash measurement tool torque.
2. Mark on tab
A. 25.4mm (1 in)

Position the dial indicator tip against the tab at a

90° angle and right on the previously scribed mark.
Gently, move the tab back and forth. Note the re-
sult.

tmr2011-032 313
Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

Rear Final Drive Installation

The installation is the reverse of the removal pro-
cedure.
PART TORQUE
70 N•m ± 5 N•m
Final drive retaining nuts
(52 lbf•ft ± 4 lbf•ft)

Refill the final drive with recommended oil. Re-

fer to PERIODIC MAINTENANCE PROCEDURES
subsection.
TYPICAL - FRONT DIFFERENTIAL SHOWN

If the drag torque is greater than 0.5 Nom

(5 lbfoin), reduce preload shim and check drag
torque again.
If the drag torque is less than 0.06 Nom (.5 lbfoin),
increase preload shim and check drag torque
again

Rear Final Drive Assembly

Ring Gear
To assemble, reverse the removal procedure. Pay
attention to the following.
Check condition of seal no. 10. Replace if dam-
aged.
Check bearings no. 11. Replace if damaged.
Tighten final drive housing screws no. 1.
PART TORQUE
Final drive housing 32.5 N•m ± 3.5 N•rn
screws (24 lbf•ft ± 3 lbf•ft)

Pinion Gear
To install, reverse the removal procedure. Pay at-
tention to the following.
Replace the 0-ring no. 13.
Install the shim(s) no. 8 then the ball bearing no. 6.
Install a new needle bearing no. 9.
Apply LOCTITE 277 (P/N 293 800 073) to pinion nut
no. 5.
NOTE: If a new pinion nut is used, a self-locking
product is already applied, do not use Loctite 277.
Install and tighten the pinion nut.
PART TORQUE
Pinion nut
180 Nom ± 15 Nom
(LEFT HAND
(133 lbf•ft ± 11 lbf•ft)
THREADED)

Lubricate oil seal no. 4.

314 tmr2011-032
 Section 07 CHASSIS
Subsection 01 (WHEELS AND TIRES)

WHEELS AND TIRES

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 767 (ANTISEIZE LUBRICANT) 293 800 070 316

GENERAL A WARNING
A WARNING — Replace tires only with the same type and
size as original tires.
Torque wrench tightening specifications
— For unidirectional tread pattern, ensure
must be strictly adhered to.
that the tires are installed in the correct
direction of rotation.
PROCEDURES
TIRES
A WARNING
Do not rotate tires. The front and rear tires
have a different size. Respect direction of ro-
tation when applicable.

Tire Pressure
A WARNING
Tire pressure greatly affects vehicle handling
and stability. Insufficient pressure may cause
tire to deflate and rotate on wheel. Excessive TYPICAL
pressure may burst the tire. Always follow 7. Direction of rotation
recommended pressure.
Tire Mounting on Beadlock Wheels

Check pressure when tires are cold before us- X Models

ing the vehicle. Tire pressure changes with tem- NOTE: Tires should be mounted, by an experi-
perature and altitude. Recheck pressure if one of enced person, in accordance to good tire mount-
these conditions has changed. ing practices using acceptable tire mounting
TIRE PRESSURE FRONT REAR equipment designed for the tire industry.
69 kPa 83 kPa 1. Mount the tire on wheel.
MIN.
(10 PSI) (12 PSI) 1.1 On the opposite side of beadlock, apply
MAX. the tire mounting lube on inner bead of tire
(USE WHEN TOTAL 83 kPa 152 kPa and wheel to ensure proper seating when
LOAD IS GREATER (12 PSI) (22 PSI) inflating.
THAN 180 KG (400 LB)) 1.2 Mount the inner bead over the wheel.
NOTICE Mount tire from beadlock side
Tire Inspection
only.
Check tire for presence of slits, bulges, wear or
other damage. Replace if necessary. 1.3 Seat the tire outer bead in the shoulder of
the beadlock inner ring and center the tire.
Tire Replacement
Use an automotive tire changer to replace tires.

tmr2011-033 315
Section 07 CHASSIS
Subsection 01 (WHEELS AND TIRES)

5. First tightening sequence: Using a torque

wrench, tighten beadlock screws at first to
3 N•rn ± 1 N•m (27 lbf•in ± 91bf•in) following
the illustrated sequence.
NOTE: To ensure even pressure on the beadlock
clamp ring, tighten screws a few turns at a time.

vb,2OtWOOi Or

1. Tire outer bead

2. Beadlock inner ring shoulder

2. Place the beadlock clamp ring on the tire. Align

the valve opening with valve.

FIRST AND SECOND TIGHTENING SEQUENCE

6. At this time check if the tire is still centered on

wheel. Reposition it if necessary.
7. Second tightening sequence: Retighten all
screws to 8 N•m ± 1 N•rn (71 lbf•in ± 91bf•in)
using the same sequence.
The beadlock clamp ring should be in contact the
beadlock inner ring.
NOTE: The beadlock clamp ring can flex slightly
1. Clamp ring valve opening
to match the tire bead. IT IS NORMAL.
3. Lubricate all beadlock screws with LOCTITE 767 8. Verify the gap between tire and beadlock clamp
(ANTISEIZE LUBRICANT) (P/N 293 800 070) or an ring, it should be practically equal all around the
equivalent product to prevent screw sticking. ring.
4. Install all beadlock screws. To avoid cross
threading, start all screws by hand.
NOTICE Do not use an impact wrench for
installing beadlock screws. The risk of screw
breaking or screw stripping is high when using
an impact wrench.

A. Gap equal all around beadlock clamp ring

If the gap is uneven:

— Loosen all screws.
— Check tire position on wheel and reposition it if
necessary.
— Restart the tightening sequence from the be-
ginning.

316 tmr2011-033
 Section 07 CHASSIS
Subsection 01 (WHEELS AND TIRES)

9. Final tightening step: 8 N•m ± 1 N•rn

(71 lbf•in ± 9 lbf•iin) following the illustrated
sequence.

TYPICAL
1. Direction of rotation

Install in the right direction of rotation.

FINAL TIGHTENING SEQUENCE Install lug nuts with the taper towards the wheel.
10. Inflate tire to seat the inner bead on wheel. Al-
ways use safe practices, such as a tire safety
cage.

A WARNING
Never exceed tire's recommended maximum
pressure for seating beads.

WHEELS TYPICAL
1. Taper (towards the wheel)
Wheel Removal
Loosen nuts just enough to be able to unscrew Tighten wheel lug nuts to the specified torque us-
them once the vehicle will be off the ground. ing the illustrated sequence.

Lift and support the vehicle. Refer to INTRODUC- WHEEL LUG NUTS
TION subsection.
100 N•m ± 10 N•m
Remove nuts, then remove wheel. TORQUE
(74 lbf•ft ± 7 lbf•ft)

Wheel Inspection
Inspect wheel for wear or damage especially at
the mounting holes.

Wheel Installation
At installation, it is recommended to apply anti-
seize lubricant on threads.
Check if tires are unidirectional.

tmr2011-033 317
 Section 07 CHASSIS
Subsection 01 (WHEELS AND TIRES)

TIGHTENING SEQUENCE

NOTICE Always use the recommended

wheel nuts for the type of wheel. Using a
different nut could cause damages to the rim
or studs.

318
tmr2011-033
 Section 07 CHASSIS
Subsection 02 (STEERING SYSTEM)

STEERING SYSTEM
SERVICE TOOLS Page
Part Number
Description 321
529 036 059
STEERING ALIGNMENT TOOL

SERVICE PRODUCTS Page

Part Number
Description 324
293 550 010
XPS SYNTHETIC GREASE

319
tmr2011-034
 Section 07 CHASSIS
Subsection 02 (STEERING SYSTEM)

X, XT Model

2.5 ± 0.5 N•rn

(22 ± 4 lbf•in)

50 ± 5 (\l•rn
(37 ± 4 lbf•ft)

50 ± 5 NI•rn
(37 ± 4 lbfefty

XPS synthetic
grease

31 ± 3 N-rn
fieV -,! (23 ± 2 lbf•ft)
.. o
m ■ ,-1 ,)

v . \0
0 ff
at,, 48 ± 6 Nl•rn
(35 ± 4 lbf•ft)

34 ± 2 N -m \ See tightening
(25 ± 1 lbf•ft) , sequence
24.5 ± 3.5 Nl-rn
(18 ± 3Ibf-ft)

72 ± 7 Nl•m
(53 ± 5 lbf•ft)

5 ± 1 Nl•rn
(44 ±- 9 lbf-in)

34 ± 2 N1•m
(25 ± 1 lbf•ft)

72 ± 7 1■1-rn
(53 ± 5 lbf-ft)
= Component must be replaced
when removed.
Imr2011 -034-100A

320
tmr2011-034
 Section 07 CHASSIS
Subsection 02 (STEERING SYSTEM)

GENERAL
The procedures described below are the same for
the RH and LH sides, unless otherwise instructed.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATIONat the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications
must strictly be adhered to. A. Steering wheel angle ± 3°
Locking devices when removed (e.g.: locking
tabs, cotter pins, etc.) must be replaced. 5. Reposition steering wheel onto steering shaft
as follows:

NOTICE Hoses, cables and locking ties re- NOTICE Make sure rack and pinion does
moved during a procedure must be reinstalled not move during steering wheel reposi-
as per factory standards. tioning.
5.1 Remove steering wheel, refer to STEER-
ADJUSTMENT ING WHEEL REMOVAL.
5.2 Reinstall steering wheel to the closest
STEERING ALIGNMENT centered position (nearest spline).
1. Place vehicle on a level surface. 6. Center steering wheel.
2. Inflate tires to recommended pressure.
3. Find rack and pinion center to center as follows:
3.1 Calculate the total steering wheel rota-
tions from side to side.
3.2 Position the steering wheel at half the to-
tal rotations.
4. Check steering wheel position:
4.1 If steering angle is within ± 3°, go to
step 6.
4.2 If steering angle is above ± 3°, go to
step 5.

A. Steering wheel centered

7. Remove two wheel lug nuts from a rear wheel.

8. Install STEERING ALIGNMENT TOOL (P/N 529 036
059) using proper spacers.

tmr201 1-034 321

Section 07 CHASSIS
Subsection 02 (STEERING SYSTEM)

9. Move vehicle to place the tool level with the

ground.
TYPICAL

15. Keep rope in this position.

16. Measure distance of the front wheel between
rope and rim as follows:
— At the front of rim
— At the rear of rim.

REAR WHEEL
1. Steering adjustment tool
2. Angle gauge or level

10. Place a rope around vehicle tires

11. Using an elastic, link both ends together.
12. Adjust rope at the center of the wheels.
13. From the front of vehicle, near the front of rim,
TYPICAL — AT THE FRONT OF RIM
move rope so that it does not touch the first
spacer of tool.

TYPICAL — AT THE REAR OF RIM

17. Calculate the difference between the rear and

the front measurement.
18. The difference must be as per the following
TYPICAL specification:

14. Slowly move rope back until it makes contact WHEEL TOE
with spacer. mm ± 4 mm (0 in ± .157 in)

19. If the wheel toe measurement is out of spec-

ification:
19.1 Adjust tie-rod end.

322 tmr2011-034
 Section 07 CHASSIS
Subsection 02 (STEERING SYSTEM)

A WARNING Steering Wheel Installation

The maximum tie-rod end length not The installation is the reverse of the removal pro-
engaged in the tie rod must not exceed cedure. However, pay attention to the following.
32 mm (1.26in). Prior to installing the steering wheel, place front
wheels parallel with longitudinal plane of vehicle.

A. Maximum tie-rod end length

19.2 Tighten tie-rod end locking nut to specifi-

cation.
A. Front wheels parallel
TIE-ROD END LOCKING NUT
TORQUE Tighten steering wheel retaining nut to specifica-
tion.
34 Nom ± 2 Nom (25 lbf•ft ± 1 lbf•ft)
STEERING WHEEL RETAINING NUT TORQUE
20. Repeat procedure for the other wheel. 50 Nom ± 5 Nom (37 lbf•ft ± 4 lbfoft)

TROUBLESHOOTING Check front wheel alignment. Refer to STEERING

ALIGNMENT in this subsection.
DIAGNOSTIC TIPS
STEERING COLUMN
Turning Radius Unequal
If vehicle turns more on one side than the other, Steering Column Removal
check rack and pinion center to center. Refer to 1. Center steering wheel.
STEERING ALIGNMENTin this subsection. 2. Remove bolt and nut securing upper universal
joint to steering shaft.
PROCEDURES
STEERING WHEEL
Steering wheel Removal
All Models Except X and XT
1. From underneath steering wheel, unscrew cap
retaining screws.
2. Remove steering wheel cap.
3. Remove nut securing steering wheel to shaft.
4. Remove steering wheel by pulling it upwards.

X and XT Models
1. Remove steering wheel cap using a small
screwdriver. 3. Remove steering wheel and steering shaft as
2. Remove nut securing steering wheel to shaft. an assembly.
3. Remove steering wheel by pulling it upwards.

tmr2011-034 323
Section 07 CHASSIS
Subsection 02 (STEERING SYSTEM)

7. Remove steering column from vehicle.

4. Remove bolt and nut securing lower universal
joint to rack and pinion. Steering Column Inspection
Check steering column for wear, cracks or bend-
ing.
Check steering shaft for wear, cracks or bending.
Check if universal joints move freely.
Check if steering shaft 0-rings are brittle, hard or
otherwise damaged.
Replace if necessary.

Steering Column Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Prior to installing the steering column, place front
wheels parallel with longitudinal plane of vehicle.
5. Pull steering column upwards to detach it from
rack and pinion.

A. Front wheels parallel

Lubricate steering shaft.

STEERING SHAFT LUBRICATION
XPS SYNTHETIC GREASE (P/N 293 550 010)

6. Carefully push steering column downwards to Install steering wheel and steering shaft. Make
release it from steering support. sure steering wheel is properly centered.
Tighten steering column U-joints to specification.
UPPER U-JOINT NUT TORQUE
31 N•m ± 3 N•rn (23 lbf•ft ± 2 lbf•ft)

324 tmr201 1-034

 Section 07 CHASSIS
Subsection 02 (STEERING SYSTEM)

LOWER U-JOINT NUT TORQUE

48 Nom ± 6 Nom (35 lbf•ft ± 4 lbf•ft)

Check front wheels alignment. Refer to STEER-

ING ALIGNMENTin this subsection.

RACK AND PINION

MARKS
Rack and Pinion Servicing
Rack and pinion is not serviceable except for Install all retaining bolts and nuts of rack and pinion
boots and tie rods replacements. loosely first.
Torque retaining nuts of rack and pinion according
Rack and Pinion Removal to specification using the following tightening se-
1. Safely lift and support the front of vehicle. Re- quence.
fer to INTRODUCTION subsection.
RACK AND PINION RETAINING NUTS TORQUE
2. Remove both front wheels.
24.5 Nom ± 3.5 Nom (18 lbf•ft ± 3 lbf•ft)
3. Remove steering column, refer to STEERING
COLUMN REMOVAL in this subsection.
4. Detach tie-rods from knuckles. Refer to TIE
ROD REPLACEMENT in this subsection.
5. Remove bolts and nuts securing rack and pinion
to frame.

TIGHTENING SEQUENCE

Check the steering alignment, refer to STEERING

ALIGNMENTin this subsection.

TIE-ROD ENDS
SOME PARTS REMOVED FOR CLARITY PURPOSE Tie-Rod End Replacement
1. Safely lift and support the front of vehicle. Re-
6. From the LH side, remove rack and pinion from
fer to INTRODUCTION subsection.
vehicle.
2. Remove front wheel.
Rack and Pinion Installation 3. Detach tie-rod end by removing:
The installation is the reverse of the removal pro- — Cotter pin
cedure. However, pay attention to the following. — Tie-rod end retaining nut
Find rack and pinion center to center as follows: — Hardened washers.
— Calculate the total pinion shaft rotations from
side to side.
— Position the pinion shaft at half the total rota-
tions.
— Align pinion shaft mark onto housing mark.

trnr201 1-034 325

Section 07 CHASSIS
Subsection 02 (STEERING SYSTEM)

11. Install front wheel.

12. Check the steering alignment, refer to STEER-
ING ALIGNMENTin this subsection.

KNUCKLES
Knuckle Removal
1. Safely lift and support the front of vehicle. Re-
fer to INTRODUCTIONsubsection.
2. Remove front wheel.
3. Detach tie-rod end from knuckle, refer to TIE-
ROD END in this subsection.
4. Remove wheel hub, refer to FRONT DRIVE
subsection.
1. Cotter pin
2. Tie-rod end retaining nut 5. Remove caliper, refer to BRAKES subsection.
3. Hardened washers

4. Discard cotter pin.

5. Replace tie-rod end.
6. Adjust tie-rod end to the nominal length.
TIE-ROD END NOMINAL LENGTH
27 mm (1.063 in)

Nionmanumsziasii10 im404aA0414e.140

tn,r2011 034-107 a

A. Nominal length
6. Detach upper suspension arm from knuckle, re-
fer to FRONT SUSPENSION.
A WARNING 7. Detach lower suspension arm from knuckle, re-
The maximum tie-rod end length not en- fer to FRONT SUSPENSION.
gaged in the tie rod must not exceed 32 mm 8. Remove knuckle from vehicle.
(1.26 in).
Knuckle Inspection
7. Tighten tie rod end locking nut to specification.
-
Check knuckle for cracks or other damages.
TIE-ROD END LOCKING NUT TORQUE Replace if necessary.
34 N•rn ± 2 N•m (25 lbf•ft ± 1 lbf•ft)
Knuckle Installation
8. Attach tie-rod end on knuckle as the reverse of The installation is the reverse of the removal pro-
removal. cedure.
9. Tighten tie-rod end retaining nut to specifica-
tion. WHEEL BEARINGS
TIE-ROD END RETAINING NUT TORQUE Wheel Bearing Inspection
72 N•m ± 7 N•m (53 lbf•ft ± 5 lbf•ft) (Maintenance)
Refer to PERIODIC MAINTENANCE PROCE-
10. Install NEW cotter pin. Both ends of cotter DURES subsection.
pins must be folded.

326 Imr2011-034
 Section 07 CHASSIS
Subsection 02 (STEERING SYSTEM)

Wheel Bearing Inspection (During Wheel Bearing Installation

Component Removal) The installation is the reverse of the removal pro-
Whenever the drive axle or knuckle is removed, cedure. However, pay attention to the following.
check wheel bearing as follows: To ease wheel bearing installation:
— Check if wheel bearing turns freely and — Place bearing in a freezer for 10 minutes.
smoothly. — Place knuckle in oven to 100°C (212°F) for
— Check seal condition. 30 minutes maximum.
Replace if necessary. When knuckle is cooled down, install NEW circlip
and NEW seal.
Wheel Bearing Removal
1. Remove knuckle from vehicle, refer to
KNUCKLE REMOVAL in this subsection.
2. Remove and discard knuckle seal.
3. Remove circlip.

1. Seal
2. Circlip

4. Install knuckle on a press.

5. Use an appropriate bearing remover.
6. Remove bearing from knuckle.

NOTE: It may be necessary to heat the knuckle to

remove bearing.

A WARNING
Clean all grease, outside and inside, from
knuckle before heating it.

tmr201 1-034 327

 Section 07 CHASSIS
Subsection 03 (FRONT SUSPENSION)

FRONT SUSPENSION
48 ± 6 Nem
(35 ± 4 lbf•ft)

Suspension
____6 grease

Suspension
grease
48 ± 6 Nem
(35 ± 4 lbf•ft)

matu—cLI,
Suspension
grease

48 -± 6 Nem
(35 ± 4 lbf•ft)
-ME
X model

(!D

Cl
/ All except X
I model I X model

1
1
Suspension
1
grease

d.
I233 = Component must be replaced when remove
tn,2011 075.100_a

329
tmr2011-035
Section 07 CHASSIS
Subsection 03 (FRONT SUSPENSION)

GENERAL
The procedure explained below is the same for
the RH and LH sides unless otherwise noted.
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications
7. Lower bolt
must strictly be adhered to.
Locking devices when removed (e.g.: locking 3. Remove shock absorber.
tabs, cotter pins, etc.) must be replaced.
Shock Absorber Inspection
NOTICE Hoses, cables and locking ties re- Remove spring from shock absorber. Refer to
moved during a procedure must be reinstalled SPRINGS in this subsection.
as per factory standards. Secure the end of shock body in a vise with its rod
upward.
PROCEDURES
SHOCK ABSORBER
Shock Absorber Removal
1. Safely lift and support the vehicle of the ground.
3 -0
Refer to INTRODUCTION subsection. Al4F013A

2. Remove bolts and nuts retaining shock ab- TYPICAL

sorber. 1. Clamp here

NOTICE Do not clamp directly on shock

body.
Extend and compress the piston several times
over its entire stroke. Check that it moves
smoothly and with uniform resistance with its
rod upward.
Check the following conditions that will denote a
defective shock:
— A skip or a hang back when reversing stroke at
mid travel.
— Seizing or binding condition except at extreme
end of either stroke.
— Oil leakage.
1. Upper bolt — A gurgling noise, after completing one full com-
pression and extension stroke.
Replace if any faults are present.

Shock Absorber Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.

330 tmr2011-035
 Section 07 CHASSIS
Subsection 03 (FRONT SUSPENSION)

Make sure to install the proper type of shock ab-

sorber no. A on the front of vehicle

1. Ball joint nut

4. Remove bolts and nuts securing suspension

arm to frame.

A. Front shock absorber /without shock body extension)

B. Rear shock absorber (with shock body extension)

SHOCK ABSORBER NUTS TORQUE

48 N•m ± 6 N•m (35 lbf•ft ± 4 lbf•ft)

SHOCK ABSORBER BUSHINGS

Refer to SHOCK ABSORBER BUSHINGS in
REAR SUSPENSION subsection for complete
procedures.

SPRINGS
1. Suspension arm nuts
Refer to SPRINGS in REAR SUSPENSIONsubsec-
tion for complete procedures. 5. Remove suspension arm.

LOWER SUSPENSION ARM

Lower Suspension Arm Removal
1. Safely lift and support the vehicle off the
ground. Refer to INTRODUCTION subsection.
2. Remove wheel, refer to WHEELS AND TIRES
subsection.
NOTE: For X model, disconnect anti-sway bar
from suspension arm.
3. Remove bolt and nut securing lower ball joint to
knuckle.

MOVE DOWNWARDS

Lower Suspension Arm Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Lubricate suspension arm. Refer to PERIODIC
MAINTENANCE PROCEDURES subsection.

tmr2011-035 331
Section 07 CHASSIS
Subsection 03 (FRONT SUSPENSION)

UPPER SUSPENSION ARM

Upper Suspension Arm Removal
1. Safely lift and support the vehicle off the
ground. Refer to INTRODUCTION subsection.
2. Remove wheel, refer to WHEELS AND TIRES
subsection.
3. Remove fasteners retaining brake hose to vehi-
cle.

1. Ball joint nut

2. Ball joint hardened washer

6. Carefully move brake hose aside.

7. Using a plastic hammer, carefully hit on the
knuckle side to separate ball joint from knuckle.
NOTE: A ball joint remover can be used if the ball
joint is jammed into knuckle.
NOTICE Never hit on suspension arm to
avoid to damage it permanently.
BRAKE HOSE FASTENERS (4X)

4. Remove and discard cotter pin retaining ball

joint.

CAREFULLY HIT ON KNUCKLE SIDE

8. Remove bolt and nut securing suspension arm

1. Ball joint cotter pin to shock absorber.
5. Remove ball joint nut and washer.

332 tmr2011-035
 Section 07 CHASSIS
Subsection 03 (FRONT SUSPENSION)

SUSPENSION ARM BUSHINGS

Suspension Arm Bushings Removal
1. Remove wear plates, cushions and inner bush-
ing from suspension arm.

1. Shock absorber nut

9. Remove radiator from vehicle. Refer to RADIA-

TOR in COOLING SYSTEM subsection.
10. Remove fasteners securing suspension arm
to frame.

LOWER SUSPENSION ARM

1. Wear plate
2. Cushion
3. Inner bushing

1. Suspension arm pivot nut

2. Suspension arm pivot bolt
3. Suspension arm pivot washers

11. Remove suspension arm.

UPPER SUSPENSION ARM
Upper Suspension Arm Installation 1. Wear plate
2. Cushion
The installation is the reverse of the removal pro- 3. Inner bushing
cedure. However, pay attention to the following.
Refer to COOLING SYSTEMsubsection for radia- Suspension Arm Bushings Installation
tor installation. The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
NOTICE Properly bleed cooling system. Re-
fer to COOLING SYSTEM subsection. Lubricate suspension arm. Refer to PERIODIC
MAINTENANCE PROCEDURES subsection.
Lubricate suspension arm. Refer to PERIODIC
MAINTENANCE PROCEDURES subsection. BALL JOINTS
Install a NEW cotter pin to secure ball joint nut.
Both end of cotter pin must be folded.
Ball Joint Removal
1. Remove suspension arm from vehicle. Refer to
SHOCK ABSORBER NUTS TORQUE SUSPENSION ARM REMOVAL in this subsec-
48 NI•rn ± 6 Nom (35 lbf•ft ± 4 lbf•ft) tion.
2. Remove circlip from ball joint.

tmr2011-035 333
Section 07 CHASSIS
Subsection 03 (FRONT SUSPENSION)

5. Remove ball joint from suspension arm.

NOTICE Make sure that suspension arm is
properly supported on the press during ball
joint removal.

Ball Joint Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install a NEW circlip to secure ball joint.

LOWER BALL JOINT

1. Circlip

UPPER BALL JOINT

1. Circlip

3. Install suspension arm on a press.

4. Use an appropriate ball joint remover.

334 tmr2011-035
 Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

REAR SUSPENSION
SERVICE TOOLS
Description Part Number Page
SPRING COMPRESSOR 529 036 184 337

rAll except X Model !

!
48 ± 6 Nom 1
(35 ± 4 lbf•ft)

.1 ,, f
■=4

,
f...N.._.
110 ± 10 Nom 1 !

,.ttejh
■j (81 ± 7 lbf•ft) 1
Alt
AID
41110
to
i
i
I . . „w.3."-".3-1."-.1" iI. !

48 ± 6 Nom
(35 ± 4 lbf•ft)

48 ± 6 Nom
51 ± 3 N•m (35 ± 4 lbf•ft)
(38 ± 2 lbf•ft)
See tightening sequence

48± 6 Nom
(35 ± 4Ibf•ft ) ---4 I
re
tit
110 ± 10 N•m
(81 ± 7 Ib•t)

Suspension
grease

PEI = Component must be replaced when removed.

0:36-100a

tmr2011-036
335
Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

GENERAL
The procedure described below is the same for
the RH and LH sides, unless otherwise instructed.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICAT/ONat the beginning of this manual for
complete procedure.

A WARNING 1. Lower bolt

Torque wrench tightening specifications

4. Remove shock absorber.
must strictly be adhered to.
Locking devices must be replaced when re-
Shock Absorber Inspection
moved (e.g.: locking tabs, cotter pins, etc.).
Remove spring from shock absorber. Refer to
SPRINGS in this subsection.
NOTICE Hoses, cables and locking ties re- Secure the end of shock body in a vise with its rod
moved during a procedure must be reinstalled upward.
as per factory standards.

PROCEDURES
SHOCK ABSORBERS
Shock Absorber Removal
A14FOBA
1. Safely lift and support the vehicle off the
ground. Refer to INTRODUCTION subsection. TYPICAL
1 Clamp here
2. Open cargo box.
NOTICE Do not clamp directly on shock
3. Remove bolts and nuts retaining shock ab-
body.
sorber.
Extend and compress the piston several times
over its entire stroke. Check that it moves
smoothly and with uniform resistance with its
rod upward.
Check the following conditions that will denote a
defective shock:
— A skip or a hang back when reversing stroke at
mid travel.
— Seizing or binding condition except at extreme
end of either stroke.
— Oil leakage.
— A gurgling noise, after completing one full com-
pression and extension stroke.
1. Upper bolt
Replace if any faults are present.

Shock Absorber Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.

336 imr2011-036
 Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

Make sure to install the proper type of shock ab-

sorber no. B on the rear of vehicle.

TYPICAL

5. Install a NEW bushing as the reverse of re-

moval.
6. Install shock absorber on vehicle.
A. Front shock absorber (without shock body extension)
B. Rear shock absorber (with shock body extension) SPRINGS
SHOCK ABSORBER NUTS TORQUE Spring Removal
48 N•m ± 6 N•m (35 lbf•ft ± 4 lbf•ft) 1. Remove shock absorber from vehicle. Refer to
SHOCK ABSORBERS in this subsection.
SHOCK ABSORBER BUSHINGS 2. Use SPRING COMPRESSOR (P/N 529 036 184).

Shock Absorber Bushing Replacement

All Shock Absorbers Except HPG with
Remote Reservoir
1. Remove shock absorber from vehicle. Refer to
SHOCK ABSORBERS in this subsection.
2. Install shock absorber on a press.
3. Use an appropriate socket to push bushing. 3. Place the tool in a vise.
4. Position the shock absorber in the tool.
5. Install the spring compressor pins.
6. Tighten spring remover screw until the spring is
sufficiently compressed to remove spring cap.
7. Remove spring cap from shock absorber.
8. Release spring remover screw.
9. Remove spring from shock absorber.

Spring Inspection
Inspect the spring for damage.
Replace if necessary.

Spring Installation
TYPICAL
The installation is the reverse of the removal pro-
4. Remove bushing from shock absorber. cedure. However, pay attention to the following.
Install spring cap opening at 180° from spring
stopper opening.

tmr2011-036 337
Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

ANTI-SWAY BAR TIGHTENING SEQUENCE

ANTI-SWAY BAR SCREWS TORQUE

CAP OPENING AT 180° 51 N•m ± 3 N•m (38 lbf•ft ± 2 lbf•ft)

ANTI-SWAY BAR TRAILING ARM

Anti-Sway Bar Removal
Trailing Arm Removal
1. Safely lift and support the vehicle off the
ground. Refer to INTRODUCTION subsection. 1. Safely lift and support the vehicle off the
ground. Refer to INTRODUCTION subsection.
2. Open cargo box.
2. Remove wheel, refer to WHEELS AND TIRES
3. Remove anti-sway bar retaining screws (4 on subsection.
each side).
3. Open cargo box.
4. Remove anti-sway bar, refer to ANTI-SWAY
BAR REMOVAL in this subsection.
5. Remove wheel hub, refer to REAR DRIVEsub-
section.
6. Remove protective plate from trailing arm.

1. Anti-sway bar retaining screw

4. Remove anti-sway bar.

Anti-Sway Bar Inspection

Check anti-sway bar for cracks, bending or other
damages. 1. Protective plate

Replace if necessary.
NOTE: If applicable, remove fasteners retaining
Anti-Sway Bar Installation brake hose to vehicle.
The installation is the reverse of the removal pro- 7. Remove nut and washer securing trailing arm
cedure. However, pay attention to the following. pivot.
Install all retaining screws of anti-sway bar loosely
first.
Torque retaining screws of anti-sway bar accord-
ing to the following sequence.

338 tmr2011-036
 Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

Trailing Arm Disassembly

Drive Shaft Bearing Removal
1. Remove circlip securing bearing into trailing
arm.

1. Pivot nut
2. Pivot washer

8. Remove lower nut retaining shock absorber.

1. Circlip

2. Install trailing arm on a press.

3. Use an appropriate bearing remover.
4. Remove drive shaft bearing from trailing arm.
Trailing Arm Pivot Bearing Removal
1. Remove both spacers and seals from trailing
arm pivot.

1. Lower nut

9. Firmly hold trailing arm then remove:

— Shock absorber lower bolt
— Trailing arm pivot bolt and washer.

1. Spacer
2. Seal

2. Install trailing arm on a press.

3. Use an appropriate bearing remover.
4. Remove pivot bearings and bushing from trail-
1. Shock absorber lower bolt ing arm.
2. Trailing arm pivot bolt

10. Remove trailing arm from vehicle.

tmr201 1-036
339
Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

1. Pivot bearings
2. Pivot bushing

Trailing Arm Inspection

Check trailing arms for:
— Cracks
— Bending.
Check seals condition.
Check inner race of each pivot bearing with your
finger:
— Bearings should turn smoothly and quietly.
Replace all damaged parts.

Trailing Arm Assembly and Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install the following NEW parts:
— Pivot bearings
— Seals
— Circlip.
TRAILING ARM PIVOT NUT TORQUE
110 Nom ± 10 N•rn (81 lbf•ft ± 7 IlDf•ft)

340 tmr2011-036
 Section 07 CHASSIS
Subsection 05 (BRAKES)

BRAKES
SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL 529 036 166 344

SERVICE PRODUCTS
Description Part Number Page
COSMO RUBBER GREASE 293 550 055 346
LOCTITE 243 (BLUE) 293 800 060 347
XPS PARTS AND BRAKES CLEANER 219 701 705 347

tmr2011-037 341
 Section 07 CHASSIS
Subsection 05 (BRAKES)

6G1 Brake Caliper Synthetic Grease

4 G2 Cosmo Rubber Grease
6 G3 XPS Synthetic Grease

T1 5.0 ± 11\l-rn (44 ± 9 Ib•n)

T2 5.5 ± 1.5 Nl•rn (49 ± 13 lbf•in)
T3 15 ± 5 Nl•rn (133 ± 44 lbf•in)
T4 19 -± 3 NJ-m (168 -± 27 IbMn)
T5 25 ± 5 NI-m (18 ± 4 lbf•ft)
T6 28.5 ± 1.5 NJ•m (21 ± 1 lbf•ft)
T7 48 ± 6 N•rn (35 ± 4 lbf•ft)

Loctite 243

= Component must be replaced when removed.

tmr2011-037-100_a

342 tmr2011-037
 Section 07 CHASSIS
Subsection 05 (BRAKES)

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded
view(s).
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPL/CAT/ONat the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices must be replaced when re-
moved (e.g.: locking tabs, cotter pins, etc.).
TYPICAL

A WARNING 2. Position force gauge on brake pedal at

Always check brake system operation after 64 mm ± 5 mm (2.5 in ± .2 in) from lower edge.
removing or servicing a brake component. If 3. Position a ruler perpendicularly to brake pedal.
brake pedal feels spongy, make sure all com-
ponents are properly installed and system is
properly bled.

NOTICE Avoid spilling brake fluid on plastic,

rubber or painted parts. Protect these parts
with a rag when servicing brake system.
NOTICE Sealing washers must be discarded
and replaced with new ones every time a Banjo
fitting is unscrewed.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
NOTE: Always clean the area around a brake com-
ponent before servicing.

INSPECTION
BRAKE SYSTEM PRESSURE
VALIDATION A. 64 mm ± 5 mm (2.5 in ± .2 in)

NOTICE Do not pump up the brake pedal re- 4. Push brake pedal from 70 mm (2-3/4 in) using
peatedly before doing the validation. force gauge.

1. Use an appropriate compression force gauge

such as MARK-10 EG-200 and a ruler.

trnr2011-037 343
Section 07 CHASSIS
Subsection 05 (BRAKES)

Brake Light Switch Resistance Test

1. Disconnect brake light switch connector.
2. Check switch operation as follows.
BRAKE LIGHT
PIN RESISTANCE
SWITCH POSITION
Firmly pushed Close to 0 52
1 2
Released Infinite (01_)

If switch is defective, replace with a new one.

If the switch tests good, verify wire continuity be-
tween harness connector and ECM-B connector.
NOTE: Use the ECM ADAPTER TOOL (P/N 529 036
166).
TYPICAL

5. Read the load recorded by the force gauge.

6. Load reading must be as per the following table.
BRAKE PEDAL LOAD AT 70 MM
Minimum 250N (561bf)

7. If load reading is not in accordance with the

specification:
7.1 Perform a brake system inspection and
cleaning.
7.2 Bleed brake system.
ECM-B HARNESS
NOTE: Refer to PERIODIC MAINTENANCE CONNECTOR CONNECTOR RESISTANCE
PROCEDURES subsection. PIN WIRES
C-3 RED/ORANGE Close to 0 S2
PROCEDURES
NOTE: If only the LH taillight does not work,
BRAKE LIGHT SWITCH check brake relay (R8) in fuse box 1.
Brake Light Switch Location Brake Light Switch Replacement
Brake light switch is located underneath LH front 1. Disconnect brake light switch connector.
fender on master cylinder.
2. Drain rear brake line.
3. Remove brake light switch from master cylin-
der.
NOTE: Use shop rags to catch any spilled brake
fluid.
4. Install NEW sealing washers.
5. Install brake light switch on master cylinder.
BRAKE LIGHT SWITCH NUT TORQUE
19 N•m ± 3 N•rn (168 lbf•in ± 271bf•in)

6. Connect brake light switch connector.

7. Refill and bleed brake system, refer to PERI-
ODIC MAINTENANCE PROCEDURES subsec-
1. Brake light switch tion.

344 tmr2011-037
 Section 07 CHASSIS
Subsection 05 (BRAKES)

MASTER CYLINDER
Master Cylinder Removal
1. Drain brake system, refer to PERIODIC MAIN-
TENANCE PROCEDURES subsection.
2. Remove master cylinder protective cover.

SOME PARTS REMOVED FOR CLARITY PURPOSE

1. Front brake hoses
2. Sealing washers

5. Remove protective rubber from underneath

dashboard.

1. Master cylinder protective cover

3. Remove brake light switch retaining rear brake

hose.

UNDERNEATH DASHBOARD
1. Protective rubber

6. Disconnect master cylinder rod from brake

pedal.
SOME PARTS REMOVED FOR CLARITY PURPOSE
1. Brake light switch
2. Rear brake hose
3. Sealing washers

4. Unscrew front brake hoses from master cylin-

der.

1. Master cylinder rod

tmr2011-037 345
Section 07 CHASSIS
Subsection 05 (BRAKES)

7. Remove master cylinder rod from master cylin- BRAKE LIGHT SWITCH NUT TORQUE
der.
19 N•m ± 3 N•m (168 lbfein ± 27 lbf•in)

Lubricate push rod end and inside master cylinder

boot.
PUSH ROD END LUBRICATION
COSMO RUBBER GREASE (P/N 293 550 055)

MASTER CYLINDER BOOT LUBRICATION

COSMO RUBBER GREASE (P/N 293 550 055)

Install NEW sealing washers.

Refill and bleed brake system, refer to PERIODIC
MAINTENANCE PROCEDURES subsection.
Adjust master cylinder rod, refer to MASTER
MASTER CYLINDER ROD REMOVED CYLINDER ROD ADJUSTMENT in this subsec-
tion.
3. Remove master cylinder retaining bolts and
nuts. Master Cylinder Rod Adjustment
1. Loosen locking nut of master cylinder rod.
2. Move brake pedal up and down to check if there
is a free play.

1. Master cylinder retaining bolts

4. Remove master cylinder from vehicle.

Master Cylinder Inspection

Check boot for crack.
5. Rotate master cylinder rod to generate a free
Check rod for wear and scratch. play according to specification.
Check master cylinder housing for leak or dam- BRAKE PEDAL FREE PLAY
age.
3.5mm ± 1.5mm (1/8in ± 1/16in)
Master Cylinder Installation
6. Tighten locking nut of master cylinder rod to
The installation is the reverse of the removal pro-
specification.
cedure. However, pay attention to the following.
Tighten brake light switch and front brake hoses ROD LOCKING NUT TORQUE
to specification. 5 N•m ± 1 N•m (44 lbfein ± 9 lbfein)
FRONT BRAKE HOSES SCREW TORQUE
28.5 N•m ± 1.5 N•m (21 lbf•ft ± 1 lbf•ft)

346 tmr2011-037
 Section 07 CHASSIS
Subsection 05 (BRAKES)

CALIPER Caliper Installation

Caliper Removal The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
1. Safely lift and support the vehicle. Refer to IN-
TRODUCTION subsection. If caliper was removed for replacement:
— Refill and bleed brake system, refer to PERI-
2. Remove wheel, refer to WHEELS AND TIRES ODIC MAINTENANCE PROCEDURES subsec-
subsection. tion.
3. If caliper is removed from vehicle for replace- — Install NEW sealing washers.
ment:
Apply threadlocker on caliper retaining screws.
3.1 Drain brake system, refer to PERIODIC
MAINTENANCE PROCEDURES subsec- CALIPER RETAINING SCREWS THREADLOCKER
tion. LOCTITE 243 (BLUE) (P/N 293 800 060)
3.2 Unscrew brake hose from caliper.
Tighten caliper retaining screws to specification.
CALIPER RETAINING SCREWS TORQUE
48 Nom ± 6 Nom (35 lbf•ft ± 4 lb -l•ft)

BRAKE PADS
Brake Pads Replacement
1. Remove caliper from knuckle, refer to CALIPER
REMOVAL in this subsection.
2. Remove brake pad pins from caliper.

TYPICAL - FRONT CALIPER SHOWN

1. Brake hose
2. Sealing washers

4. Remove fasteners retaining brake hose to

knuckle.
5. Remove screws securing caliper support to
knuckle.

1. Brake pad pins

3. Remove brake pads.

4. Clean pistons end using XPS PARTS AND
BRAKES CLEANER (P/N 219 701 705).
5. Push caliper pistons inward.
NOTE: To avoid damaging pistons, use an old pad
to push it into the caliper using a C-clamp.
TYPICAL - FRONT CALIPER SHOWN 6. Ensure brake pad spring is properly positioned
1. Caliper screws
onto caliper.
6. Place caliper assembly onto a support.
NOTICE Do not let caliper hangs by the hose
and do not stretch or twist hose.
tmr2011-037 347
Section 07 CHASSIS
Subsection 05 (BRAKES)

1. Brake pad spring

7. Install NEW brake pads.

8. Clean then lubricate brake pad pins using 4. Replace brake disc.
an appropriate BRAKE CALIPER SYNTHETIC
5. Install wheel studs using a press.
GREASE
6. Align wheel stud knurling into hub grooves.
9. Install brake pad pins on caliper.
NOTE: If wheel studs are damaged, replace
10. Install caliper on knuckle, refer to CAL/PER IN-
them.
STALLATION in this subsection.
7. Install wheel hub then caliper.
BRAKE DISC 8. Install NEW cotter pin to secure wheel hub nut.

Brake Disc Inspection

1. Check disc surfaces for scratches or grooves on
both sides.
2. Measure thickness of the disc.
DISC MINIMUM THICKNESS
FRONT 4.1 mm (.161 in)
REAR 4.1 mm (.161 in)

NOTICE Brake discs must never be ma-

chined.

3. Check warpage of the disc.

MAXIMUM DISC WARPAGE
FRONT
0.2 mm (.01 in)
REAR

Brake Disc Replacement

1. Remove caliper from knuckle, refer to CAL/PER
REMOVAL in this subsection.
2. Remove wheel hub, refer to FRONT DRIVE or
REAR DRIVE subsection.
3. Remove wheel studs using a press.

348 tmr2011-037
 Section 07 CHASSIS
Subsection 06 (BODY)

BODY
SERVICE TOOLS
Description Part Number Page

OETIKER PLIERS 295 000 070 359

BODY (Parts Nomenclature)

1. Driver seat
2. CVT air inlet cover
3. LH front fender
4. LH headlight trim
5. Hood
6. Front fascia
7. Service cover
8. RH headlight trim
9. RH front fender
10. Front lateral panel
11. Central lateral panel
12. Rear lateral panel
13. Cargo box
14. Passenger seat

tmr2011-038 349
Section 07 CHASSIS
Subsection 06 (BODY)

COCKPIT - PASSENGER SIDE (Parts Nomenclature)

1. Lower console
2. Upper console
3. RH inner kick panel
4. Glove box
5. Right front bulkhead
6. Right floor panel
7. Right lateral console panel
8. Fuel tank cowl
9. Right rear bulkhead

tmr2011-038
350
 Section 07 CHASSIS
Subsection 06 (BODY)

COCKPIT - DRIVER SIDE (Parts Nomenclature)

1. Lower console
2. Upper console
3. LH inner kick panel
4. Bulkhead access panel
5. Left front bulkhead
6. Dash
7. Left floor panel
8. Left lateral console panel
9. Under seat storage compartment
10. Left rear bulkhead

tmr2011-038 351
 Section 07 CHASSIS
Subsection 06 (BODY)

FRONT BODY PARTS (Torques and Service Products)

•
• •
.1 •

1.6 ± 0.4 N•m

(14 ± 4 lbf•in)
5 ± 1 N•m (L?
(44 ± 9 Ibf•in)

1.6 ± 0.4 N•rn

(14 ± 4 lbf•in)
2.5 ± 0.5 N•rn
2 ± 0.5 N•rn / (22 ± 4 lbf•in)
(18 ± 4 lbf•in)

1.6 ± 0 4 N•m
(14 ± 4 lbf•in)

4.5 ± 0.5 N•rn 2.5 -± 0.5 N•rn

(40 ± 4 lbf•in) (22 ± 4 lbf•in)

41/
itk 2 ± 0.5 N•m
(18 ± 4 lbf•in)

1.6 ± 0.4 N•rn

4.5 ± 0.5 N•m (14 ± 4 lbf•in)
(40 ± 4 lbf•in)

trnr2011-038-004_a

352 tmr2011-038
 Section 07 CHASSIS
Subsection 06 (BODY)

SIDE BODY PARTS (Torques and Service Products)

T1 2 ± 0.5 N•m (18 ± 4 lbf•in)

T2 2.5 ± 0.5 N•m (22 ± 4 Ib•n)
T3 3.5 ± 0.5 N•m (31 ± 4 lbf•in)
T4 6.5 ± 0.5 N•m (58 ± 4 lbf•in)

tmr2011 , 038 005ra

tmr2011-038 353
 Section 07 CHASSIS
Subsection 06 (BODY)

COCKPIT TRIMS - DRIVER SIDE (Torques and Service Products)

2 -± 0.5 N•m
(18 ± 4 lbf•in)

2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
2 ± 0.5 N•m
(18 ± 4 lbf•in)

4.5 ± 0.5 N•rn

(40 ± 4 lbf•in) II

C41-i\-1

CE Model

tmr2011 038-006_a

354 tmr2011-038
 Section 07 CHASSIS
Subsection 06 (BODY)

COCKPIT TRIMS - PASSENGER SIDE (Torques and Service Products)

2.5 ± 0.5 f\I•m

(22 ± 4 lbf•in)

2 ± 0.5 N•rri
(18 ± 4 lbf•in)

2 ± 0.5 NI•rn
(18 ± 4 Ib•n)

2.5 ± 0.5 Ni•m

(22 ± 4 lbf•in)

tmr2011-038-016_a

tmr2011-038 355
 Section 07 CHASSIS
Subsection 06 (BODY)

COCKPIT STRUCTURE PANELS - PASSENGER SIDE (Torques and Service Products)

2.5 ± 0.5 N•m 2.5 ± 0.5 N•m

(22 ± 4 lbf•in) (22 ±- 4 lbf•in)

2 -±- 0.5 N•m

(18 ± 4 lbf•in)

4.5 ± 0.5 N•m

(40 ± 4 lbf•in)

2 ± 0.5 N•m
(18 ± 4 lbf•in)

5.5 ± 0.5 N•m

(49 ± 4 lbf•in)

2 ± 0.5 N•m
(18 ± 4 lbf•In)

2.5 ± 0.5 N•m

(22 ± 4 lbf•in)

tr.2011 038 007_e

356
tmr2011-038
 Section 07 CHASSIS
Subsection 06 (BODY)

COCKPIT STRUCTURE PANELS - DRIVER SIDE (Torques and Service Products)

2.5 ± 0.5 N•rrl

2.5 ± 0.5 N•rn
(22 ± 4 lbf•in)
(22 ± 4 lb•n)

5.5 ± 0.5 N•rn

(49 ± 4 lbf•in)
2 ± 0.5 N•rn
(18 ± 4 lbf•n)

2 ± 0.5 NI-m --oy-

(18 ± 411g•in)

5.5 ± 0.5 N•rri

(49 -±- 4 lbf•in)

2.5 ± 0.5 N•rn

(22 ± 4 lbf•in)

-43

2 ± 0.5 N•m
(18 ± 4 lbf•in)

2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
trnr2011-038 01 -/a

tmr2011-038 357
 Section 07 CHASSIS
Subsection 06 (BODY)

SEATS

358 tmr2011-038
 Section 07 CHASSIS
Subsection 06 (BODY)

GENERAL Pull decal slowly and when necessary apply more

heat to ease removal on the area that has to be
During assembly/installation, use the torque val- peeled off.
ues and service products as in the exploded
If decal tears while pulling off, it has to be heated
views.
for a few seconds longer. If decal tends to stretch
Clean threads before applying a threadlocker. Re- while pulling off, stop heating and wait a few sec-
fer to SELF-LOCKING FASTENERS and LOCTITE onds to let it cool, then peel it off.
APPL/CAT/ONat the beginning of this manual for
complete procedure. Decal Installation
A WARNING Using isopropyl alcohol, clean the surface and dry
thoroughly.
Torque wrench tightening specifications
must strictly be adhered to. Apply liquid soap to new decal and carefully posi-
Locking devices when removed (e.g.: locking tion it. Using a sponge or a squeegee, remove the
air bubbles and surplus water working from the
tabs, elastic stop nuts, cotter pins, etc.) must
center toward the edges. Allow to air dry.
be replaced.
NOTICE Do not apply isopropyl alcohol or
Hoses, cables or locking ties removed during a solvent directly on decals. Use these products
procedure must be reinstalled as per factory stan- in a well ventilated area.
dards.
UPPER CONSOLE
PROCEDURES
Upper Console Removal and
PLASTIC RIVET Installation
1. Remove:
Plastic rivets are used in the riveting of the vari-
— Screws
ous body parts. Plastic rivets can be reused many
times. Use the OETIKER PLIERS (P/N 295 000 070) — Plastic rivets.
to remove them.

1. Top screws
2. Plastic rivets

2. Pull out the upper console and disconnect elec-

trical connectors.
3. Remove the upper console.
TYPICAL The installation is the reverse of the removal pro-
1. Pliers
2. Plastic rivet cedure.

DECALS LOWER CONSOLE

Decal Removal Lower Console Removal and
Using a heat gun warm up one end of decal for a Installation
few seconds until decal can roll off when rubbing 1. Remove both seats.
with your finger.
359
tmr2011-038
Section 07 CHASSIS
Subsection 06 (BODY)

2. Remove screws and plastic rivets securing the LATERAL CONSOLE PANELS
upper console and place it on the hood.
Lateral Console Panels Removal and
3. Remove the LH passenger handhold screw. Installation
1. Remove seat.
2. Remove plastic rivets securing the lateral con-
sole panel.
3. Remove the lateral console panel.
NOTE: On following illustrations, the cage and
the side net are removed for clarity purpose.

1. LH passenger handhold

4. Remove the front screw of the shift lever indi-

cator.

1. RH lateral console panel

2. Plastic rivets

1. Shift lever indicator

2. Front retaining screw

5. Remove all plastic rivets securing the lower

console.
FRONT PORTION OF THE LH LATERAL CONSOLE PANEL
1. LH lateral console panel
2. Plastic rivets

1. Plastic rivets

6. Remove the lower console.

The installation is the reverse of the removal pro-
REAR PORTION OF THE LH LATERAL CONSOLE PANEL
cedure. 1. LH lateral console panel
2. Plastic rivets

360 tmr2011-038
 Section 07 CHASSIS
Subsection 06 (BODY)

The installation of the lateral console panels is the

reverse of the removal procedure.

GLOVE BOX REMOVAL AND

INSTALLATION
1. Remove the glove box trim.

1. Glove box trim

2. Remove glove box retaining screws.

1. Glove box retaining screws

3. Pull glove box to remove it.

The installation of the glove box is the reverse of
the removal procedure.

tmr2011-038 361
 Section 07 CHASSIS
Subsection 07 (CARGO BOX)

CARGO BOX
CARGO BOX TRIMS

5 ± 1 N•rn
2 ± 0.5 N•m (44 ± 9 lbf•in)
(18 ± 4 lbf•in)

5 ± 1 N•rn
.411111‘ (44 ± 9 lbf•in)
.4111 ..-
alai
c;,:-..le wow, lip)
5 ± 1 N•m Iiillilitt 2 ± 0.5 N•m
(44 ± 9 lbf•in) itikomikii. 0 i
f (18 ± 4 Ibf•in -7
..,tr,..0.1.....
.. 47.
.
*V

5 ± 1 N•rn
(44 ± 9 lbf•in)

1mr2011-043-001a

tmr2011-043 363
 Section 07 CHASSIS
Subsection 07 (CARGO BOX)

CARGO BOX TILT RELEASE MECHANISM

Loctite 406 14)

(glue)
6

5 -± 1 N•rn
(44 ± 9 lb•n)

5 ± 1 f\l•rn
(44 ± 9 lbf•in)
\,

6
Loctite 406
(glue)

1mr2011 -043 002_a

364
tmr2011-043
 Section 07 CHASSIS
Subsection 07 (CARGO BOX)

CARGO BOX SUPPORT

11 ± 1 N•ni
(97 ± 9 lbf•in)

11 ± 1 N•rn
(97 ± 9 lbf•in) 4 ± 0.5 N•ni
(35 ± 4 lbf•in)

tm r201 1 -043-003_a

tmr2011-043
365
 Section 07 CHASSIS
Subsection 07 (CARGO BOX)

UPPER TAIL GATE

7 -± 1 N•m
(62 ± 9 lbf•in)

5 ± 1 N•m
(44 ± 9 lbf•in)

5 ± 1 N•m
(44 ± 9 lbf•in)

2.2 ± 0.2 N•m

(19 ±- 2 Ibf•in)
5 ± 1 N•m
(44 ± 9 lbf•in)

7 ± 1 N•m
(62 ± 9 lbf•in)

2.2 ± 0.2 Nom

(19 ± 2 lbf•in)

5 ± 1 N•m
(44 ± 9 Ibf•in)

tmr2011 -043-004_a

366
tm r20 1 1 -043
 Section 07 CHASSIS
Subsection 07 (CARGO BOX)

LOWER TAIL GATE

7 ± 1 N•rn 5 ± 1 N•rri
(62 ± 9 lbf•n) (44 ± 9 lbf•in)
41/11,-.„ 2.5 ± 0.5 NI•m
(22 ± 4 lbf•in)

2.2 ± 0.2 N•rn

5 ± 1 N•rn (19 ± 2 lbf•in)
(44 ± 9 lbf•in)
5 ± 1 N•rn
(44 ± 9 lbf•in)
2.5 ± 0.5 N•rn
/— (22 ± 4 lbf•n)

7 ± 1 N•rn
(62 ± 9 lbf•in)

5 ± 1 N•rn
(44 ± 9 lbf•in)

All except CE model CE model

2.5 ± 0.5 N•rn

(22 ± 4 lbf•in)

2.5 ± 0.5 N•rn

(22 ± 4 lbf•in)

2.5 ± 0.5 N•rn

(22 ± 4 lbf•n) 5 ± 1 N•rn
(44 ± 9 Ib•n)

2.5 ± 0.5 N•n-1

(22 ± 4 lb•n)

tmr2011-043-005_a

tmr2011-043
367
 Section 07 CHASSIS
Subsection 07 (CARGO BOX)

CARGO BOX ACCESSORIES

5 ± 1 N•rn
(44± 9 lbf•in)

5 1 N•m
(44 ± 9 lbf•in)

XT model

2± 0.5 N•rn
(18 -± 4 lbf•in) 5 ± 1 N•rn
--T( ;.1
(44 ± 9 lbf•in)

2 ± 0.5 N•rn
(18 ± 4 lbf•in)

tmr2011-043-006_a

368
tmr2011-043
 Section 07 CHASSIS
Subsection 07 (CARGO BOX)

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATIONat the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications CARGO BOX HEIGHT GAP
must strictly be adhered to. 1. Top of cargo box side
2. Top of rear lateral panel
Locking devices when removed (e.g.: locking
A. Maximum of 6mm (15/64 in)
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced. If an adjustment is required, proceed as follows:
1. Loosen cargo box pivot point nuts.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan- 2. Remove adjuster bolts securing the cargo box
dards. to cargo box support adjuster.

ADJUSTMENT
CARGO BOX ADJUSTMENTS
Cargo Box Alignment
The cargo box is properly aligned when:
— The gap between the cargo box and rear lat-
eral panel is equalled on each side (± 19 mm
(3/4 in)).
— Cargo box side and rear lateral panel are
flushed. The top of cargo box side may be
raised for a maximum of 6mm (15/64 in) over TYPICAL - RH SIDE SHOWN
the top of rear lateral panel. 1. Cargo box pivot point nuts
2. Adjuster bolt

3. Position cargo box to align it as described

above.
4. Reinstall adjuster bolts in corresponding holes.

GAP BETWEEN CARGO BOX AND REAR LATERAL PANEL

1. Cargo box side
2. Rear lateral panel
A. Approximately 19mm (3/4 in)

1. Corresponding holes

5. Tighten nuts and bolts.

tmr201 1-043 369
Section 07 CHASSIS
Subsection 07 (CARGO BOX)

PART TORQUE
110 Nom ± 2 Nom
Adjuster bolts
189 lbfoin ± 18 lbfoin)
Cargo box pivot point 24.5 Nom ± 3.5 Nom
nuts (18 lbfoft ± 3 lbfoft)

6. Verify the cargo box retainer height.

Cargo Box Retainer Height Adjustment

1. Open cargo box.
2. Loosen rubber bumpers.
CARGO BOX RETAINER GAP
1. Cargo box retainer
A. 1.5 mm to 3.0mm (.059in to .718 in)

NOTE: No vertical gap is permitted between

cargo box retainer and the end of the latch lever.

RH SIDE SHOWN
1. Rubber bumper

3. Close the cargo box and check the gap between

cargo box retainer and the end of the latch lever.
3.1 Break torque from cargo box retainer bolts.
1. No gap here

4. Check the tilt release handle stroke.

4.1 Determine a reference point on the body.
4.2 With the cargo box unlatch, measure the
distance between the handle and your ref-
erence point.
4.3 Latch the cargo box and repeat the mea-
surement using same reference points
(handle and body).
4.4 The difference between measurements
should be approximately 2 mm (.079 in).

TYPICAL - RH SIDE SHOWN

1. Cargo box retainer nuts
2. Cargo box retainer

3.2 Using a small hammer, reposition the

cargo box retainer. Temporarily retighten
bolts.
3.3 Close the cargo box and check the cargo
box retainer gap.

370 tmr2011-043
 Section 07 CHASSIS
Subsection 07 (CARGO BOX)

CARGO BOX
Cargo Box Removal
1. Unlock and raise the cargo box.
2. Unplug the cargo box harness connector.

1. Reference point
A. Difference: approximately 2 mm (.079 in)

5. Repeat steps 3 and 4 until cargo box is properly

adjusted.
6. Retighten all cargo box retainer bolts.
PART TORQUE 1. Cargo box harness connector

24.51\10m ± 3.5 1l•rn 3. From the LH of vehicle, cut all locking ties se-
Cargo box retainer bolts
(18 lbfeft ± 3 lbfeft) curing harness to frame.
7. Reposition the rubber bumper against the cargo 4. Secure the cargo box with wooden blocks (or
box without any pressure. an equivalent) and remove the upper gas shock
bolt.
5. Remove supports and lower cargo box.
6. From underneath of cargo box, remove nuts,
support plates and halve housings.

PROCEDURES is ,--
11!
1
CARGO BOX GAS SHOCK imr2011 043-014

RH SIDE SHOWN
Cargo Box Gas Shock Replacement 1. Nuts
2. Support plate
1. Unlock and raise the cargo box. 3. Half housing
2. Secure the cargo box with wooden blocks (or
7. Unlock the cargo box.
an equivalent).
8. Using a hoist or with the help of another person,
3. Remove the upper and lower gas shock bolts.
remove the cargo box.
4. Remove gas shock from vehicle and install the
new one. A CAUTION To avoid injury or vehicle dam-
5. Remove supports and lower cargo box. ages, never handle the cargo box alone.

Cargo Box Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.

tmr201 1-043 371

 Section 07 CHASSIS
Subsection 07 (CARGO BOX)

If any parts of the locking mechanism have been

replaced or loosen, check cargo box adjustments.
Refer to CARGO BOX ADJUSTMENTS.

372 tmr2011-043
 Section 07 CHASSIS
Subsection 08 (FRAME)

FRAME
SERVICE TOOLS - OTHER SUPPLIER
Description Part Number Page
BLIND THREADED INSERT INSTALLER model 9600 377

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE) 293 800 060 376

t m r2011 -03 9
373
 Section 07 CHASSIS
Subsection 08 (FRAME)

T1 10 ± 2 N•rn (89 ± 18 lbf•in)

T2 5 ± 0.5 N•m (44 ± 4 lbf•in)
T3 25 ± 3 N•ni (18 ± 2 lbf•ft)
T4 48 ± 6 N•m (35 ± 4 lbf•ft)
T5 21 ±3 N•rn (15 ± 2 lbf•ft)

T4
6 Loctite 243

6
Loctite 243
T1

CE Models only

XT Model
T4
T3
!l7;-7Ni!

tmr2011-039-001a

tmr2011-039
374
 Section 07 CHASSIS
Subsection 08 (FRAME)

10 ± 2 IN41•m
(89 ± 18 lbf•in)

25 ± 3 N•m
(18 ± 2 lbf•ft)

25 ± 3 N•ni
(18 ± 2 lbf•ft)

25 ± 3 N•rn
(18 ± 2 lbf•ft) 13 ± 1 N•m
op (115 ± 9 lbf•in)

25 ± 3 N•m
(18 ± 2 lbf•ft)

unr20114)39-002_a

tmr2011-039
375
Section 07 CHASSIS
Subsection 08 (FRAME)

GENERAL 2. Position straps on cage tubes as shown.

3. Install lifting straps to the cage. Make a loop
During assembly/installation, use the torque val-
in the strap to prevent the cage to slip while
ues and service products as in the exploded
views. manipulating.

NOTE: It is recommended to use new screws and

nuts when removed.
If the same fasteners are reused, clean threads
before applying a threadlocker. Refer to
SELF-LOCKING FASTENERS and LOCTITE AP-
PLICATION at the beginning of this manual for
complete procedure.

A WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices must be replaced (e.g.: lock-
ing tabs, elastic stop nuts, cotter pins, etc.).

PROCEDURES 1. Loops in the strap around the cage tubes

4. Using a hoist, lift the cage assembly over the

CAGE vehicle and carefully position it on vehicle.
A WARNING
Never modify the mounting points of the A CAUTION To avoid injury or vehicle dam-
shoulder nets and the seat belts. If they are ages, never handle the cage alone.
found modified or damaged, contact a BRP NOTE: As an alternate method, 4 persons at each
service representative. attachment point can position the cage on the ve-
hicle.
A WARNING 5. Insert the rear of cage first. Loosely install
Never drill holes, weld or modify the cage. screws.
Since this is an important protection com-
ponent, any modification might compromise
passenger safety.

Cage Inspection
Check cage for bending, cracks, weld damages or
any other damage.

A WARNING
Any damaged cage components must be re-
placed.
RH REAR CAGE ATTACHMENT POINT SHOWN
Cage Installation 1. Mounting screws

A WARNING 6. Insert the front of cage last. Loosely install

When the cage mounting bolts are removed, screws.
they must be replaced with new ones or have NOTE: Installing the top screw first will ease the
their threads cleaned then have LOCTITE 243 assembly.
(BLUE) (P/N 293 800 060) applied. Ensure to use
only 8.8 grade fasteners.

1. Loosely assemble the cage.

tmr2011-039

376
 Section 07 CHASSIS
Subsection 08 (FRAME)

Frame Replacement
NOTE: Blind threaded inserts are not installed on
replacement frames. Make sure to order 14 in-
serts when replacing frame.

RH FRONT CAGE ATTACHMENT POINT SHOWN

1. Install top screw first

7. Properly torque all the following cage screws to

48 N•m ± 6 N•rn (35 lbfeft ± 4 lbf•ft) in this or-
der.
— Rear attachment points
— Joints between front and rear portion of cage
— Front attachment points.

FRAME
Frame Inspection
Check frame for bending, cracks, weld damages
or any other damage. Replace frame as neces-
sary.

Frame Welding
No welding should be done on frame except if
mentioned or required on an approved BRP Bul-
letin.

Frame Insert Replacement

To install a new blind threaded insert, use the fol-
lowing tool: BLIND THREADED INSERT INSTALLER
(P/N MODEL 9600) from Textron. See their web
site at: www.textronfasteningsystems.com .

After insert installation, ensure insert can hold the

torque applied to the screw it retains. Otherwise,
install a new insert.

tmr2011-039
377
 Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 800R AND 1000)

COMMANDER 800R AND 1000

COMMANDER COMMANDER
MODEL
800R 1000
ENGINE
ROTAX® 810 I ROTAX® 1010
Engine type 4-stroke, Single Over Head Camshaft
(SOHC), liquid cooled
Number of cylinders 2
Number of valves 8 valves (mechanical adjustment)
Bore 91 mm (3.58 in)
Stroke 61.5 mm (2.42 in) 75 mm (2.95 in)
Displacement 799 cm 3 (48.8 in3 ) 976 cm 3 (59.6 in 3)
Compression ratio 10.3:1 10.5:1
Maximum HP RPM 7250 rpm 7000 rpm
Exhaust system Spark arrestor approved by USDA Forest Service
Air filter Flat corrugated composite fiber
Intake valve opening 5° BTDC
Intake valve closing 45° ABDC 60° ABDC
Exhaust valve opening 55° BBDC 65° BBDC
Exhaust valve closing 5° ATDC - 5° ATDC
Intake 0.06 mm to 0.14 mm (.0024 in to .0055 in)
Valve clearance
Exhaust 0.11 mm to 0.19 mm (.0043 in to .0075 in)
New 4.966 mm to 4.980 mm (.1955 in to .1961 in)
Intake
Service limit 4.930 mm (.1941 in)
Valve stem diameter
New 4.956 mm to 4.970 mm (.1951 in to .1957 in)
Exhaust
Service limit 4.930 mm (.1941 in)
New 0.005 mm (.0002 in)
Valve out of round Intake and exhaust
Service limit 0.06 mm (.0024 in)
New 4.998 mm to 5.018 mm (.1968 in to .1976 in)
Valve guide diameter
Service limit 5.050 mm (.1988 in)
New 40.81 mm (1.607 in)
Valve spring free length
Service limit 39.00 mm (1.535 in)
New 1.05 mm to 1.35 mm (.041 in to .053 in)
Intake
Service limit 1.8 mm (.071 in)
Valve seat contact width
New 1.25 mm to 1.55 mm (.049 in to .061 in)
Exhaust
Service limit 2 mm (.079 in)
New 12.036 mm to 12.050 mm (.4739 in to .4744 in)
Rocker arm bore diameter
Service limit 12.060 mm (.4748 in)
New 12.000 mm to 12.018 mm (.4724 in to .4731 in)
Rocker arm shaft diameter
Service limit 11.990 mm (.472 in)
New 90.950 mm to 90.966 mm (3.5807 in to 3.5813 in)
Piston diameter
Service limit 90.900 mm (3.5787 in)
New 0.027 mm to 0.057 mm (.0011 in to .0022 in)
Piston/cylinder clearance
Service limit 0.100 mm (.0039 in)

tmr2011-040 379
Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 800R AND 1000)

COMMANDER COMMANDER
MODEL
800R 1000
ENGINE (CONT'D)
1st Upper compression ring, rectangular
Piston ring type 2nd Lower compression ring, tapered face
3rd Oil scraper ring
Rectangular 0.20 mm to 0.40 mm (.008 in to .016 in)
Tapered face New 0.20 mm to 0.40 mm (.008 in to .016 in)
Oil scraper ring 0.20 mm to 0.70 mm (.008 in to .028 in)
Ring end gap
Rectangular 0.60 mm (.024 in)
Tapered face Service limit 0.70 mm (.028 in)
Oil scraper ring 1.00 mm (.039 in)
Rectangular 0.03 mm to 0.07 mm (.0012 in to .0028 in)
Tapered face New 0.02 mm to 0.06 mm (.0008 in to .0024 in)
Oil scraper ring 0.01 mm to 0.18 mm (.0004 in to .0071 in)
Ring/piston groove clearance
Rectangular 0.15 mm (.0059 in)
Tapered face Service limit 0.15 mm (.0059 in)
Oil scraper ring 0.25 mm (.0098 in)
Cylinder bore New 90.993 mm to 91.007 mm (3.5824 in to 3.583 in)
Maximum New 0.038 mm (.0015 in)
Cylinder taper
Service limit 0.090 mm (.0035 in)
Maximum New 0.015 mm (.0006 in)
Cylinder out of round
Service limit 0.020 mm (.0008 in)
New 34.959 mm to 34.975 mm (1.3763 in to 1.377 in)
Timing chain side
Service limit 34.950 mm (1.376 in)
Camshaft main bearing journal
New 21.959 mm to 21.980 mm (.8645 in to .8654 in)
Spark plug side
Service limit 21.950 mm (.8642 in)
New 35.000 mm to 35.025 mm (1.378 in to 1.3789 in)
Timing chain side
Service limit 35.040 mm (1.3795 in)
Camshaft main bearing journal bore
New 22.000 mm to 22.021 mm (.8661 in to .867 in)
Spark plug side
Wear limit 22.040 mm (.8677 in)
32.890 mm to 33.090 mm 32.960 mm to 33.160 mm
New
Intake valve (1.2949 in to 1.3028 in) (1.2976 in to 1.3055 in)
Service limit 32.870 mm (1.2941 in) 32.940 mm (1.2969 in)
Camshaft lobe
32.950 mm to 33.150 mm 32.860 mm to 33.060 mm
New
Exhaust valve (1.2972 in to 1.3051 in) (1.2937 in to 1.3016 in)
Service limit 32.930 mm (1.2965 in) 32.840 mm (1.2929 in)

Crankshaft main bearing journal diameter New 42.016 mm to 42.040 mm (1.6542 in to 1.6551 in)
(MAG/PTO side) Service limit 42.000 mm (1.6535 in)
Crankshaft radial play (MAG/PTO side) Service limit 0.07 mm (.0028 in)
New 34.016 mm to 34.040 mm (1.3392 in to 1.3402 in)
Crankshaft bearing journal diameter (in PTO cover)
Service limit 34.010 mm (1.339 in)
Crankshaft radial play (PTO cover bearing) Service limit 0.10 mm (.0039 in)
New 0.200 mm to 0.500 mm (.0079 in to .0197 in)
Crankshaft axial play
Service limit 0.600 mm (.0236 in)

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 Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 800R AND 1000)

COMMANDER COMMANDER
MODEL
BOOR 1000
ENGINE (CONT'D)
40.009 mm to 40.025 mm 41.986 mm to 42.010 mm
New
Crankshaft pin diameter (1.5752 in to 1.5758 in) (1.653 in to 1.6539 in)
Service limit 39.990 mm (1.5744 in) 41.967 mm (1.6522 in)
Crankshaft deflection MAG/PTO side New 0.050 mm (.002 in)
Crankcase plain bearing MAG/PTO side Service limit 42.100 mm (1.6575 in)
PTO cover plain bearing Service limit 34.120 mm (1.3433 in)
Connecting rod big end diameter Service limit 40.100 mm (1.579 in) 1 42.100 mm (1.6575 in)
Connecting rod big end radial play Service limit 0.09 mm (.0035 in)
0.200 mm to 0.500 mm 0.250 mm to 0.550 mm
New
Connecting rod big end axial play (.008 in to .02 in) (.0098 in to .0217 in)
Service limit 0.600 mm (.024 in)
20.010 mm to 20.020 mm 22.010 mm to 22.020 mm
New
Connecting rod small end diameter (.7878 in to .7882 in) (.8665 in to .8669 in)
Service limit 20.060 mm (.7898 in) 22.050 mm (.8681 in)
19.996 mm to 20.000 mm 21.996 mm to 22.000 mm
New
Piston pin diameter (.7872 in to .7874 in) (865.984 in to 866.142 in)
Service limit 19.980 mm (786.614 in) 21.980 mm (.8654 in)
Connecting rod/piston pin clearance (radial play) Service limit 0.080 mm (.0031 in)
LUBRICATION SYSTEM
Type Wet sump. Replaceable cartridge oil filter
Oil filter BRP Rotax paper type, replaceable
Engine oil pressure Minimum 300 kPa (44 PSI) at 6000 RPM
Capacity
2.2 L (2.3 qt (U.S. 14))
(oil change with filter)
For the summer season, use XPS synthetic
blend oil (summer grade) (P/N 293 600 121).
Engine oil For the winter season, use XPS synthetic
Recommended oil (winter grade) (P/N 293 600 112).
If not available, use a 5W40 motor oil that
meets the requirements for API service
classification SM, SL or SJ
COOLING SYSTEM
Ethyl glycol/water mix (50% coolant, 50% water).
Use premixed coolant sold by
Type
Coolant BRP (P/N 219 700 362) or
coolant specifically designed for aluminum engines
Capacity 3.9 L (1 U.S. gal.) I 4.3 L (1.1 U.S. gal.)
Starts to open 65°C (149°F)
Thermostat
Fully open 75°C (167°F) I 88°C (190°F)
Radiator cap opening pressure 110 kPa (16 PSI)

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Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 800R AND 1000)

.... . COMMANDER COMMANDER

MODEL 800R 1000
TRANSMISSION
Type CVT (Continuously Variable Transmission)
Engagement RPM 1750 ± 100 RPM
Drive belt width Service limit 30.00 mm (1.181 in)
New 13.70 mm to 13.80 mm (.539 in to .543 in)
Governor cup roller outer diameter
Service limit 13.20 mm (.52 in)
New 8.05mm to 8.15 mm (.317 in to .321 in)
Governor cup roller inner diameter
Service limit 9.00 mm (.354 in)
New 6.078 mm to 6.100 mm (.239 in to .24 in)
Centrifugal lever pivot bolt diameter
Service limit 6.000 mm (.236 in)
New 6.035 mm to 6.078 mm (.2376 in to .2393 in)
Centrifugal lever bore diameter
Service limit 6.200 mm (.244 in)

Drive pulley sliding half centrifugal lever pivot bolt bore New 6.113 mm to 6.171 mm (.241 in to .243 in)
diameter Service limit 6.300 mm (.248 in)
New 55.000 mm to 55.040 mm (2.165 in to 2.167 in)
Drive pulley sliding half large bushing
Service limit 55.200 mm (2.173 in)
New 32.000 mm to 32.040 mm (1.26 in to 1.261 in)
Drive pulley sliding half small bushing
Service limit 32.200 mm (1.268 in)
Drive pulley spring free length Service limit 85 mm (3.346 in) I 105 mm (4.134 in)
Drive pulley spring free squareness Service limit 4mm ( 157 in)
New 9.2 mm to 9.4 mm (.362 in to .37 in)
Spring sleeve length
Service limit 9.0 mm (.354 in)
New 30.060 mm to 30.100 mm (1.183 in to 1.185 in)
Driven pulley sliding half bushing
Service limit 30.200 mm (1.189 in)
New 30.060 mm to 30.100 mm (1.183 in to 1.185 in)
Driven pulley sliding fixed bushing
Service limit 30.200 mm (1.189 in)
Torque gear on driven pulley Service limit 7.500 mm (.295 in)
Driven pulley spring free length Service limit 125 mm (4.921 in)
Driven pulley spring free squareness Service limit 3.8 mm (.15 in)
GEARBOX
Type Dual range (HI-LO) with park, neutral and reverse
Capacity 450 ml (15 U.S. oz)
Gearbox oil XPS synthetic gear oil (P/N 293 600 140)
Recommended
or a 75W140 API GL-5 synthetic gear oil
New 5.25 mm to 5.35 mm (.207 in to .211 in)
Coupling sleeve groove width
Service limit 5.50 mm (.217 in)
New 4 95 mm to 5.05 mm (.195 in to .199 in)
Coupling fork claw thickness
Service limit 4.80 mm (.189 in)

Shift fork claw thickness New 5.10 mm to 5.20 mm (.201 in to .205 in)
(high, low and reverse gear shift fork) Service limit 5.00 mm (.197 in)
New 5.30 mm to 5.40 mm (.209 in to .213 in)
Width of shift fork engagement groove
Service limit 5.50 mm (.217 in)

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 Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 800R AND 1000)

COMMANDER COMMANDER
MODEL
800R 1000
GEARBOX (CONT'D)
New 29.000 mm to 29.013 mm (1.1417 in to 1.1422 in)
Diameter free pinions
Service limit 29.015 mm (1.1423 in)
New 24.987 mm to 25.000 mm (.9837 in to .9843 in)
Intermediate gear shaft
Service limit 24.977 mm (.983 in)
New 19.977 mm to 19.990 mm (.7865 in to .787 in)
MAG side
Service limit 19.973 mm (.7863 in)
Countershaft
New 24.977 mm to 24.990 mm (.9833 in to .9839 in)
CVT side
Service limit 24.970 mm (.9831 in)
Free pinion New 24.987 mm to 25.000 mm (.9837 in to .9843 in)
bearing Service limit 24.984 mm (.9836 in)
Main shaft
Bearing journal New 16.980 mm to 16.991 mm (.6685 in to .6689 in)
MAG/CVT side Service limit 16.976 mm (.6683 in)
ELECTRICAL SYSTEM
Magneto generator output 650 W @ 6000 RPM
Stator resistance (20C) 0.15 to 0.30 12
Ignition system type IDI (Inductive Discharge Ignition)
Ignition timing Not adjustable
Quantity 2
Spark plug Make and type NGK DCPR8E
Gap 0.7 mm to 0.8 mm (.028 in to .031 in)
Forward 8050 rpm
Engine RPM limiter setting 20 km/h to 25 km/h (12 MPH to 16 MPH)
Reverse
(8050 rpm with Override)
Type Maintenance free
Voltage 12 volts
Battery
Nominal rating 18 A* h
Power starter output 0.7 KW
Headlight 4 x 60 W
Taillight 2 X 8/21 W
Turn signals (CE) 10 W
Position light LED, 0.7 V approximately (each)

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Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 800R AND 1000)

COMMANDER COMMANDER
MODEL 1000
800R
ELECTRICAL SYSTEM (CONT'D)
— Main MF1 30 A
— Main accessories MF2 40 A
— Brake lights switch
— Gauge
F4 10 A
— Taillights
— Brake relay
— Ignition coils
— Fuel injectors F5 7.5 A
— Speed sensor
— Engine control module (ECM) F6 5A
— Handlebar switches F7 5A
Fuses
— Gauge
F8 5A
— Ignition switch
— Fan motor FY 30 A
— Euro controls F10 5A
— Lights relay F11 30 A
— Connectors (DC3 and DC4)
— 12 V power outlet F12 15 A
— Communication connector
— Relays coils (R1 and R3) F13 5A
— Connector DC6 F14 15 A
— Fuel pump F15 5A
FUEL SYSTEM
Electronic Fuel Injection (ER), 54 mm throttle
Fuel delivery Type body with iTC (Intelligent Throttle Control),
1 injector per cylinder
Type Electrical (in fuel tank)
Fuel pump
Operating pressure 350 kPa (51 PSI)
Idle speed 1250 rpm ± 100 (not adjustable)
Type Regular unleaded gasoline
Fuel Inside North America 87 (R+M)/2 or higher
Octane rating
Outside North America 92 RON or higher
Fuel tank capacity 37.8L (10 U.S. gal.)
Fuel remaining when low fuel light turns ON ± 12 L (3.2 U.S. gal.)

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 Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 800R AND 1000)

COMMANDER COMMANDER
MODEL 1000
800R
DRIVE SYSTEM
Front drive Visco-lokt front differential
Front drive ratio 3.6:1
Rear drive Shaft driven/spool
Rear drive ratio 3.6:1
Capacity 500 ml (17 U.S. oz)
Front differential oil XPS synthetic gear oil (P/N 293 600 043)
Recommended
or synthetic gear oil 75W90 API GL-5
Capacity 350 ml (11.8 U.S. oz)
Rear final drive oil XPS synthetic gear oil (P/N 293 600 140)
Recommended
or synthetic gear oil 75W140 API GL-5
CV joint grease CV joint grease (P/N 293 550 019)
Propeller shaft grease Hi-temp bearing grease NLGI-2 or an equivalent
STEERING
Steering wheel Adjustable tilt steering
Turning radius 240 cm (94.5 in)
Total toe (vehicle on ground) 0 mm ± 4 mm (0 in ± .157 in)
Camber angle (vehicle on ground) 0.7° positive
Tie-rod maximum length unengaged threads 32 mm (1.26 in)
FRONT SUSPENSION
Suspension type Double suspension-arm with dive-control geometry
Suspension travel 254 mm (10 in)
Qty 2
Shock absorber Standard and XT Oil
Type
X HPG Clicker (gas)
Standard 355.6 mm (14 in(
Spring free length X N.A. I 350 mm (13.78 in)
XT 363 mm (14.291 in)
Standard 706 200 859 (YL)
X N.A. 706 201 124 (YL)
Spring P/N 706 200 860 (YL)
706 200 860 (YL)
XT 706 201 367 (RD)
706 201 369 (BK)
706 201 369 (BK)
Standard and XT 5 positions cam
Preload adjustment type
X Threaded spring retainer

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Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 800R AND 1000)

COMMANDER COMMANDER
MODEL 1000
800R
REAR SUSPENSION
Torsional Trailing arm Independant (ill)
Suspension type with external sway bar
Suspension travel 254 mm (10 in)
Qty 2
Shock absorber Standard and XT Oil
Type
X HPG Clicker (gas)
Standard 358 mm (14.094 in)
Spring free length X N.A. I 373 mm (14.685 in)
XT 358 mm (14.094 in)
Standard 706 000 667 (YL)
X N.A. 706 000 821 (YL)
Spring P/N 706 000 667 (YL)
706 000 667 (YL)
XT 706 001 043 (RD)
706 001 045 (BK)
706 001 045 (BK)
Standard and XT 5 positions cam
Preload adjustment type
X Threaded spring retainer
BRAKES
Qty 2
Front brake 214 mm ventilated disc brakes with hydraulic
Type
twin-piston calipers
Qty 1
Rear brake 214 mm ventilated disc brake with hydraulic
Type
twin-piston caliper
Capacity 125 ml (4.2 U.S. oz)
Brake fluid
Type DOT 4
Caliper Floating
Front Metallic
Brake pad material
Rear Metallic
Minimum brake pad thickness 1 mm (.04 in)
Front 4.1 mm (.161 in)
Minimum brake disc thickness
Rear 4.1 mm (.161 in)
Maximum brake disc warpage 0.2 mm (.01 in)
TIRE
Maximum: 83 kPa (12 PSI)
Front
Minimum: 69 kPa (10 PSI)
Pressure
Maximum: 152 kPa (22 PSI)
Rear
Minimum: 83 kPa (12 PSI)
Minimum tire thread depth 3 mm (.118 in)
Standard 27 x 9 x 12 (in)
Front X 27 X 9 X 12 (in)
XT 27 X 9 X 14 (in)
Size
Standard 27 x 11 x 12 (in)
Rear X 27 X 11 X 12 (in)
XT 27 X 11 X 14 (in)

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 Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 800R AND 1000)

COMMANDER COMMANDER
MODEL
800R 1000
WHEELS
Standard Steel
Type X Aluminum beadlock wheels
XT Cast Aluminum
Standard 12 X 6 (in)
Front X 12 X 6 (in)
XT 14 X 7 (in)
Rim size
Standard 12 X 8 (in)
Rear X 12 X 7.5 (in)
XT 14 X 8.5 (in)
Wheel nuts torque 100 N•m ± 10 N•m (74 lbf•ft ± 7 lbf•ft)
CHASSIS
50 mm (2 in) diameter, high strength steel,
Cage type
BOPS-approved cage
DIMENSION
Overall length 300.4 cm (118.3 in)
Overall width 148.9 cm (58.6 in)
Overall height 182.9 cm (72 in)
Wheel base 192.4 cm (75.7 in)
Front 125.7 cm (49.5 in)
Wheel track
Rear 121.9 cm (48 in)
Ground clearance 27.9 cm (11 in)
WEIGHT AND LOADING CAPACITY
Dry weight 584 kg (1,2871b) I 587 kg (1,2951b)
Weight distribution I Front/rear 44/56
Total (upper + lower) 272 kg (600 lb)
Cargo box capacity Upper 181 kg (4001b)
Lower 272 kg (600 lb)
Total vehicle load allowed
(including driver, passenger, all other loads and added 363 kg (800 lb)
accessories)
Gross vehicle weight rating 990 kg (2,183 lb)
50. 8 mm (2 in) X
Towing capacity Hitch support 680 kg (1,500 lb)
50.8 mm (2 in)
Tongue capacity 68 kg (1501b)

N.A.: Not Available

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 Section 09 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM INFORMATION)

WIRING DIAGRAM INFORMATION

GENERAL Connector Housing Area

WIRING DIAGRAM LOCATION >----

XX/XX-18 -BF-A
The wiring diagram is stored in the back cover
pocket.
VO6G1HA
2
WIRING DIAGRAM CODES
The first number in the connector/pin contact
1 2 3 4 5 number represents the area in the vehicle where
the connector is located.

XX/XX-18 2-BF-A
VOOGOFA

1. Wire colors
2. Wire gauge
3. Connector housing area
4. Connector identification
5. Wire location in connector

Wire Colors
It identifies the color of a wire. When a 2-color
scheme is used, the first color is the main color
while the second color is the tracer color.

XX/XX AREA LOCATION

1 Steering, dashboard and upper console area
XX/XX 2-BF-A 2 Under dashboard and front bulkhead area
VO6G1 FA
3 Front of vehicle
THE SHADED PART INDICATES THE WIRE COLOR
4 Engine, seat and lower console area
Example: YL/BK is a YELLOW wire with a BLACK
5 Rear of vehicle
stripe.

Wire Gauge Connector Identification

The number after wire color indicates the gauge The letters in the middle of the connector/pin con-
of a wire. tact number Indicates the connector's function. If
there are many connectors in the same area, this
helps to identify which wire is in which connector.
18
X X/X 18 2-BF-A XX/XX-18
VO6G1 GA

THE SHADED PART INDICATES THE WIRE GAUGE

VO6G1JA
BF
Example: The number that follows the wire color THE SHADED PART INDICATES A CONNECTOR
indicates the wire size used, in this case 18 gauge
wire.

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Section 09 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM INFORMATION)

ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION

BA Ignition coil STSW Start switch
BAT Battery SW Winch relay
BD 2WD/4WD switch SWW Winch switch
BP Battery power TPS Throttle position sensor
CA Magneto TAS Throttle accelerator sensor
CAPS Camshaft position sensor WM Winch motor
CC Ignition switch
CI Multifunction speedometer
Wire Location in Connector
This is the wire position in the connector. The
CPS Crankshaft position sensor
number or letter given refers to the physical iden-
CTS Coolant temperature sensor tification stamped or molded on the connector.
CV Speed sensor
DB Diagnostic connector
DC DC outlet
XX/XX-1 8 2- .Br-] Al
ECM Engine control module
VO6G 1 KA
A
ETA Electric throttle actuator
THE SHADED PART INDICATES THE CONNECTOR LOCATION
ETC Electronic throttle control IN HOUSING
FP Fuel pump
FRA Brake light switch
FT Cooling fan
GBPS Gearbox position sensor
HIBM High beam (headlights)
Harness interconnect
H IC
(engine/vehicle)
INJ1 and INJ2 Fuel injector
Manifold air pressure and
MAPTS
temperature sensor
MD 2WD/4WD actuator
MG multifunction switch
OPS Oil pressure switch
OV Override button
PD RH headlight
PF1 Fuse Holder (main)
PF2 Fuse Holder
PG LH headlight
RD Voltage regulator/rectifier
SB Seat belt
SD 2WD/4WD actuator switch
TYPICAL
SM Starter motor
SPK1 and SPK2 Spark plug
SS Starter solenoid

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 Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

CONNECTOR INFORMATION
SERVICE TOOLS
Description Part Number Page
CRIMPING TOOL (HEAVY GAUGE WIRE) 529 035 730 399
ECM ADAPTER TOOL 529 036 166 396
ECM TERMINAL REMOVER 2.25 529 036 175 397
ECM TERMINAL REMOVER 3.36 529 036 174 397

SERVICE TOOLS - OTHER SUPPLIER

Description Part Number Page
GM TERMINAL EXTRACTOR 12094430 398
SNAP-ON TERMINAL REMOVER TOOL TT600-4 394

GENERAL
DEUTSCH CONNECTORS
Deutsch Connector Application
A variety of Deutsch connectors are used on var-
ious systems:
— Engine connector
— Magneto connector.
The following procedures may be used on each as
they are similar in construction.

Deutsch Connector Removal from its

TYPICAL - MALE CONNECTOR REMOVED FOR CLARITY
Support 1. Insert screwdriver here
1. Insert a small flat screwdriver between the sup-
port and the Deutsch connector. Deutsch Connector Disconnect
2. Pry the connector away from the support 1. To disconnect a Deutsch connector, press the
slightly while sliding it out in the direction release tab and twist a small flat screwdriver
shown. between the male and female housing to dis-
engage and disconnect them.

TYPICAL - MALE CONNECTOR REMOVED FOR CLARITY

1. Insert screwdriver here

tmr2011-042 391
Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

Deutsch Connector Disassembly and

Reassembly

TYPICAL - DEUTSCH CONNECTOR

TYPICAL 7. Male connector
1. Release tab 2. Female connector
2. Deutsch connector 3. Secondary lock
4. Sealing cap

NOTICE Do not apply dielectric grease on ter-

minal inside connector.
Terminal Removal
To remove terminals from connector, proceed as
follows:
1. Using long nose pliers, pull out the secondary
plastic lock from between the terminals.

TYPICAL
1. Deutsch connector
2. Press release button

FEMALE CONNECTOR
1. Female lock

TYPICAL
1. Flat screwdriver
2. Deutsch connector

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 Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

3. Pull back on the terminal wire to be sure the

retention fingers are holding the terminal.
4. After all required terminals have been inserted,
the lock must be installed.

MALE CONNECTOR
1 Male lock

NOTE: Before pin extraction, push wire forward CONNECTOR PIN-OUT

to relieve pressure on retaining tab. 1. Terminal position identification numbers

2. Insert a 4.8 mm (.189 in) wide screwdriver

blade inside the front of the terminal cavity. PACKARD CONNECTORS
3. Pry the retaining tab away from the terminal Packard Connector Application
while gently pulling the wire and terminal out
of the back of the connector. Packard connectors are used to connect:
— Electrical harnesses
— Gauges
— VCM
— EFB.

3-Pin Packard Connector

FEMALE CONNECTOR
1. Retaining tab

Terminal Insertion
1. For insertion of a terminal, ensure the sec-
VIEW OF A 3-PIN PACKARD CONNECTOR
ondary plastic lock is removed. 1. Identification letters
2. Insert terminal through the back of the connec-
NOTE: This type of connector also comes in other
tor in the appropriate position, and push it in as
pin configurations.
far as it will go. You should feel or hear the ter-
minal lock engage.

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 Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

To remove a terminal from a 3-pin Packard connec-

tor, use the SNAP-ON TERMINAL REMOVER TOOL
(P/N TT600-4).

a WARNING
Ensure all terminals are properly crimped on
wires and connectors are properly fastened.

PACKARD CONNECTOR
(MULTIFUNCTION GAUGE)
Firmly push down tab and hold to unlock connec-
tor while pulling it out.
CONNECTOR PINOUT

Push on both tabs to remove retainer.

TYPICAL
1. Retainer
2. Tab (one on each side)

Open housing by lifting 4 tabs.

TYPICAL
1. Tabs (2 on each side)

394 trn r201 1 -042

 Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

Lift the top plastic lock of the female terminal to 2. Press and hold the locking tab on the connector
be removed and hold in position. Lift the female to be disconnected.
terminal to unlock from the housing and push out
of housing.

LOCKING TAB TO PRESS AND HOLD

3. As you hold the locking tab, rotate the connec-

tor locking cam until it stops.
TYPICAL
1. Lift and hold plastic lock
2. Lift to unlock and push out

MOLEX CONNECTOR
Molex Connector Application
The Molex connector is used on the ECM.
There are 2 MOLEX connectors on the ECM.
The engine wiring harness connector is con-
nected to ECM connector "A". The vehicle wiring
harness connector is connected to ECM connec-
tor "B".
Each ECM connector has 48 pins.
CONNECTOR LOCKING CAM ROTATION TO RELEASE

4. Pull connector off ECM.

ECM CONNECTORS

Do not apply any product to the pins in the ECM

connector.

Connector Removal
1. To access the ECM, refer to ELECTRONIC
FUEL INJECTION subsection.

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 Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

Connector Installation
1. Fully open connector locking cam.

LOCKING TAB FULLY OUT

Connector Inspection
CONNECTOR LOCKING CAM IN RELEASE POSITION Before replacing an ECM, always check electrical
connections.
2. Insert connector on ECM.
3. As you push the connector onto the ECM, ro- 1. Ensure connector locking mechanism is func-
tioning properly.
tate the connector locking cam until it snaps
locked. 2. Ensure all wire terminals (pins) are properly
locked in the connector.
3. Ensure they are very tight, make good contact
with the pins in the ECM.
4. Ensure the pins in the harness connector
and the ECM connector are clean, shiny and
corrosion-free.
5. Check wiring harness for signs of scoring.
NOTE: A "defective ECM module" could possi-
bly be repaired simply by disconnecting and recon-
necting it.
NOTICE Do not apply any lubricant product
to the pins of the ECM connector.

Connector Probing
1. Locked here The most recommended and safest method to
probe the MOLEX (ECM) connector terminals is
4. Ensure the locking tab is fully out. to use the ECM ADAPTER TOOL (P/N 529 036 166).
This tool will prevent deforming or enlarging of
the terminals, which would lead to bad ECM ter-
minal contact creating intermittent or permanent
problems.

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 Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

1. Remove rear protector from connector.

1. Disconnect the ECM connector to be probed, 2. Pull out the connector lock.
and reconnect it on the ECM adapter.
2. Probe wire terminals of the circuit to be tested
directly in the adapter holes.

TYPICAL 3. Insert tool to unlock terminal.

7. ECM connector
2. ECM adapter

NOTICE Never probe directly on the ECM

harness connector. This could change the
shape or enlarge the terminals and create in-
termittent or permanent contact problems.

Connector Terminal Removal (Harness

Connector)
To remove a signal terminal from the ECM har-
ness connector, use the ECM TERMINAL RE-
MOVER 2.25 (P/N 529 036 175).
To remove a power terminal, use the ECM TERMI-
NAL REMOVER 3.36 (P/N 529 036 174).
1. Unlock here

4. Gently pull on the wire to extract the terminal

out the back of the connector.

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Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

Step 2: Insert GM extractor tool (P/N 12094430)

3. Gently pull on the wire to extract the pin out the

NOTICE Before installing wire terminals in back of the connector.
the connector, ensure all terminals are prop-
erly crimped on wires. After installation of
wire terminals in the connectors, ensure they
are properly locked by gently pulling on them
as if to extract them.

FURUKAWA CONNECTOR
Furukawa Connector Application
Voltage regulator/rectifier.

Terminal Removal
1. Remove the secondary lock (plastic insert).

Step 3: Pull wire to extract pin

NOTICE Before installing terminals in the

connectors, ensure all terminals are properly
crimped on the wires. After installation of the
wire terminals in the connectors, ensure they
are properly locked by gently pushing on them
as if to extract them.

BATTERY AND STARTER CABLE

TERMINALS
Cable Crimping
Step 1: Remove the secondary lock
Carefully strip the wire approximately to 10 mm
2. Carefully insert the GM TERMINAL EXTRACTOR (3/8 in) in length, using a wire stripping tool or
(P/N 12094430) between the lock and the pin to sharp blade/knife.
release the pin.

GM TERMINAL EXTRACTOR (P/N 12094430)

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 Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

A. 10 mm (3/8 in)

NOTE: Make sure not to cut wire strands while

stripping the wire.
Install the appropriate terminal on the wire ac-
cording to the requirement. Refer to appropriate POSITIONING THE CRIMPING PLIERS
PARTS CATALOG. Step 1: Step 1: Press
Step 2: Step 2: Rotate

After positioning the crimping pliers, crimp the ter-

minal already installed on wire.

INSTALLATION OF TERMINAL

Follow the instructions provided with the CRIMP-

ING TOOL (HEAVY GAUGE WIRE) (P/N 529 035 730)
to select the proper position of the tool.

CRIMPING OF WIRE
NOTE: Different wires require different crimping
pliers settings.

PROPERLY CRIMPED WIRE

To verify, if the wire is properly crimped, apply

some pulling force on wire and the terminal at the
same time from both directions.
NOTICE Never weld the wire to the terminal.
Welding can change the property of the wire
and it can become brittle and break.
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 Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

Install the protective heat shrink rubber tube on

the terminal. Heat the heat shrink rubber tube us-
ing the heat gun so that it grasps the wire and the
terminal.
NOTICE Make sure that the protective heat
shrink rubber tube has been properly installed
and no part of wire is exposed.

400 tmr2011-042