Can-Am 2011 commander 1000, Shop Manual

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Page 2: ...2011 Shop Manual CommanderTM 800R 1000 Series can am ...

Page 3: ... Printed in Canada Technical Publications Bombardier Recreational Products Inc BRP Valcourt QC Canada TM Trademarks of Bombardier Recreational Products Inc BRP or its affiliates Trademarks of Bombardier Inc used under license 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...

Page 4: ...ELT 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 SENSO...

Page 5: ...LED 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 P...

Page 6: ...LUTCH 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 CH...

Page 7: ...ROCEDURES 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 SPECI...

Page 8: ...ECTION 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 G...

Page 9: ...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...

Page 10: ...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...

Page 11: ...1 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 ...

Page 12: ... 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 h...

Page 13: ...rovement of its products without imposing upon itself any obligation to install them on products previously manufactured Due to late changes there may be some differ ences between the manufactured product and the description and or specifications in this document BRP reserves the right at any time to discontinue or change specifications designs features mod els or equipment without incurring oblig...

Page 14: ...n 6 Lower hydraulic lift and ensure vehicle is sup ported safely onto both jack stands HOISTING THE VEHICLE The vehicle may be lifted off the ground by the cage using a hoist and a lifting strap NOTICE The lifting strap must be wrapped around the horizontal side tubes at the top of the cage NOT fore and aft Lifting vehicle by the fore and aft tubes of the cage can cause damage INTRODUCTION 1 Hydra...

Page 15: ...raps 6 Pass a tie down strap inside each rear wheel 7 Firmly attach the rear wheels tie down straps to both sides of the rear of the trailer with ratch ets 8 Ensure that both the front and rear wheels are firmly secured to the trailer ENGINE EMISSIONS INFORMATION MANUFACTURER S RESPONSIBILITY Manufacturers of engines must determine the exhaust emission levels for each engine horse power family and...

Page 16: ...ch the procedure is contained A number of procedures throughout the book re quire the use of special tools Before starting any procedure be sure that you have on hand all re quired tools or their approved equivalents The use of RIGHT and LEFT indications in the text are always referenced to the driving position sit ting on the vehicle TYPICAL 1 Left 2 Right This manual uses technical terms which m...

Page 17: ...ed with a new one Illustration number for publishing process Document number for 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 it Page number Drop represents a service product to be applied Dotted box contains parts applicable to a specific model Bold ...

Page 18: ...tal cleaner CAUTION Clean magneto flywheel using only Indicates specific a clean cloth procedure to be Magneto Flywheel Removal carried out Remove muffler refer to the EXHAUST SYSTEM section Remove acoustic panel Remove rewind starter Remove starting pulley no 2 A mmr2008 001 Section 03 ENGINE Subsection 09 MAGNETO SYSTEM TYP1CA 41 NOTE To remove starting pulley bolts hold mag veto flywheel with a...

Page 19: ...teners 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 Property class and head markings 4 8 4 8 8 8 8 8 9 8 9 8 10 9 10 IMII 2 9 12 9 0 iggli 129 14 81 II 8 81 II 9 8 WI OPT UPI MI IIIPI Mil Property class and nut markings A00A813S 0 5 I 0 0 8 I 0 _ 0 10 MI 0 0 _ 12 am an 0 FASTENE...

Page 20: ...ocking the fas 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 Threadlocker Application for Uncovered Holes Bolts and Nuts 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 a...

Page 21: ...stall stud 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 Threadlocker Application for Pre Assembled Parts 1 Apply here 2 Do not apply 1 Clean bolts and nuts with solvent 2 Assemble components 3 Tighten nuts 4 Apply a few drops of proper strength Loctite on bolt nut contact surfaces 5 Avoid touchin...

Page 22: ...ud 3 Follow Standard Thread Repair procedure 4 Allow 30 minutes for Loctite FORM A THREAD to cure 5 Complete part assembly Gasket Compound Application 1 Proper strength Loctite 2 Loctite Primer N P N 293 800 041 and Gasket Eliminator 518 P N 293 800 038 on both sides of gasket 3 Loctite Primer N only 1 Remove old gasket and other contaminants us ing LOCTITE CHISEL GASKET REMOVER P N 413 708 500 Us...

Page 23: ...e 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 3 Apply a strip of proper strength Loctite on lead ing edge of outer metallic gasket diameter NOTE Any Loctite product ...

Page 24: ...lEla PLL 9E0 6Z9 N d 1001 103NNODSICI 60E 66Z abed S00 9E0 6ZS N d 801DVEL1X3 1N10r AD no sco 6Z9 N d 90103101dd 1JVHS INVEID LW 9E0 6M N d 1109 9N1 1001 1JVHSNNVHD OEL 9E0 6Z9 N d 39IM 3onvo AAV3H 1001 DNIdV 111 10 00Z 9E0 6Z9 N d 1001 NO111S0d DalldVHSNNVED LEO 9E0 6Z9 N d Old DVW ibioddns 3SVDNNVHD LOZ 9E0 6Z9 N d 1001 DNIV 111 _l_dVHSVWD 9L abed FRG U 9S0 9E0 6ZS N d _IN 4 1371nd 310H GNI18 zs...

Page 25: ... 661 9E0 6Z9 N d SSANHVH 311SONDVIG 013N9VV J ZZO 9E0 6Z9 N d 1001 DNIldll 3NIDN3 6Z0 9E0 6Z9 N d H01D310Hd 1V S 110 IdVHS 3A1EIG KO 9E0 6Z9 N d H311V1SN1 1V3S 110 1JVHS 3A1HG 17L1 9E0 6Z9 N d 9E E H3 OLAJ34 1 1VNIVN1H31 V 13A X3CINI S7001 331A1 13S Esz abed smiatt tolettion t e 11 teenee0A EZO 9E0 6Z9 N d E131dVGV SOH i nJ 991 abed ILL 9E0 6Z9 N d H aioH Foinio N3AIHC1 99 179 e 6 ed 009 ZEO 6Z9 N...

Page 26: ... 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 DNILIV3E1 NIV1d 8L0 9E0 6Z9 N d ClIdVD 33Vd1 131N1 Z IdlAl ...

Page 27: ... 3A1VA 0t7L 9E0 6zg N d 3A1VA 008 LZO 6Z9 N d dIAInd 31 InssaidivvrinDeA LEE abed 19U 9E0 6Z9 N d HOSS38dV 100 9NIEldS 3 V1VA X3CINI S1001 331AE3S a 690 9E0 6Z9 N d 1001 INTAINDITV DNIH331S 01 I 96 ed VZ6 9E0 6zs N d WW 9 H3ACHA3LI ainD 3 VIVA ...

Page 28: ...N INSPECTION CHART Replace Adjust lighten Lubricate Clean I Inspect 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 p...

Page 29: ...HART Replace Adjust Tighten Lubricate Clean I Inspect 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 ...

Page 30: ...el Inspect the drive shaft joints condition Inspect the front rear propeller shaft joint condition Grease the front rear propeller shaft joints Inspect the tie rod ends Inspect shock absorbers for any leaks Lubricate shock absorber spherical bearings X model Inspect and lubricate front suspension arms EVERY 3 000 KM 2 000 MI OR 100 HOURS OF OPERATION OR 1 YEAR whichever comes first Inspect seat be...

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Page 32: ...s Maintenance procedures The following systems should be serviced accord 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 ac...

Page 33: ...nd in air filter housing clean it using a vacuum cleaner Install air filter Install air filter housing cover and latch all clamps Install service cover 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 Muffler cover 2 Exhaust tail pipe Remove and discard the ta...

Page 34: ... arrester for any damage Replace as required For installation reverse the removal procedure However pay attention to the following Install new gasket and retaining screws PART TORQUE Tail pipe retaining screws 11 N m 1 N m 97 lbf in 9 lbf in ENGINE OIL LEVEL VERIFICATION 1 Dipstick 3 Reinstall dipstick screw in it completely 4 Remove dipstick and check oil level It should be near or equal to the u...

Page 35: ... ft 1 lbf ft Replace oil filter Refer to ENGINE OIL FILTER RE PLACEMENT in this subsection Refill engine with recommended engine oil ENGINE OIL CAPACITY 2 2 L 23 25qt U S fig RECOMMENDED ENGINE OIL SEASON TYPE Summer XPS SYNTHETIC BLEND OIL SUMMER GRADE P N 293 600 121 Winter XPS SYNTHETIC OIL WINTER GRADE P N 293 600 112 If recommended XPS oil is not available use a 4 stroke SAE 5W 40 engine oil ...

Page 36: ... Install the filter into the cover Apply engine oil on 0 ring and grease on the end of filter OIL FILTER COVER SCREWS TIGHTENING TORQUE 10 N m 1 N rn 891bf in 9 lbf in RECOMMENDED ENGINE COOLANT COOLANT BRP RECOMMENDED PRODUCT BRP PREMIXED COOLANT P N 219 700 362 ALTERNATIVE OR IF NOT AVAILABLE Distilled water and antifreeze solution 50 demineralized water 50 antifreeze NOTICE Always use ethylene ...

Page 37: ...he coolant expansion tank under the RH front fender COOLANT EXPANSION TANK 1 MAX level 2 MIN level 3 Operating range 8 Add coolant if level is below MIN mark Use a funnel to avoid spillage Do not overfill 9 Properly reinstall coolant expansion tank cap 10 Reinstall service cover NOTE A cooling system that frequently requires addition of coolant is an indication of leaks or en gine problems ENGINE ...

Page 38: ...ant into a suitable container NOTE Take note of the position of the hose clamp on the lower radiator hose at the radiator Section 01 MAINTENANCE Subsection 03 PERIODIC MAINTENANCE PROCEDURES 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 R...

Page 39: ... 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 BLEED SCREW INSTALLATION GASKET RING TORQUE New 4 4 N m to 5 6 N m 39 lbf in to 50 lbfein 6 Continue adding coolant until system is full up to the pressure cap seat in the refill adapter 1 Cooling system refill adapter...

Page 40: ...ssure cap 16 Check coolant level in the coolant expansion tank and fill to the MIN level as required 17 Run engine at idle with the pressure cap ON until the cooling fan cycles on for a second time 18 Stop the engine and let it cool down 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...

Page 41: ... COOLANT SPECIFIC GRAVITY CHECKas detailed in this subsection 5 Carry out a PRESSURE CAP TESTas detailed in this subsection 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 serv...

Page 42: ... 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 EXHAUST 0 11 mm to 0 19 mm 0043 in to 0075 in INTAKE 0 06 mm to 0 14 mm 0024 in to 0055 in If the valve clearance is out of specification adjust valves as follows tmr201 1 044 N...

Page 43: ... cracks fraying or abnormal wear Replace if necessary Check drive belt width at cord level Replace if it is out of specification see table below DRIVE BELT WIDTH SERVICE LIMIT I 30 mm 1 181 in 1 Drive belt 2 Cord in drive belt 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...

Page 44: ...earbox 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 condition inside the gearbox See TROU BLESHOOTING in this subsection Clean the magnetic drain plug from metal shav ings and dirt Presence of debris gives an indica tion of failure inside the gearbox Check...

Page 45: ...em leaks must be repaired Dam aged worn or leaking fuel system com ponents should be replaced to ensure fuel system tightness FUEL PUMP PRESSURE TEST Refer to FUEL TANK AND FUEL PUMP subsec tion for procedure FUEL PUMP PREFILTER CLEANING 1 Remove fuel pump from fuel tank refer to FUEL PUMP REMOVAL in FUEL TANK AND FUEL PUMP subsection 2 Clean the fuel pump prefilter strainer using XPS PARTS AND BR...

Page 46: ...ING 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 NOTE A dirty VSS will cause erratic speedometer readings FRONT DIFFERENTIAL OIL LEVEL VERIFICATION Clean filler plug prior to checking oil level FRONT RIGHT SIDE OF VEHICLE 1 Filler plug With vehicle on a level surface check oil level by removing filler plug O...

Page 47: ...in plug 2 Filler plug Install drain plug Refill the rear final drive RECOMMENDED OIL QUANTITY XPS SYNTHETIC GEAR OIL 75W 140 P N 293 600 140 or a 75W 140 API GL 5 gear oil 350 ml 12 U S oz It is possible to verify the oil level by inserting a wire with a 90 bend through the oil filler hole Oil level is within the following distance from the bottom of oil filler plug threads when the vehicle is lev...

Page 48: ...k for any play 3 If there is any loose replace wheel bearing re fer to STEERING SYSTEM subsection NOTE To properly locate play during this inspec tion be sure to check other components for wear or loose ball joints suspension pivots etc If necessary repair or replace all defective parts before checking the wheel bearing condition Be careful not to misjudge loose in the ball joint and loose in the ...

Page 49: ...lustrated 5 Install 0 rings then shock sleeves 6 Install shock absorber FRONT SUSPENSION ARM LUBRICATION Lubricate suspension arm at grease fittings SUSPENSION ARM LUBRICATION SUSPENSION GREASE P N 293 550 033 UPPER SUSPENSION ARM 1 Grease fitting FRONT SUSPENSION ARM INSPECTION Check suspension arm for Cracks Pitting Bending Distortion Check suspension arm for abnormal play Side to side Up and do...

Page 50: ...er for cleaning them 3 Lubricate caliper sliders and pins using an appropriate BRAKE CALIPER SYNTHETIC GREASE Brake Disc 1 Check brake disc as follows Check disc thickness Check disc surfaces Check disc warpage NOTE Refer to BRAKE DISC INSPECTION in BRAKES subsection for details 2 Clean brake disc using XPS PARTS AND BRAKES CLEANER P N 219 701 705 Master Cylinder 1 Check master cylinder as follows...

Page 51: ...it 2 Install the VACUUM PRESSURE PUMP P N 529 021 800 onto caliper bleeder 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 oth...

Page 52: ...dure 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 mount...

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Page 54: ...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 ...

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Page 56: ...TABILIZER 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 Engine Internal Lubrication Engine internal parts mu...

Page 57: ...l 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 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 In...

Page 58: ... s a t engine Drain the entire air intake sys em Inspect the throttle body Remove parts as required Replace the air filter tmr2011 006 Drain inspect and clean the CVT Empty muffler removal required Unplug ECM connectors and open fuse boxes Check for presence of water Dry as necessary Replace the engine oil without starting the en gine Remove spark plugs Crank engine in drowned mode to expel any wa...

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Page 60: ...35 9 lbf n 4 9 0 4 N rn 43 4 lbf in 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 imr2011 007 001 a mmr2011 007 37 ...

Page 61: ...IN TRODUCTIONsubsection 3 Unplug the BLACK cable from battery then the RED cable NOTICE Always unplug battery cables ex actly in the specified order the BLACK cable first 4 Remove the front section of the cage 5 Remove seats 6 Refer to BODYsubsection and remove the fol lowing plastic parts Upper and lower consoles LH and RH lateral console panels Under seat storage compartment Fuel tank cowl Glove...

Page 62: ...TS 2 Coolant plastic housing 22 Detach the shifter cable from its bracket and remove it 23 Remove the upper engine support with its rub ber isolator 7 Rubber isolator is located between frame and engine support 24 Disconnect the CVT inlet duct from the CVT cover 25 Disconnect the crankcase vent hose 26 Unplug all remaining connectors and remove required cables from engine Cut all necessary locking...

Page 63: ...the reverse of the removal pro cedure However pay attention to the following Prior to install engine inspect condition of engine mounts 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 fr...

Page 64: ...Section 02 ENGINE CVT AND GEARBOX Subsection 02 AIR INTAKE SYSTEM AIR INTAKE SYSTEM SERVICE PRODUCTS Description Part Number Page LOCTITE 5910 293 800 081 44 tmr2011 008 41 ...

Page 65: ...6 1 N rn ky L 53 9 lbf in 2 5 0 5 1 l rn 22 4 lbf in Section 02 ENGINE CVT AND GEARBOX Subsection 02 AIR INTAKE SYSTEM AIR FILTER HOUSING To Throttle Body To PTO cover tm r2011 008 001 _a 42 tmr2011 008 ...

Page 66: ... 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 AIR FILTER HOUSING Air Filter Housing Removal 1 Remove the following parts 1 1 Service cover 1 Service cover 1 2 RH inner panel FROM INSIDE OF COCKPIT PASSENGER SIDE 1...

Page 67: ...llation 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 1 Intake adapter recess into air filter housing notch TORQUE Gear clamps 2 5 N rn 0 5 N m 22 lbfein 41bf in Air filter housing...

Page 68: ... 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 Section 02 ENGINE CVT AND GEARBOX Subsection 03 EXHAUST SYSTEM EXHAUST SYSTEM tmr2011 009 45 ...

Page 69: ...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 PROCEDURES SPARK ARRESTER For spark arrester servicing refer to PERIODIC MAINTENANCE PROCEDURES subsection MUFFLER 1 Muffler Muffler Rem...

Page 70: ...tment 2 Remove the following parts Springs from Y exhaust pipe Imr2011 009 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 Rub...

Page 71: ...t 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 ...

Page 72: ...ATION 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 ...

Page 73: ...bf ft Loctite 24 3 6 0 7 N rn 53 6 lbf iin 10 1 N rn 89 9 lbf in Engine oil Engine oil 4ite 0 Loctite 243 7 0 5 N rn 62 4 lbf in gpyi Component must be replaced when removed 12 1 N m 106 9 lbf in 8 1 N m 71 9 lbf in Loctite 243 Section 02 ENGINE CVT AND GEARBOX Subsection 04 LUBRICATION SYSTEM COMPONENTS TnIr201 GM d 50 tmr2011 010 ...

Page 74: ...UBRICATION 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 ...

Page 75: ...ications check the points described in TROUBLESHOOT ING section Remove oil pressure gauge and adapter hose NOTE To remove adapter hose from oil pressure gauge use the DISCONNECT TOOL P N 529 035 714 Reinstall the oil pressure switch TROUBLESHOOTING LOW OR NO OIL PRESSURE 1 Oil level is too low Refill engine with recommended engine oil Re fer to OIL LEVEL VERIFICATION in the PERIODIC MAINTENANCE PR...

Page 76: ...ace valve stem seals 3 Worn piston rings blue exhaust smoke Replace piston rings PROCEDURES OIL COOLER Oil Cooler Removal Drain engine oil Refer to ENGINE OIL CHANGE in the PERIODIC MAINTENANCE PROCEDURES subsection Drain coolant Refer to COOLING SYSTEM sub section Remove oil cooler retaining screws 1 Retaining screws 2 Oil cooler Place rags or towels under oil cooler to catch re maining oil and c...

Page 77: ...he resistance be tween as shown OPS CONNECTOR ENGINE NOT RUNNING ENGINE RUNNING PIN RESISTANCE S2 4 Engine ground Close to 0 52 normally closed switch Infinite open when pressure reaches 20 kPa to 40 kPa 2 9 PSI to 5 8 PSI 54 If resistance values are incorrect replace the oil pressure switch If the values are correct check wiring Oil Pressure Switch Removal Unplug the oil pressure switch connector...

Page 78: ...pring for free length 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 NOTE At installation always replace the gasket ring of the plug screw by a new one OIL PUMP The oil pump is located on the eng...

Page 79: ...ther 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 Oil pump bore 2 Outer rotor 3 Oil pump shaft 4 Needle pin 5 Inner rotor Check inner rotor for corrosion pin holes or other damages If so replace oil pump shaft assembly 1 Pittings on the teeth Using a fee...

Page 80: ...TE When the axial clearance of the oil pump shaft assembly increases the oil pressure de creases tmr2011 010 Oil Pump Installation For installation reverse the removal procedure Pay attention to the following details NOTE The outer rotor and inner rotor are marked When installing make sure both markings are on the outer side TYPICAL 1 Markings After reinstallation of the remaining parts check for ...

Page 81: ...er 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 TO...

Page 82: ... 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 LOCTITE 243 BLUE 413 293 707 800 000 060 78 66 tmr2011 011 59 ...

Page 83: ...n 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 Section 02 ENGINE CVT AND GEARBOX Subsection 05 COOLING SYSTEM RADIATOR 8008 Engine IZE3 Component must be replaced when removed trn12011 011 1CO_a 60 tmr2011 011 ...

Page 84: ...7 4 lbf in Engine 3 0 5 Wm 27 4 lbf in j 10 2 N m 10 8 I 8 18 lbf in 1 _ 4 tr _ 3 0 5 N rn 27 4 lbf in Engine Imm Component must be replaced when removed I 2011011 101_a Section 02 ENGINE CVT AND GEARBOX Subsection 05 COOLING SYSTEM RADIATOR 1000 Engine tmr2011 011 61 ...

Page 85: ...te 111 5 _t 0 6 N rn 44 5 lbf in 411111 Loctite 243 5 0 6 N rn 44 5 lbf in 6 0 7 N rn 53 6 lbf in 6 0 7 NI rn 53 6 lbf in 0 111 16 2 N rn 142 18 lbfqn Loctite 243 CTS See EFI Section 02 ENGINE CVT AND GEARBOX Subsection 05 COOLING SYSTEM WATER PUMP 800R Engine imr2011 011002a 62 tmr2011 011 ...

Page 86: ...bf in 0 Loctite 243 6 0 7 N m 53 6 lbf in Loctite 243 5 0 6 Nem 44 5 lbf in 20 2 Nem 15 1 lbf ft 10 1 N m 89 9 lbf in Engine oil 2 5 0 3 N m 22 3 lbf in CZ Molycote 111 Section 02 ENGINE CVT AND GEARBOX Subsection 05 COOLING SYSTEM WATER PUMP 1000 Engine tmr2011 011 001_0 tmr2011 011 63 ...

Page 87: ...locking fasteners etc PROCEDURES THERMOSTAT The thermostat is a single action type Thermostat Location 8008 Models The thermostat is located in the thermostat hous ing at the top of the front cylinder RH side TYPICAL THERMOSTAT LOCATION 800R MODELS 1 Front cylinder 2 Thermostat housing 1000 Models The thermostat is mounted in line in the cooling system circuit There are two possible locations see ...

Page 88: ...r hose lower hose RH side similar 2 Drain remainder of cooling system refer to PERIODIC MAINTENANCE PROCEDURES 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...

Page 89: ...6 N rn 0 6 N rn 531bf in 5Ibf in 1000 Models Reverse removal procedures All Models Refill cooling system Bleed cooling system refer to PERIODIC MAIN TENANCE PROCEDURES subsection 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 pres...

Page 90: ...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 1 C...

Page 91: ... 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 TERMINAL RESISTANCE 30 87 Open circuit OL 4 Connect battery as shown and probe relay again as follows TERMINAL RESISTANCE 30 87 0 5 C2 max continuity If relay failed any test replace it RADIATOR COOLING FAN Radiator Cooling Fan Operation The ECM controls the ...

Page 92: ...underneath the dashboard on the driver s side 1 Cooling fan fuse Fuel Pump 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 Radiator Cooling Fan Test...

Page 93: ...Harness and connectors good NO Repair or replace defective part s YES 4 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 dure WATER PUMP HOUSING It is located...

Page 94: ...eads 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 cedure NOTICE Be careful not to damage impeller fins during installation WATER PUMP SHAFT AND SEALS Rotary Seal and Oil Seal Removal Assemb...

Page 95: ...CE Be careful not to damage the crankcase while removing outer part of the rotary seal 4 Thoroughly remove carefully sealing residue and burr of rotary seal using a scraper NOTICE Be careful not to damage water pump shaft 1 Scraper 5 Install 2 wooden screws in the seal 1 Wooden screws 2 Oil seal 6 Remove oil seal from crankcase by puling screws with pliers 72 tmr2011 07 1 ...

Page 96: ...STALLATION 4 Ensure that the oil seal is properly seated in wa ter pump cavity 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 2 Place rotary seal onto water pump shaft and pull out water pump shaft by hand NOTICE Do not install the rotary seal com plete...

Page 97: ...surface If required grind the pusher bolt 1 4 x tubes 70mm 2 75in length 2 4 x screws M6 x 85 3 Plane surface on pusher bolt 8 Apply a little grease at the end of tool pusher bolt 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 ...

Page 98: ...8 flat washer P N 420 227 935 onto water pump shaft 17 Install M8 x 1 25 nut P N 233 281 414 onto water pum p shaft 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 ROTARY SEAL PROPERLY SEATED ON CRANKCASE 19 Place a robust M8 flat washer onto wate...

Page 99: ...rmediate driven gear on water pump shaft 1 Circlip 2 Water pump gear 3 Remove the Water pump intermediate driven gear Needle pin Thrust washer 1 Water pump intermediate driven gear removed 2 Needle pin 3 Thrust washer 4 Using a soft hammer push out water pump shaft with inner portion of rotary seal from inside of crankcase MAG side 1 Water pump shaft 2 Crankcase MAG side 5 To remove outer part of ...

Page 100: ...rifices for oil seal removal Water Pump Shaft Seal Inspection Disassembled Engine Inspect water pump gear for wear and damage on the snap mechanism to the needle pin Replace if damaged Check water pump intermediate drive gear for wear or broken teeth Replace if damaged NOTICE Never use the circlip a second time Always install a NEW one 1 Water pump intermediate drive gear 2 Circlip 3 Intermediate ...

Page 101: ...usher When installing the oil seal on the pusher make sure the sealing lip points outwards Push NEW oil seal in place 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 Apply engine oil on the water pump shaft and in termediate shaft Slide water pump shaft with the new rotary seal into crankcase To properly install water pump sh...

Page 102: ...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...

Page 103: ......

Page 104: ...AFT 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 ...

Page 105: ... lubricant 25 3 N m 18 2 lbf ft tmr2011 012 001_a 10 1 N m 89 9 lbf in 11 1 N m 97 9 lbf in 150 10 N m 111 7 lbf ft See ELECTRONIC FUEL INJECTION EFI 6 0 7 N m 53 6 lbf in Drei Bond sealing compound Loctite 243 so 4 0 3 N m 35 3 lbf in Engine oil Loctite 648 5 30 2 N m 22 1 lbf ft Engine oil 82 tmr2011 012 ...

Page 106: ...tie raps Disconnect magneto connector Remove dipstick and oil level tube with 0 rings 1 Dipstick 2 Oil level tube 3 Crank position sensor CPS 4 0 rings Remove magneto cover retaining screws 1 Magneto cover 2 Retaining screws Pull out magneto cover Magneto Cover Inspection and Cleaning Check magneto cover for cracks or other damage Replace if necessary NOTE Clean all metal components in a non ferro...

Page 107: ...r Access Refer to BODYand remove upper console 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 TERMINAL RESISTANCE 20 C 68 F 1 and 2 0 15 0 30 S2 1 and 3 2 and 3 TYPICAL 6 If any reading is out of specificati...

Page 108: ...age as per following table TEST ENGINE SPEED TERMINAL VOLTAGE 4000 RPM 1 and 2 10 25 Vac 1 and 3 2 and 3 tmr2011 012 7 If voltage is lower than specification replace stator 8 Re plug connectors properly Stator Removal Remove MAGNETO COVER See procedure in this subsection Remove screws securing the wire holding strip Remove stator retaining screws then the stator Stator Inspection Check stator wind...

Page 109: ...ot clogged 1 Rotor 2 Oil bore Check keyway of the rotor for wear or damages Check if trigger wheel teeth are bent or otherwise damaged 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 Screw magneto puller bolt to remove rotor Rotor Inspection Insta...

Page 110: ...clutch gear 1 Starter double gear 2 Sprag clutch gear 3 Intermediate gear SPRAG CLUTCH Sprag Clutch Removal Remove MAGNETO COVER See procedure in this subsection Heat screws in order to break the Loctite Loosen sprag clutch housing screws located in side rotor 1 Sprag clutch 2 Sprag clutch housing 3 Sprag clutch gear 4 Apply engine oil here Slide rotor onto crankshaft The woodruff key and the keyw...

Page 111: ... installation reverse the removal procedure Pay attention to the following details Apply LOCTITE 648 GREEN P N 413 711 400 on threads of sprag clutch housing screws Install screws but do not torque yet Apply engine oil on sprag clutch and inside sprag clutch gear hole 1 Sprag clutch 2 Sprag clutch housing 3 Sprag clutch gear 4 Apply engine oil here Install rotor then torque sprag clutch housing sc...

Page 112: ...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 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 a...

Page 113: ...f ...

Page 114: ... 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 ...

Page 115: ...9 9 lbf in 10 1 N m 89 9 lbf in 6 0 7 Nom 53 6 lbf in Loctite 243 Engine i oil 10 1 N m 89 9 lbf in Loctite 243 6 0 7 N m 53 6 lbf in Engine oil See ELECTRONIC FUEL INJECTION EFI Engine oil 20 2 5 Nem 15 2 lbf ft Section 02 ENGINE CVT AND GEARBOX Subsection 07 TOP END INTAKE MANIFOLD ynr2011 013 001a 92 tmr2011 013 ...

Page 116: ...in 12 1 N m 106 9 lbf in See tightening procedure Engine oil 12 1 N m 106 9 lbf in Component must be replaced 6 Engine oil Loctite 648 when removed 10 1 N rn 89 9 lbf in Section 02 ENGINE CVT AND GEARBOX Subsection 07 TOP END CYLINDER HEAD NO 1 tmr2011 013 002a tmr2011 013 93 ...

Page 117: ...e See tightening procedure 20 2 N m 5 1 5 lbf ft See Ignition System Engine oil 6 Engine oil 10 1 N rin 89 9 lbf in Engine oil 6 6 Loctite 648 Component must be replaced when removed 0 Section 02 ENGINE CVT AND GEARBOX Subsection 07 TOP END CYLINDER HEAD NO 2 tmr2011 013 003_a 94 tmr2011 013 ...

Page 118: ...Section 02 ENGINE CVT AND GEARBOX Subsection 07 TOP END CYLINDERS AND PISTONS Imr2011 013 95 ...

Page 119: ...uts cotter pin etc must be replaced When disassembling parts that are duplicated in the engine e g valves it is a strongly rec ommended to note their position PTO MAG side front rear cylinder and to keep them as a 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 caus...

Page 120: ...n is at ignition TDC To turn crankshaft there are two possible proce dures First Procedure Turn the drive pulley Second Procedure 1 Remove plug screw with 0 ring from magneto cover 2 Use a 14 mm Allen key and turn crankshaft NOTE If a dial gauge is not available use a screw driver or another similarly suitable tool 1 Marks on camshaft timing gear 2 Cylinder head base Leak Test Connect to adequate ...

Page 121: ...rews 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 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...

Page 122: ...ING SCREWS TIGHTENING TORQUE 20 N rn 2 5 N m 15 lbfeft 2 lbf ft Enable fuel pump using B U D S VALVE COVER Valve Cover Removal To remove cylinder 1 valve cover remove plenum Remove valve cover screws of valve cover 1 Valve cover screws 2 Valve cover Remove valve cover and gasket 1 Valve cover 2 Gasket Repeat the procedure for the other valve cover if required Valve Cover Inspection Check the gaske...

Page 123: ...o TIMING CHAIN subsection Remove timing chain tensioner and camshaft tim ing gear refer to TIMING CHAIN subsection Remove pan head screw and camshaft retaining plate 1 Rocker arm shaft 2 Rocker arm exhaust side 3 Rocker arm intake side 4 Adjustment screw 5 Lock nut Remove rocker arm assembly exhaust side and intake side with adjustment screws and lock nuts Remove thrust washers Remove rocker arm s...

Page 124: ...heck adjustment screws for free movement cracks and or excessive play 1 Free movement of adjustment screw top Rocker Arm Shaft Check for scored friction surfaces if so replace parts Measure rocker arm shaft diameter A Measure rocker arm shaft diameter here ROCKER ARM SHAFT DIAMETER NEW 12 00 mm to 12 018 mm 4724 in to 4731 in SERVICE LIMIT 11 990 mm 472 in Any area worn excessively will require pa...

Page 125: ...al 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...

Page 126: ...shaft bearing journal spark plug side Cylinder Head Installation NOTE Never invert front and rear cylinder heads On the 800R cylinder heads are not identical For installation reverse the removal procedure Pay attention to the following details Ensure dowel pins are in place NOTICE Timing chain guide fixed has to be fixed between cylinder and cylinder head TYPICAL 1 Timing chain guide tensioner sid...

Page 127: ... equipped with two different camshafts 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 Each camshaft is different in design Thus it is im portant not to mix up any parts of the camshaft as sembly with that of the other cylinder Keep parts as a group Remove valve cover see VALVE COVER in t...

Page 128: ...NEW 32 950 mm to 33 150 mm 1 2972 in to 1 3051 in SERVICE LIMIT 32 930 mm 1 2965 in CAMSHAFT LOBE INTAKE NEW 32 890 mm to 33 090 mm 1 2949 in to 1 3028 in SERVICE LIMIT 32 870 mm 1 2941 in 1000 CAMSHAFT LOBE EXHAUST NEW 32 860 mm to 33 060 mm 1 294 in to 1 302 in SERVICE LIMIT 32 840 mm 1 293 in CAMSHAFT LOBE INTAKE NEW 32 960 mm to 33 160 mm 1 298 in to 1 306 in SERVICE LIMIT 32 940 mm 1 297 in C...

Page 129: ...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 lead to engine damage Place the camshaft retaining plate in the slot of the camshaft Compress valve spring using VALVE SPRING COM PRESSOR P N 529 035 724 and VALVE SPRING COMPRESSOR CUP P N 529 035 764 A WARNING Always wear safety glasses when disasse...

Page 130: ...9 00 mm 1 535 in Replace valves springs if not within specifications 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 v...

Page 131: ...als whenever valves are re moved Valve Inspect valve surface check for abnormal stem wear and bending If out of specification replace by a new one VALVE OUT OF ROUND INTAKE AND EXHAUST VALVES NEW 0 005 mm 0002 in 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 r...

Page 132: ...e 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 VALVE SEAT CONTACT WIDTH EXHAUST VALVE NEW 1 25 mm to 1 55 mm 049 in to 061 in SERVICE LI...

Page 133: ...see CYLINDER HEAD in 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 remover 2 Valve guide Valve Guide Inspection Always replace valve stem seals whenever valve guides are removed Clean the valve guide bor...

Page 134: ...nsure to seat valves properly Apply marking paste to ease checking contact pattern Repeat procedure until valve seat valve face fits together CYLINDER Cylinder Removal Remove chain tensioner see CHAIN TENSIONER in the TIMING CHAIN subsection 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 cyl...

Page 135: ...Take the same measuring points like de scribed in CYLINDER TAPER above A Perpendicular to crankshaft axis B Parallel to crankshaft axis 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 Cr...

Page 136: ...ove one piston circlip and discard it 1 Piston circlip NOTE The removal of both piston circlips is not necessary to remove piston pin Push piston pin out of piston 1 Piston 2 Piston pin Detach piston from connecting rod Piston Inspection Inspect piston for scoring cracking or other dam ages Replace piston and piston rings if neces sary Using a micrometer measure piston at 8 mm 315 in perpendicular...

Page 137: ...used piston is not worn If clearance exceeds specified tolerance replace piston by a new one and measure piston cylinder clearance again NOTE Make sure the cylinder bore gauge indica tor is set exactly at the same position as with the micrometer otherwise the reading will be false Connecting Rod Piston Pin Clearance Using synthetic abrasive woven clean piston pin from deposits Inspect piston pin f...

Page 138: ... piston pin Insert piston pin into piston and connecting rod For each cylinder install piston with the punched arrow on piston dome is pointing toward the rear side of the engine Front cylinder Mark on top of piston must show to intake side Rear cylinder Mark on top of piston must show to exhaust side 1 Piston of cylinder 1 2 Mark on piston must show to intake side of cylinder 1 3 Piston of cylind...

Page 139: ... properly CORRECT POSITION OF THE PISTON CIRCLIP PISTON RINGS Ring Removal Remove the piston see PISTON in this subsec tion 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 NEW 0 03 mm to 0 07 mm 0012 in to 0...

Page 140: ...feeler gauge check ring end gap Replace ring if gap exceeds above described specified tol erance Ring Installation For installation reverse the removal procedure Pay attention to the following details 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 ...

Page 141: ......

Page 142: ...MING CHAIN TIMING CHAIN SERVICE TOOLS Description Part Number Page CAMSHAFT TIMING TOOL CRANKSHAFT TDC POSITION TOOL 529 529 036 036 201 200 123 124 126 128 SERVICE PRODUCTS Description Part Number Page LOCTITE 243 BLUE 293 800 060 124 tmr201 1 045 119 ...

Page 143: ...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 Section 02 ENGINE CVT AND GEARBOX Subsection 08 TIMING CHAIN TIMING CHAIN Irnr2011 045 001 120 tmr2011 045 ...

Page 144: ... chain tensioner 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 dam...

Page 145: ...ke sure that the camshaft timing gear can be moved back and forth 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 camshaft timing gear Screw the plunger in an additional 1 8...

Page 146: ...ar 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...

Page 147: ...ING CHAIN TENSIONER in this subsection Apply LOCTITE 243 BLUE P N 293 800 060 on the camshaft timing gear retaining screw threads Install and tighten camshaft timing gear retaining screws to specified torque NOTICE Crankshaft and camshaft must be locked at TDC ignition position to place camshaft timing gear and timing chain in the proper position Place camshaft timing gear along with the timing ch...

Page 148: ... covers of both cylinders Remove the plug and 0 ring of magneto cover 1 CPS 2 Screw Use a 14 mm Allen key to turn crankshaft until piston 2 rear is at TDC ignition 1 Allen key 14 mm When rear piston is at TDC ignition marks on magneto flywheel 2 and on the magneto cover are aligned Section 02 ENGINE CVT AND GEARBOX Subsection 08 TIMING CHAIN 1 Plug 2 0 ring Remove the crankshaft position sensor CP...

Page 149: ...ar 2 Cylinder head base To lock crankshaft at TDC ignition proceed as fol lows Insert CRANKSHAFT TDC POSITION TOOL P N 529 036 200 in CPS orifice to lock crankshaft in posi tion Make sure to match the crankshaft TDC position tool teeth with the magneto rotor shape 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 pu...

Page 150: ...t 280 counterclockwise until marks on magneto fly wheel 1 and magneto cover are aligned CYLINDER 1 AT TDC IGNITION 1 Mark 1 on magneto flywheel 2 Notch on magneto cover 3 Location of crankshaft position sensor NOTE At TDC ignition the printed marks on the camshaft timing gear have to be parallel to cylin der head base as per following illustration TYPICAL 1 Printed marks on camshaft timing gear 2 ...

Page 151: ... 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 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 ti...

Page 152: ... excessive radial play CHECKING TIMING CHAIN RADIAL PLAY Check chain condition for wear and teeth condi tion 1 Timing chain If chain is excessively worn or damaged replace it as a set camshaft timing gear and timing chain Check timing chain guides for wear cracks or de forming Replace as required NOTE Check also the timing chain guide ten sioner side Timing Chain Installation The installation is e...

Page 153: ...nsioner 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 ...

Page 154: ...35 617 146 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 LOCTITE CHISEL GASKET REMOVER 293 413 800 708 081 500 136 136 tmr2011 014 131 ...

Page 155: ...antiseize lubricant 4 Super Lube grease 4 Loctite 5910 4 Section 02 ENGINE CVT AND GEARBOX Subsection 09 BOTTOM END ENGINE DRIVE SHAFT Engine oil Loctite 5910 10 1 N m 6 89 9 lbf in 4 Super Lube grease trnr2011 014 001a 132 tmr2011 014 ...

Page 156: ...t 10 1 N rrl Super 89 9 lbf ri Lube grease 5 0 6 N rn 44 5 lbf in 25 3 Nl rn 18 8 lbf ft 0 Engine oil 0J Engine oil 10 1 NI rri 89 9 lbf in Loctite 243 Engine oil Super Lube grease Section 02 ENGINE CVT AND GEARBOX Subsection 09 BOTTOM END CRANKCASE AND PTO COVER tmr2011 014 133 ...

Page 157: ...n Loctite 243 Engine oil See torquing procedure inside See torquing procedure inside Engine oil 1141111110 1 11 rn 89 9 lbf in it Section 02 ENGINE CVT AND GEARBOX Subsection 09 BOTTOM END CRANKSHAFT Loctite 243 11 m2011 014 003a 134 tmr2011 014 ...

Page 158: ...ove the engine Refer to ENGINE REMOVAL AND INSTALLATIONsubsection To remove the rear oil seal the gearbox has to be removed from the engine Refer to GEARBOX AND 4X4 COUPLING UN Tsubsection To replace drive shaft oil seals the bearing cover has to be removed For bearing cover removal and installation refer to ENGINE DRIVE SHAFT REMOVAL INSTALLATION in this subsection FRONT OF ENGINE 1 Water pump co...

Page 159: ...y Engine Drive Shaft Installation 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 fi...

Page 160: ... 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 NOTICE Avoid scoring surfaces with tool 1 PTO cover 2 Oil seal PTO O...

Page 161: ... Driven pulley CVT air guide Disconnect vent hose Remove PTO cover screws and pull PTO cover PTO Cover Inspection Check the PTO cover for cracks or other damage Replace PTO cover if damaged Clean oil breather bore in PTO cover from contam inations with part cleaner then use pressurized air to dry it A WARNING Always wear skin and eye protection Chem icals can cause skin rash skin burns and se vere...

Page 162: ...earings 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 PLAIN BEARING REMOVER INSTALLER PTO COVER The PTO cover has to be supported from below with suitable support with straight surface in or der to prevent damage of the s...

Page 163: ...in bearings must be positioned near to oil bore in counter clockwise direction 1 Partition 2 PTO cover inside 3 Oil bore PTO Cover Installation For installation reverse the removal procedure Pay attention to the following details NOTE At installation replace PTO cover gasket and oil seal Tighten PTO cover screws following the illustrated sequence TIGHTENING SEQUENCE DRIVE GEARS The drive gears are...

Page 164: ...uipped with a breather gear which prevents engine oil coming out through the breathing system into the air intake system Check if oil seal is brittle hard or damaged Re place if necessary Drive Gear Installation The installation is essentially the reverse of the re moval procedure Adequately oil the ball bearing of the breather gear CRANKCASE Crankcase Disassembly 1 Refer to PERIODIC MAINTENANCE P...

Page 165: ...using 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 1 Electric starter 2 Screw NOTE Before splitting the crankcase measure crankshaft axial play Refer to CRANKSHAFT Remove retai...

Page 166: ...G SERVICE LIMIT I 42 100 mm 1 6575 in Clean crankcase using a part cleaner Dry crankcase using compressed air Blow the oil supply lines Oil Strainer Clean the engine oil strainer same procedure as for the crankcase Crankcase Inspection Check crankcase halves for cracks or other dam age Replace if damaged Check main bearings in MAG and PTO crankcase half for scorings or other damages Plain Bearing ...

Page 167: ...crankcase support sleeve under crankcase halves before installing the plain bearings refer to BEARING REMOVAL PROCE DURE Carefully press in the plain bearings in the same di rection as during disassembly from the crankcase inside towards the outside During reassembly make sure not to damage the sealing surfaces of the crankcase halves NOTE Use an 0 ring 0 42 x 1 mm to 1 5 mm 04 in to 06 in thickne...

Page 168: ... Oil the plain bearings before mounting the crank shaft NOTICE Correctly reinstall crankshaft refer to CRANKSHAFT Properly reinstall engine oil strainer and screws Reinstall water pump shaft shafts gears refer to COOLING SYSTEM section Tightening sequence for screws on crankcase is as per following illustration TIGHTENING SEQUENCE CRANKSHAFT 1 Crankcase MAG 2 Crankshaft Crankshaft Locking Procedur...

Page 169: ...Crankcase PTO side front side Use a 14 mm Allen key to turn crankshaft until piston 2 rear is at TDC When rear piston is at TDC marks on magneto fly wheel 2 and on the magneto cover are aligned 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 Screwdriver Lock crankshaft ...

Page 170: ...r otherwise damaged 1 Crankshaft timing gears 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 NEW 0 200 mm to 0 500 mm 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 mea...

Page 171: ...ted initially Carry out the tightening procedure described in CRANKSHAFT ASSEMBL Yin this subsection A Connecting rod big end plain bearing BOOR Engine CRANKSHAFT PIN DIAMETER NEW 40 009 mm to 40 025 mm 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 CLEARANCE SERVICE LIMIT I 0 09 mm 0035 in 1...

Page 172: ...cover Refer to PTO COVER in this sub section 1 Micrometer 2 Crankshaft journal PTO support bearing CRANKSHAFT JOURNAL DIAMETER PTO COVER BEARING NEW 34 016 mm to 34 040 mm 1 339 in to 1 34 in SERVICE LIMIT 34 010 mm 1 339 in CRANKSHAFT RADIAL PLAY PTO COVER BEARING SERVICE LIMIT 0 10 mm 0039 in If crankshaft journal diameter is out of specifica tion replace crankshaft If crankshaft radial play PTO...

Page 173: ...ly They are not reusable 800R Engine Tighten screws in the following sequence CONNECTING RODS SCREWS TIGHTENING SEQUENCE 1 Tighten to 1 2 of specified torque 2 Tighten to 20 N rn 2 Nom 15 lbf ft 1 lbf ft 3 Torque by an additional 60 5 turn using an angle torque wrench NOTE Do not apply any thread locker 1 Angle torque wrench NOTICE Failure to strictly follow this proce dure may cause screw to loos...

Page 174: ...e wrench NOTE Do not apply any thread locker 1 Angle torque wrench NOTICE Failure to strictly follow this proce dure may cause screw to loosen and lead to se vere engine damage Crankshaft Installation 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 Obs...

Page 175: ...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 tmr2011 014 ...

Page 176: ... 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 tmr2011 015 153 ...

Page 177: ...ON CVT Loctite 243 10 1 N rn 89 9 lbf in Isoflex grease Topas NB 52 60 7 N rn 44 5 lbf ft Isoflex grease Topas NB 52 Pulley flange cleaner 00 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 tmr2011 015 ...

Page 178: ...Section 02 ENGINE CVT AND GEARBOX Subsection 10 CONTINUOUSLY VARIABLE TRANSMISSION CVT tmr2011 015 155 ...

Page 179: ...rmed by an authorized Can Am dealer Subcompo 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 Do not use SAE...

Page 180: ...TIGHTENING SEQUENCE CVT COVER SCREWS TIGHTENING TORQUE 7 N m 0 8 Nom 62 lbf in 7 lbf in DRIVE BELT Drive Belt Removal CVT cover and air outlet must be cleaned Remove CVT COVER 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 Drive Belt Installation For installation reverse the removal procedure Pay attention to...

Page 181: ...sliding sheave and governor cup to ensure correct index ation at reinstallation 1 Mark on drive pulley sliding sheave 2 Mark on governor cup Block the drive pulley using one of the following methods First Locking Method Remove spark plugs Lock crankshaft at TDC position Refer to BOT TOM END section Second Locking Method Block drive pulley with the DRIVE PULLEY HOLDER CVT P N 529 006 400 1 Pulley h...

Page 182: ...N Sliding sheave of drive pulley is spring loaded 1 Thrust washer 2 Conical spring washer 3 Drive pulley screw 4 Sliding sheave with governor cup Step 1 Push Slowly release and remove sliding sheave Screw CLUTCH PULLER P N 529 035 746 in fixed sheave to remove fixed pulley NOTICE Make sure to use the specified tool Using another tool will damage the crankshaft threads 1 Drive pulley puller 2 Fixed...

Page 183: ... Use a flat screwdriver if necessary 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 1 Removal direction 2 Assembly direction NOTE Whenever removing a governor cup with already two marked boxes replace it by a new one Sliding Sheave Unscr...

Page 184: ...crankshaft tapered end and the taper inside 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...

Page 185: ... 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 ROLLER OUTER DIAMETER NEW 13 70 mm to 13 80 mm 539 in to 543 in SERVICE LIMIT 13 20 mm 519 in ROLLER INNER DIAMETER NEW 8 05 to 8 15 mm 317 to 321 in SERVICE LIMIT 9 mm 354 in Centrifugal Lever Pivot Bolt Measure diameter of centrifugal lever pivot bo...

Page 186: ...e pulley will oc cur because of levers difference Sliding Sheave Check sliding sheave for cracks and sliding con tact surface for excessive wear Replace sliding sheave if necessary Measure centrifugal lever pivot bolt bores Re place sliding sheave if bores are out of specifica tion or otherwise damaged A Centrifugal lever pivot bolt bore diameter CENTRIFUGAL LEVER PIVOT BOLT BORE DIAMETER NOMINAL ...

Page 187: ...ew 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 1 One way clutch 2 Bearings Measure length of spring sleeves and check if edges on top of the spring sleeve are excessively worn If they out of speci...

Page 188: ...f bearing sleeve 2 Mating surface of slider shoes 3 Vice Each time when replacing the bearing sleeves sign the foreseen box with a punch NOTICE Do not tap too hard Violent damage of the governor cup may appear Section 02 ENGINE CVT AND GEARBOX Subsection 10 CONTINUOUSLY VARIABLE TRANSMISSION CVT NOTICE Rollers must move easily after in stallation Insert slider shoes into governor cup to properly s...

Page 189: ...rew with jobber ones Always use BRP genuine parts for this particular case Section 02 ENGINE CVT AND GEARBOX Subsection 10 CONTINUOUSLY VARIABLE TRANSMISSION CVT To tighten the drive pulley screw lock the drive pulley Refer to the DRIVE PULLEY REMOVAL in this subsection for locking procedures Tighten drive pulley screw to specified torque DRIVE PULLEY SCREW TIGHTENING TORQUE 120 N m 8 N m 89 lbf f...

Page 190: ...e of driven pulley 3 Spring 4 Cam Driven Pulley Disassembly Fixed Sheave Remove retaining ring and lift torque gear 1 Retaining ring 2 Torque gear 3 Fixed sheave of driven pulley Section 02 ENGINE CVT AND GEARBOX Subsection 10 CONTINUOUSLY VARIABLE TRANSMISSION CVT 1 Driven pulley screw 2 Thrust washer 3 Locking washer Remove the driven pulley with the spring and the cam NOTE The following procedu...

Page 191: ...l 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 Section 02 ENGINE CVT AND GEARBOX Subsection 10 CONTINUOUSLY VAR...

Page 192: ...R NOMINAL 30 060 mm to 30 100 mm 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 M...

Page 193: ... SPRING FREE LENGTH SERVICE LIMIT I 125 mm 4 921 in CLUTCH SPRING SQUARENESS SERVICE LIMIT I 3 8 mm 15 in 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 o...

Page 194: ...tance sleeve must face gearbox side 1 0 ring 2 Distance sleeve 3 Chamfered area of distance sleeve Install cam on countershaft end the right way on the countershaft splines 1 Countershaft splines 2 Cam Install sliding sheave into fixed sheave Place spring behind sliding sheave then align driven pulley with cam 1 Cam 2 Spring 3 Sliding sheave 4 Fixed sheave With your hand push the driven pulley on ...

Page 195: ...lbf ft 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 CVT Air Guide Inspection Clean CVT air guide from contamination Check 0 rings if brittle hard or damaged Replace if necessary 7 CVT air guide 2 0 rings CVT ...

Page 196: ...CM 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 ...

Page 197: ...Loctite 5910 3 0 3 N m 27_ 3 lbf in Loctite 243 28 3 N m 21 2 lbf ft 6 0 7 N rn 53 6 lbf in Loctite 243 6 Engine oil 25 3 N m 18 8 lbf ft EWA Engine oil Super Lube grease 6 Loctite 243 10 1 N m 89 9 lbf in Engine oil Engine oil per Lube 0 5 grease 441 5 0 6 N m 44 0 5 lbf in Section 02 ENGINE CVT AND GEARBOX Subsection 11 GEARBOX AND 4X4 COUPLING UNIT GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM ...

Page 198: ...d sensor VSS 4 Actuator 5 4WD indicator switch 1 Center housing 2 Left cover 3 Countershaft 4 Output shaft 5 Shift shaft TROUBLESHOOTING 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 m...

Page 199: ...k 1 from main relay R2 VSS Input Voltage Test 1 Use the FLUKE 115 MULTIMETER P N 529 035 868 and select Vdc 2 Turn ignition switch ON 3 Back probe the VSS connector using FLUKE RIGID BACK PROBE P N TP88 or equivalent 4 Measure voltage as per following table VEHICLE SPEED SENSOR INPUT VOLTAGE TEST TEST PROBES RESULT KEY ON PIN A RED wire P IN C BLACK GREEN wire Battery voltage If voltage is not as ...

Page 200: ...o its values for proper operation A reset must be carried out each time any of the following parts has been replaced Gearbox assembly 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...

Page 201: ... Select an other position P R H or L Re peat substeps 8 2 and 8 3 until all position are verified NOTE The vehicle must be in movement to complete the procedure on R H and L posi tion 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 Set shift leve...

Page 202: ...osition Sensor GBPS GBPS Installation For installation reverse the removal procedure Pay attention to the following details Shift lever must be in the NEUTRAL position Align GBPS with the flat on the shift drum shaft 7 Flat on shift drum shaft Reset the GBPS Refer to GBPS RESET in this subsection 4WD INDICATOR SWITCH 4WD Indicator Switch Access To reach the 4WD indicator switch remove the followin...

Page 203: ...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 Unplug actuator connector Turn ignition key ON Measure vo tage as follows SWITCH POSITION SWITCH WIRE VOLTAGE 2WD WHITE BLUE WHITE Battery voltage 4WD WHITE BLACK If the selector is out of specifications check wires connectors and replace the selector if nec essar...

Page 204: ...lled 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 ...

Page 205: ...on 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 NOTICE Oil seal must be installed with seal ing lip toward gea...

Page 206: ...ore beginning the installation ensure gearbox is set to PARK position Apply SUPER LUBE GREASE P N 293 550 030 on sealing lips Apply engine oil on outer diameter of oil seal to avoid damaging it during installation Place oil seal on output shaft using the OIL SEAL INSTALLER P N 529 036 204 with a flat washer P N 250 200 102 and a M12 x 1 25 x 35 hexag onal screw P N 207 683 544 1 Output shaft oil s...

Page 207: ...te 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 184 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 lift the left cover POS...

Page 208: ...r clockwise and remove index washer 1 Index lever 2 Index washer 3 Shift drum Remove the index lever with washer step ring and spring 1 Washer 2 Index lever 3 Step ring 4 Index spring Main Shaft and Shift Forks Remove bearing pin reverse intermediate gear and thrust washers NOTE Take care not to lose lower thrust washer during removal 1 Bearing pin 2 Reverse intermediate gear 3 Needle bearing 4 Th...

Page 209: ...ifting sleeve HIGH range gear 2 Shift fork Section 02 ENGINE CVT AND GEARBOX Subsection 11 GEARBOX AND 4X4 COUPLING UNIT Remove shifting sleeve HIGH range gear and shift fork 1 Snap ring 2 Free pinion HIGH range gear 3 Free pinion LOW range gear 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 ...

Page 210: ...haft 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 1 5 screws M8 x 55 2 2 screws M6 x 85 3 2 screws M6 x 55 4 8 screws M6 x 35 To remove cover use 2 big screwdrivers POSITION FOR BIG FLAT SCREWDRIVER Shift Shaft and Shift Drum Withdraw shift shaft assembly 7 Shift shaft assembly ...

Page 211: ... AND 4X4 COUPLING UNIT 1 Screw 2 Washer 3 Intermediate gear 4 Dowel pin Remove shift fork shaft Disengage shift forks from shift drum 1 Shift drum 2 Thrust washer Output Shaft and 4x4 Coupling Mechanism Remove output shaft from center housing and withdraw 4x4 coupling sleeve Remove shift drum and thrust washer Remove set screw coupling fork shaft and cou pling fork from right cover 188 tmr2011 016...

Page 212: ...NG 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 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 Remove screw securing the countershaft bearing in the left...

Page 213: ...t dogs and slots Worn shift fork engagement groove Worn splines on shafts and shifting sleeves Bearings Check if ball bearings turn freely and smoothly Check all bearings bearing points tooth flanks and taper grooves Free Pinions NOTE Always replace snap rings and use special pliers to install them DIAMETER FREE PINION NEW 29 000 mm to 29 013 mm 1 1417 in to 1 1422 in SERVICE LIMIT 29 015 mm 1 142...

Page 214: ... 1 Bearing pin A Outer diameter BEARING PIN OUTER DIAMETER NEW 24 987 mm to 25 000 mm 984 in to 984 in SERVICE LIMIT 24 977 mm 9833 in Check countershaft bearing journals for wear A MAG side B Bearing journal CVT side COUNTERSHAFT BEARING JOURNALS MAG SIDE NEW 19 977 mm to 19 990 mm 786 in to 787 in SERVICE LIMIT 19 973 mm 786 in CVT SIDE NEW 24 977 mm to 24 990 mm 983 in to 984 in SERVICE LIMIT 2...

Page 215: ...gs Shift Forks Check both shift forks for visible damage wear or bent shift fork claws Check engagement rollers for wear and smooth movement Measure the shift fork claw thickness I Micrometer A Shift fork claw thickness SHIFT FORK CLAW THICKNESS NEW 5 10 mm to 5 20 mm 201 in to 205 in SERVICE LIMIT 5 00 mm 197 in Shift Fork Shaft Check shift fork shaft for visible damage or wear Check if shift for...

Page 216: ...ess machine only 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 before installing ball bearings Install new o...

Page 217: ...aft assembly with shift fork LOW REVERSE range gear into inner splines of shifting sleeve HIGH range gear Install reverse intermediate gear Finally engage shift forks in shift drum and install shift fork shaft NOTE Run all gears as a final function check be fore installing left housing Index Lever and Index Washer Fit step ring into index lever 1 Index spring 2 Step ring 3 Index lever 4 Washer 5 S...

Page 218: ...ns in their corresponding groove on the shift drum Install shift fork shaft NOTE Turn gears to validate proper operation Sealing Compound Application NOTE Unless otherwise specify the procedure to apply the sealant is the same for right or left cover Clean all metal components in a solvent Gearbox housing mating surfaces are best cleaned using a combination of LOCTITE CHISEL GASKET REMOVER P N 413...

Page 219: ...engage parking lock lever slot onto index washer pin 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 nstall 0 ring including distance sleeve on counter shaft CVT side NOTICE Place 0 ring including distance sleeve right away Chamfered bore of distance sleeve has to face the gearbox COUNTERSHAFT END CVT SIDE 1 0 ri...

Page 220: ...arbox 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 ...

Page 221: ......

Page 222: ... 5 1 5 N rn 137 13 lbf in 24 5 3 5 N rn 18 3 lbfqt 24 5 3 5 N rn 18 3 lbf t CE Model 9 1 N rn 80 9 lbf in Section 02 ENGINE CVT AND GEARBOX Subsection 12 SHIFTER SHIFTER trnr2011 017 100a tmr201 1 017 199 ...

Page 223: ...r 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 1 Refer to BODYsubsection and remove the fol lowing components Seats 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 S...

Page 224: ...5 Tighten shift lever handle nut to specification SHIFT LEVER HANDLE NUT TORQUE 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 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 posi...

Page 225: ... Readjust as required NOTE To properly check shift lever alignment into notch move shift lever toward the RH side then let it return to position SHIFT PLATE Shift Plate Removal NOTE Do not remove shift plate needlessly 1 Remove shifter cable from shift plate 1 Shift plate 2 Shifter cable 2 Index shift plate and shift shaft 10 Test the shifter to confirm that the system works properly in all positi...

Page 226: ...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 SHIFT PLATE ANGLE FROM VERTICAL PLANE A 20 2 5 Adjust shifter cable refer to SHIFTER CABLE AD JUSTMEIVTin this subsection...

Page 227: ...204 ...

Page 228: ...18 100_a COOLING FAN CPS Crankshaft Position Sensor CTS Cooling Temperature Sensor ECM Engine Control Module ETA Electric Throttle Actuator FRONT FUEL PUMP GBPS GearBox Position Sensor IGN COIL Ignition coil IGN SW Ignition switch IN Input INJ 1 Injector 1 INJ 2 Injector 2 MAPTS Manifold Air Pressure Temperature Tensor OPS Oil Pressure Switch OUT Output SEAT BELT SWITCH SPORT SWITCH START SWITCH S...

Page 229: ...res a permanent memory that will store the information on the various ignition keys programmed to the vehicle fault codes cus tomer information and other engine information even when the battery is removed from the vehi cle Diagnostic Mode The ECM features a self diagnostic mode that is activated on system power up ignition key ON for certain systems and components and when the engine is running f...

Page 230: ...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 ...

Page 231: ......

Page 232: ...2 status lights that indicate the connection condition USB and CAN Both lights must be GREEN for the MPI 2 to function prop erly Otherwise refer to the following charts Prerequisite for USB Communication PC Computer turned on MPI 2 connected to PC computer USB LIGHT STATUS WHAT TO DO Light is OFF Check USB connection between MPI 2 and PC computer Check USB operation on PC computer hardware or Wind...

Page 233: ...ed remove the connec tor from the module and test for the following Proper input voltage to the module Ground circuit continuity CAN bus continuity Refer to the applicable WIRING DIAGRAM or appropriate subsection for details 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 TY...

Page 234: ... in its protective cap on the lower RH side of the bat tery rack 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 Connecting the PC to the Vehicle 1 Locate the 6 pin diagnostic connector refer to DIAGNOSTIC CONNECTOR LOCATION in this subsection 2 Dis...

Page 235: ...arry 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 ...

Page 236: ...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 to date the update icon will not appear Refer to the Service Bulletins to see if there is an update available Use the Module submenu and check all modules one at a time to see which module s can be up dated TYPICAL MODULE SUB...

Page 237: ...stic 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 ting in the module by clicking the Write Data button TYPICAL 1 Diagnostic connector in its storage cap NOTICE Failure to secure the diagnostic con nector in its protective cap may result in corro sion or other ...

Page 238: ...ill turn on or blink in the multifunction gauge If the fault that caused the pilot lamp to come on is momen tary the pilot lamp may turn off automatically or may need to be reset by powering down the ve hicle and then restarting it A message may also be displayed to provide ad ditional information related to the fault that turned on the pilot lamp Refer to the following chart PILOT LAMP MULTIFUNCT...

Page 239: ...es may be viewed in the Faults page of B U D S Only fault codes in an active state may be viewed in the multifunction gauge Active Fault Codes An active fault code is an indication of a fault that is presently active The active fault may or may not compromise normal operation of the system s in question as indicated by the fault code s Service action should be taken to correct the problem that cau...

Page 240: ...igital Gauge Proceed as follows to view the active fault codes 1 Turn ignition key to ON with lights position 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 1 M mode button 2 S set button pressed repea...

Page 241: ...ure to view all active fault codes To exit the fault code display function press both the M and S buttons simultaneously LCD Gauge 1 Turn ignition key to ON with lights position GNITION SWITCH POSITION 1 OFF 2 ON with lights 3 ON 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 TYPICAL EH ENGINE HOUR DISPLAY ...

Page 242: ...e 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 TAS Fault If one TAS throttle accelerator sensor signal is missing LIMP HOME MODE will be activated and the check engine light will come ON Pre...

Page 243: ......

Page 244: ...the accelerator pedal demand less if normal mode is selected Vehicle speed is limited to 70 km h 43 MPH Performance Key When a performance key is used engine delivers 100 of the accelerator pedal demand less if nor mal mode is selected The vehicle speed is lim ited to 120 km h 75 MPH Work Key Option When a work key is used engine delivers approxi mately 50 of the accelerator pedal demand less if n...

Page 245: ...me Mode When certain faults are occurring the ECM will enter the limp home mode In this mode the en gine will deliver less than the accelerator pedal de mand PROCEDURES SPORT NORMAL SWITCH Sport Normal Switch Wire Information FUNCTION PIN COLOR Signal to ECM B pin D4 1 BROWN GREEN Ground through ECM to ECM B pin Al 2 ORANGE VIOLET SEAT BELT SWITCH Seat Belt Switch Wire Information FUNCTION PIN COL...

Page 246: ...ng on the pedal position which confirms the TAS signal reaches the ECM ACCELERATOR PEDAL RETAINING NUTS TIGHTENING TORQUE 13 Nom 1 Nom 1151bf in 9Ibf in 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 ...

Page 247: ......

Page 248: ...lectronic fuel injection system EFI is com prised of various sensors used for detecting ongo ing operating conditions of the engine and vehicle and includes all the components that perform the required adjustments to the engine Electrical System ECM Electronic Control Module From input signals the ECM acknowledges driver demands and converts them to an engine torque requirement through calculation...

Page 249: ...rails which are used to secure the injectors to the manifold also provide to the injectors the fuel pressure that they receive from the fuel pump The fuel pressure applied to the fuel rails is regu lated by the fuel pressure regulator located in the fuel pump module Fuel Injectors The fuel injectors are used to inject fuel into the intake ports of the cylinder head One injector is used per cylinde...

Page 250: ...lated Problems It is important to check the following in the elec trical system Battery voltage 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 codes Electrical Connections Pay particular attention to ensure that terminals and pins are not out of their con...

Page 251: ...S If the operation is successful a message will be displayed stating that the reset was successful If an error occurred or a component is out of range a message may be displayed Follow the instructions in the message and repeat the pro cedure 5 Check for fault codes If a fault code is generated carry out the service actions reset the fault and repeat the reset pro cedure 6 Start engine and make su...

Page 252: ...e following Main relay Wiring and connections refer to the WIRING DIAGRAM Continuity Test of ECM Ground Circuits 1 Disconnect connector B from ECM 2 Install the ECM ADAPTER TOOL P N 529 036 166 on ECM B connector 3 Use the FLUKE 115 MULTIMETER P N 529 035 868 and select Q 4 Probe adapter terminals as per following table ECM ADAPTER BATTERY POST RESISTANCE Pins B L1 B M2 and B M3 Ground Close to 05...

Page 253: ...lowing methods If the faulty ECM can be read with B U D S refer to ECM AUTOMATED DATA TRANSFER If the faulty ECM cannot be read with B U D S refer to ECM MANUAL DATA ENTRY ECM Automated Data Transfer 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...

Page 254: ...arts ECM Manual Data Entry 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 2 Collect the information from the vehicle and BOSSWeb 1st Collecting Method Obtaining the Data from a Saved mpem File 1 Use the B U D S NOTE It is not necessary to perform any connec tion The PC computer ...

Page 255: ... 2 Record the following numbers using BOSSWeb Look in Service menu and choose Unit history 1 Vehicle serial number 2 Vehicle model number 3 Customer name 3 Enter the recorded data in the new ECM as de tailed in ENTERING THE COLLECTED INFOR MATION INTO THE ECM Entering the Collected Information Into the ECM 1 Use the applicable B U D S version Refer to COMMUNICATION TOOLS AND B U D S sub section 2 ...

Page 256: ... not enter the M at the beginning of the engine number 3 Customer name VEHICLE TAB 6 Click on the following tabs History Part Replacement Add Part in History 7 Enter the old ECM serial number in the Add Part In History window ADDING PART IN HISTORY I History page tab 2 Part Replacement tab 3 Add part in history button 4 ECM selection 5 Add ECM serial number here NOTE The ECM serial number can be f...

Page 257: ...TION 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 Install a fuel pressure gauge as described in FUEL PUMP PRESSURE TEST of FUEL TANK AND FUEL PUMP subsection 2 Connect vehicle to the applica...

Page 258: ...he fuel injector to be tested TYPICAL 1 Click on injector to activate You should hear the injector functioning This will validate the injector mechanical and elec trical operation If the injector does not function carry out the FUEL INJECTOR RESISTANCE TEST Fuel Injector Resistance Test Disconnect connector A from the ECM Disconnect the engine connector HIC NOTE The HIC connector is located to the...

Page 259: ...nd 12 Vdc REAR TYPICAL If supply voltage is not good check continuity between fuse F5 and injector see WIRING DIA GRAMS NOTE Probe fuse exactly as shown This vali dates fuse at the same time Use a multimeter and set it to Q Read resistance CYLINDER INJECTOR CIRCUIT MEASUREMENT WIRE FRONT VIOLET BLUE Fuse F5 Close to 0 Q REAR If continuity is good check relay and wiring from battery If continuity i...

Page 260: ...ngine oil to 0 rings to ease insertion in rail Install fuel injector with your hand Do not use any tool Position the manifold 0 ring on injector as in fol lowing illustration TYPICAL MANIFOLD 0 RING POSITION Carefully insert injector in manifold paying atten tion to the manifold 0 ring Firmly push injector until it bottoms out Reinstall fuel rail FUEL RAIL Fuel Rail Replacement Fuel Rail Removal 1...

Page 261: ...l 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 FUEL RAIL INSTALLATION INJECTOR 0 RINGS RETAINING SCREW TORQUE NEW Lubricate with engine oil 10 N m 1 N m 89 Ibt in 91bf in After securing fuel hose quick...

Page 262: ...A CAUTION Ensure ignition key is removed so that nobody can activate the electrical sys tem otherwise the ECM would turn on and the throttle actuator ETA would cycle This could cause serious finger injury as the throttle plate moves quickly 6 Gently open throttle plate and hold fully open to reach all surfaces 7 To remove residual dirt spray cleaner on throt tle plate and on bore 8 Reinstall remov...

Page 263: ...ly set TPS may lead to improper idle speed too low or too high poor engine performance poor engine starting and engine stop on deceleration fault codes and possible engine damage Emission compli ance may also be affected 1 Connect vehicle to the applicable B U D S software version refer to COMMUNICATION TOOLS AND B U D S subsection 2 In B U D S select the following Read Data button Setting page ta...

Page 264: ...n the throttle body using a blunt tool without sharp tip A CAUTION Do not move throttle plate with your fingers Otherwise if ECM should turn off it would quickly close the throttle plate which could cause finger injury 1 Push here 8 Check the indication movement again If the indication moves as expected check the throttle accelerator sensor TAS Refer to THROTTLE ACCELERATOR SENSOR TAS in this subs...

Page 265: ...ation 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 Section 04 FUEL SYSTEM Subsection 02 ELECTRONIC FUEL INJECTION EFI TYPICAL LH SIDE OF VEHICLE 1 CPS connector location...

Page 266: ...tance value is incorrect repair the connec tors or replace the wiring harness between ECM connector and the CPS CPS Replacement Disconnect CPS connector and cut harness lock ing tie Remove CPS retaining screw and pull up on CPS to remove it TYPICAL 1 CPS 2 Retaining screw Install new CPS and secure harness with a new locking tie CPS INSTALLATION 0 RING PRODUCT XPS SYNTHETIC GREASE P N 293 550 010 ...

Page 267: ...sure reading while the engine is stopped 4 Perform the same test with a new MAPTS and compare both readings Values have to be within 3 4 kPa 0 5 PSI MAPTS PRESSURE FUNCTION QUICK TEST RESULT SERVICE ACTION NO READING Circuit Continuity Test of MAPTS Pressure Function MAPTS Input Voltage Test Repair or replace wiring VALUE IS OUT OF RANGE Replace MAPTS MAPTS Input Voltage Test Check the voltage out...

Page 268: ...eel same ambient air temperature If there is no reading carry out a MAPTS RESIS 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 MAPTS MEASUREMENT PIN RESISTANCE 52 20 C 68 F 1 I 2 2280 2740 If resistance is not within specification rep...

Page 269: ...bf in LOCTITE 243 BLUE 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 Driver s seat LH lateral console panel 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 ME...

Page 270: ... 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 COOLI...

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Page 272: ...ber 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 ...

Page 273: ...Section 04 FUEL SYSTEM Subsection 03 FUEL TANK AND FUEL PUMP CE Model 6 Component must be replaced when removed 250 tmr2011 023 ...

Page 274: ... disconnect the fuel 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 SYSTEM DESCRI...

Page 275: ...ubsection and remove the fol lowing RH passenger seat RH lateral console panel Fuel tank cover panel 3 Remove the vent hose from the fuel tank vent valve 4 Using the VACUUM PRESSURE PUMP P N 529 021 800 and a short piece of hose pressurize the fuel tank through the vent valve 1 Fuel tank vent valve 2 Vent hose to vacuum pressure pump PRESSURE TIME WITHOUT PRESSURE DROP 14 kPa 2 PSI 3 minutes If pr...

Page 276: ...TER P N 529 036 023 be tween disconnected hose and fuel rail in line installation PRESSURE GAUGE T FITTING 9 Using B U D S reactivate fuel pump by select ing Enabled 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 R...

Page 277: ...3 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 ...

Page 278: ...p Fuel pump runs Replace fuel pump module Repair or replace Fuel pressure less than specifications Fuel pressure within specifications Fuel pressure more than specifications A Fails A Fails Check fuel line rail for leaks OK Perform fuel pump test Crank or start engine Fast pressure drop Fuel pressure less than specifications Fuel pressure more than specifications Fuel pressure within specification...

Page 279: ...hen validate fuel system tightness by performing a fuel pressure test Oetiker Clamp Replacement To secure or cut Oetiker clamps on fuel lines use OETIKER PLIERS P N 295 000 070 1 Securing clamp 1 Securing clamp in limited access FUEL TANK Fuel Tank Draining Remove fuel tank cap and siphon gas into an ap proved fuel container Fuel Tank Removal 1 Drain fuel tank Refer to FUEL TANK DRAINING above in ...

Page 280: ... 12 Pull fuel tank out from the RH side of vehicle Fuel Tank Inspection Inspect fuel tank for any damages or cracks which may result in fuel leaks Inspect tank and protector attachment points for damages Inspect protector for damages If cracks gouges or other damages which may lead to a fuel leak or damages to attachment points that could prevent the tank from being secure are found replace fuel t...

Page 281: ... 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 1 Fuel pump fuse Fuel Pump Input Voltage Test 1 Remove RH passenger seat and fuel tank cover refer to BODYsubsection ...

Page 282: ...the fuel pump fuse 2 Remove connector B from the ECM and con nect it to the ECM ADAPTER TOOL P N 529 036 166 3 Set multimeter to Q 4 Measure fuel pump resistance as follows FUEL PUMP RESISTANCE TEST AT ECM AND FUSE TEST PROBES RESISTANCE C2 20 C 68 F Fuse box contact 5D ECM B M1 Approximately 2 S2 If resistance test failed disconnect fuel pump connector and measure resistance at fuel pump connecto...

Page 283: ...el pump locking ring A WARNING Fuel vapors are flammable and explosive un der certain conditions Use only non spark ing tools 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 sender accuracy 8 Discard gasket ring Fuel Pump In...

Page 284: ...ing ring until it is fully engaged FUEL PUMP LOCKING RING INSTALLATION 1 Notch in locking ring 2 Raised portion in locking ring 5 places 3 Lock position on tank flange 5 places 7 Using B U D S enable the fuel pump 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 FUEL PRESSURE TEST as described in this subsection 9 Check fuel...

Page 285: ...ed replace fuel pump 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 TYPICAL FUEL PUMP 1 Fuel level sender Fuel Level Sender Resistance Test 1 Remove and discon...

Page 286: ...voltage 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 wiring Fuel Level Sender Replacement Replace fuel pump See fuel pump removal and installation procedures in this subsection FUEL TANK VENT VALVE Fuel Tank Vent Valve Test Test for Normal Operati...

Page 287: ...ows freely through the valve when upside down and the vacuum indication does not increase on the pump gauge Fuel Tank Vent Valve Removal and Installation 1 When removing or installing the fuel tank vent valve pay attention to the following Valve lock position index dual Valve unlock position index 1 Lock position index dual 2 Unlock position index 2 Remove the vent hose from the valve 3 Use an ope...

Page 288: ...TAGE REGULATOR RECTIFIER ACCESSORIES RELAY R3 0 0 0 0 0 52 F7 5A SWITCHES ILLUMINATION 2WD 4WD SWITCH WINCH SWITCH STARTER RELAY GAUGE F8 5A IGNITION SWITCH WINCH RELAY COMMUNICATION CONNECTOR 000000 FAN MOTOR FAN RELAY R1 F9 30A OH F13 5A F11 30A F12 15A F10 5A EURO CONTROLS LIGHTS RELAY H I CONSOLE ACCESSORY CONNECTOR 1 DC3 I 12 VOLT POWER OUTLET UNDER DASH ACCESSORY CONNECTOR DC4 COMMUNICATION ...

Page 289: ... A 11 30 A 12 15 A 13 5 A 14 15 A 15 5 A RELAY IDENTIFICATION Relays 1 Cooling fan 2 Main 3 Accessories 4 Headlights 8 Brake lights FUSE BOX 2 FUSE IDENTIFICATION Fuse 1 Main 30 A 2 Fan accessories 40 A Section 05 ELECTRICAL SYSTEM Subsection 01 POWER DISTRIBUTION 266 tmr2011 024 ...

Page 290: ...cation 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...

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Page 292: ... AND FAULT CODES subsection Always refer to the WIRING DIAGRAM when troubleshooting an electrical circuit Refer to POWER DISTRIBUTION for fuse and re lay information 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 ENGINE WILL NOT START ENGINE TURNS OVER 1 Fouled or defectiv...

Page 293: ...W ORANGE D E S S signal E ORANGE RED 12 Vdc output ECM starter solenoid and start switch F BLACK YELLOW Ignition Coil Access Refer to BODYand remove upper console Ignition Coil Installation Install a new elastic nut and tighten to the speci fied torque IGNITION COIL RETAINING BOLT TIGHTENING TORQUE 8 N m 1 N rn 71 lbf in 9 lbf in Quick Test with B U D S Connect to the latest applicable B U D S sof...

Page 294: ...ings 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 PRIMARY CIRCUIT ENGINE NE CONCTOR HIC ECM CONN ECTOR q RESISTANCE 0 20 C 68 F Cylinder 1 front Pin E A M1 3 6 C2 Cylinder 2 rear A M2 If any resistance is not good measure resistance directly on coil If second test is ok check wiring Secondary Wi...

Page 295: ...sis 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...

Page 296: ...receives AC current from the mag neto and transforms it into direct current DC The voltage regulator included in the same unit limits voltage to prevent any damage to electrical components TYPICAL VOLTAGE REGULATOR RECTIFIER 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 e...

Page 297: ...TO SYSTEM subsection TROUBLESHOOTING It is good practice to check for fault codes using the B U D S software as a first troubleshooting step Refer to DIAGNOSTIC SYSTEM AND FAULT CODES subsection BATTERY REGULARLY DISCHARGED OR WEAK 1 Loose or corroded battery cables connections Tighten or repair battery cables connections 2 Worn or defective battery Charge and test battery 3 Defective magneto stat...

Page 298: ...s into the test check battery voltage TIME TO MEASURE INTO TEST VOLTAGE 14 seconds Min 10 5 Vdc 20 C 68 F Battery Removal 1 Disconnect BLACK cable first then the RED cable NOTICE Always respect this order for re moval disconnect BLACK cable first 2 Remove battery strap retaining nut 1 Battery strap 2 Battery strap retaining nut 3 Unhook the top of battery strap 4 Remove battery Battery Cleaning Cl...

Page 299: ...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 ...

Page 300: ...the ignition switch is left ON for more than 15 minutes engine will not start unless igni tion switch is turned OFF then ON again TROUBLESHOOTING It is good practice to check for fault codes using the B U D S software as a first troubleshooting step Refer to DIAGNOSTIC SYSTEM AND FAULT CODES subsection NOTE Clear any fault code after solving a prob lem Always refer to the WIRING DIAGRAM when troub...

Page 301: ...witch is OFF 2 Disconnect pins SS1 and SS2 from starter sole noid 3 Disconnect ECM connector B 4 Connect ECM ADAPTER TOOL P N 529 036 166 to the ECM connector B 5 Set multimeter to diode check 6 Test diode as per following table D2 DIODE TEST MULTIMETER POSITIVE PROBE MULTIMETER NEGATIVE PROBE RESULT ECM B pin A2 ECM B pin L4 Overload open ECM B pin L4 ECM B pin A2 Approximately 0 5 volts If diode...

Page 302: ...battery terminal 3 Momentarily connect SS2 to the chassis ground If starter runs carry out the STARTER SOLENOID INPUT VOLTAGE TEST If starter does not run carry out the STARTER SO LENOID WINDING RESISTANCE TEST Starter Solenoid Input Voltage Test 1 Disconnect connector with BLACK YELLOW wire 2 Turn ignition switch ON 3 Measure voltage as per following table STARTER SOLENOID INPUT VOLTAGE TEST TEST...

Page 303: ...rns test other starting system compo nents Starter Removal Turn OFF ignition switch Disconnect BLACK cable from battery A WARNING Always disconnect BLACK cable first and reconnect last Disconnect RED cable from starter Clean starter area Remove starter retaining screw TYPICAL SOME PARTS REMOVED FOR CLARITY PURPOSE ONLY Carefully pry starter out of the engine crankcase Starter Installation Installa...

Page 304: ...LE NUT TIGHTENING TORQUE PRODUCT 6 Nom 53Ibfoin DIELECTRIC GREASE 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 ...

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Page 306: ...n 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 DIAGNOSTIC TIPS NOTE It is a good practice to check for fault codes using B U D S software as a first trou bleshooting step If D E S S key is not recognized by the ECM key is defective or there is a wiring problem CHECK ENGINE light will turn on and a message will be di...

Page 307: ...s ing 5m2011 079 001 1913011 001 052_ a Modtie Tools Help vrer 2006 012 100_50r Section 05 ELECTRICAL SYSTEM Subsection 06 DIGITALLY ENCODED SECURITY SYSTEM D E S S 0 Grime Ft Free roe frce 1 2 ea r7 rll Add Ereemence Key J iekiNretetelKey 11 17011 001 053 tl 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 ...

Page 308: ...cal connections Make sure they are tight make good contact and are corrosion free Dirty loose or corroded contacts are poor conductors and are often the source of a system or component malfunction Pay particular attention to ensure that pins are not bent or pushed out of their connectors Ensure all wire terminals are properly crimped on wires and connector housings are properly fas tened Check for...

Page 309: ...om fuse 1 of fuse block 2 Supplied with main relay activated Fuse 4 of fuse block 1 from main relay R2 Multifunction Gauge Removal 1 Remove gauge cover 2 Disconnect gauge connector 3 Release retaining clips at the top of gauge ANALOG DIGITAL GAUGE SHOWN 1 Retaining clips 4 Tilt top of gauge rearward then pull it up to re move it from its support Multifunction Gauge Installation For the installatio...

Page 310: ...2011 030 007_a Imr2011 030 006_b Custer Language lEnglistt 1m12011 030 006_c Section 05 ELECTRICAL SYSTEM Subsection 07 LIGHTS GAUGE AND ACCESSORIES Click on the Reset Service button 7 Reset Service button Multifunction Gauge Set Up Using B U D S Connect to the applicable B U D S software Re fer to COMMUNICATION TOOLS AND B UD S subsection Scroll and select the appropriate tire diameter see inscri...

Page 311: ... Activation and Cluster tabs Click on the WOW Test button TYPICAL 1 WOW Test button Indicator Lights Monitoring Select Monitoring and Cluster tabs Use the Cluster Lamp Active box to monitor dif ferent indicator lights outputs CLUSTER LAMP ACTIVE BOX This function confirms that the signals are broad casting and the indicator lights should be ON in the multifunction gauge Switches Input Monitoring S...

Page 312: ...ut to high beam headlights 3 BLUE HEADLIGHT LOW HIGH BEAM SWITCH EUROPE IN MULTIFUNCTION SWITCH FUNCTION PIN COLOR 12 volt input from headlights relay MGC 4 GREEN 12 volt output to high beam headlights HI position MGC 5 BLUE 12 volt output to high beam headlights PASS position MGC 2 BLUE Headlights Circuit Protection CONDITION CIRCUIT PROTECTION Supplied at all times Fuse 11 of fuse block 1 from f...

Page 313: ...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 1 Light beam center A 5 m 17 ft B 131 mm 5 in 1 Headlight center lines 2 Light beam center Beam Aiming Adjus...

Page 314: ...t from brake light switch relay winding input 1 1B RED ORANGE 12 volt output to LH brake light 11A WHITE ORANGE Relay winding ground to ground terminal BK2 12A BLACK BRAKE LIGHT SWITCH FUNCTION PIN COLOR 12 volt input from fuse F4 2 ORANGE GREEN 12 volt output to RH brake light and R8 relay winding 1 RED ORANGE Taillight Brake Light Circuit Protection CONDITION CIRCUIT PROTECTION Supplied with mai...

Page 315: ...nal BN4 is connected to the diodes used to prevent electric arcs in the switch WINCH SWITCH FUNCTION PIN COLOR 12 volt input from fuse 7 2 RED BLACK 12 volt output to relay winding IN 1 GREEN BLUE 12 volt output to relay winding OUT 3 LIGHT BLUE A WARNING Before testing make sure the winch is in FREESPOOL mode Freespool clutch disen gaged SIMPLIFIED WINCH WIRING DIAGRAM 1 Winch motor 2 Winch relay...

Page 316: ...wires the yellow wire at rear and the blue one at front Install a new cotter pin on the hook pin TURN SIGNALS HAZARD EC MODELS ONLY Turn Signal Wire Identification FLASHER MODULE FUNCTION PIN COLOR 12 volt input from fuse F10 MC2 1 RED WHITE 12 volt input from fuse F4 MC1 5 ORANGE GREEN RH turn 12 volt input from turn signal switch MC1 1 BEIGE ORANGE LH turn 12 volt input from turn signal switch M...

Page 317: ...se block 1 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 fuse F10 MGB 1 ORANGE GREEN 12 volt output to horn MGB 6 BEIGE BLUE HORN FUNCTION PIN COLOR 12 volt input from horn switch 2 BEIGE BLUE Ground 1 BLACK Horn Circuit Protection CONDITION CIRCUIT PROTECTION Supplied with main relay R2 activated Fu...

Page 318: ...UREMENT 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 tmr2011 031 295 ...

Page 319: ... lbf ft 70 5 N rn 52 4 lbf in XPS Synthetic grease See STEERING SYSTEM To Engine 75 5 N rn 2_41 55 4 lbf in See BRAKES Loctite 271 225 15 N rn 166 11 lbf ft Component must be replaced when removed nlri011 031 001 PROPELLER SHAFT Hi temp bearing grease NLGI 2 or equivalent e 1 11 W AA 00 a MD XPS Synthetic grease XPS Synthetic grease 296 tmr2011 031 ...

Page 320: ... 24 2 lbf ft 12 11 1 33 3 N m 24 2 lbf ft 10 11 12 0 4I Mira 8 13 r T r 14 7 5 0 5 N rn 66 4 lbf in _J NEW Loctite 277 XPS Synthetic grease 180 15 N rn 133 11 lbf ft LEFT HAND THREADED MEI Component must be replaced when removed r 2011 031 002a tmr2011 031 297 ...

Page 321: ...es a pressure proportional to wheel speed differential meaning the difference in rotational speed be tween the two wheels This pressure engages the friction clutch via a piston to transmit the torque In the event of a failure the entire Visco Lok pump and its carrier will have to be replaced The Visco Lok pump itself is a non serviceable item If the pump is disassembled the viscous fluid contained...

Page 322: ...l inner splines should be done Front Drive Shaft Installation The installation is the reverse of the removal pro cedure However pay attention to the following Install a NEW stop ring 1 Stop ring 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 fro...

Page 323: ...h 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 300 FROM THE LEFT SIDE OF VEHICLE 1 Front retaining screw 2 Rear retaining nuts Remove the upper differential bolts Remove nuts securing the lower bolts Pull bolts to free the left support NOTE...

Page 324: ...co Lok carrier pinion gear or housing is are changed Install recommended shims accordingly with the following table RECOMMENDED SHIMS PINION GEAR 1 67 mm 0 04 mm 066 in 002 in BACKLASH 0 5 mm 02 in for preliminary adjustment PRELOAD 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 1 Backla...

Page 325: ...ase preload shim by 0 05 mm 002 in and check drag torque again Front Differential Assembly Visco Lok Carrier Ring Gear To assemble reverse the removal procedure Pay attention to the following Check condition of seal no 10 Replace if dam age Check bearings no 11 Replace if damage Tighten differential housing screws no 1 PART TORQUE Differential housing screws 33 N m 3 Nom 24 lbf ft 2 lbf ft Pinion ...

Page 326: ...Move the differential forwards Dislodge the propeller shaft from the engine and 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 Howeve...

Page 327: ... 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 304 tmr2011 031 ...

Page 328: ...REMENT 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 ...

Page 329: ...c 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 75 5 Nom 55 4 lbf in Loctite 271 trn r2011 032 001_a XPS Synthetic grease 225 15 N rn 166 11 lbf4 Component must be replaced when removed To Engine emo PROPELLER SHAFT Iii temp bearing grease grease NLGI 2 or equivalent XPS Synthetic grease XPS Synthetic 306 tmr2011 032 ...

Page 330: ...E XPS Synthetic grease Component must be replaced when removed 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 1 180 15 N rn 133 11 lbf ft LEFT HAND THREADED trra2011 03 2 902 a tmr2011 032 307 ...

Page 331: ...INTRODUC TION section for proper procedure Remove the wheel Remove the following parts Cotter pin Wheel hub nut Belleville washer 1 Cotter pin 2 Wheel hub nut 3 Belleville washer NOTE On RH side remove also the brake caliper Remove wheel hub Wheel Hub Inspection Check wheel hub for cracks or other damages Check inner splines for wear or other damages If any damage is detected on wheel hub replace ...

Page 332: ...on The installation is the reverse of the removal pro cedure However pay attention to the following Install a NEW stop ring 1 Stop ring After drive shaft insertion in rear final drive vali date if properly locked DRIVE SHAFT BOOT Drive Shaft Boot Removal Remove the drive shaft from vehicle See proce dure in this subsection Remove drive shaft boot clamps using the follow ing tools TOOL OETIKER PLIE...

Page 333: ...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 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...

Page 334: ... pusher fully seat bearing cap on one side nstall snap ring Complete installation for the other bearing caps Grease U joint Refer to PERIODIC MAINTE NANCE PROCEDURES subsection 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 ...

Page 335: ...to keep track of shims no 2 on ring gear no 3 Extract ring gear out of half housing NOTE The pinion nut is left hand threaded Un screw by turning clockwise Remove the bearing no 6 at the same time as the pinion gear no 7 Be careful to keep track of shims no 8 The pinion gear and bearing can be easily removed using the following suggested tool PART QTY Pipe 89 mm 3 1 2 in diameter x 127 mm 5 in in ...

Page 336: ...rk 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 Rotate pinion gear 1 2 turn and check backlash again Note the result Rotate pinion gear 1 turn and check backlash again If backlash is below 0 05 mm 002 in increase backlash shim and check the backlash again If backlash i...

Page 337: ...rn 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 n...

Page 338: ...re us ing the vehicle Tire pressure changes with tem perature and altitude Recheck pressure if one of these conditions has changed TIRE PRESSURE FRONT REAR MIN 69 kPa 10 PSI 83 kPa 12 PSI MAX USE WHEN TOTAL LOAD IS GREATER THAN 180 KG 400 LB 83 kPa 12 PSI 152 kPa 22 PSI Tire Inspection Check tire for presence of slits bulges wear or other damage Replace if necessary Tire Replacement Use an automot...

Page 339: ...rst 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 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 Th...

Page 340: ... just enough to be able to unscrew them once the vehicle will be off the ground Lift and support the vehicle Refer to INTRODUC TION subsection Remove nuts then remove wheel 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 TYPICAL 1 Direct...

Page 341: ...n 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 ...

Page 342: ...section 02 STEERING SYSTEM STEERING SYSTEM SERVICE TOOLS Description Part Number Page STEERING ALIGNMENT TOOL 529 036 059 321 SERVICE PRODUCTS Description Part Number Page XPS SYNTHETIC GREASE 293 550 010 324 tmr2011 034 319 ...

Page 343: ...efty XPS synthetic grease o m fi 1 eV v 0 0 31 3 N rn 23 2 lbf ft ff at 48 6 Nl rn 35 4 lbf ft 34 2 N m 25 1 lbf ft 72 7 Nl m 53 5 lbf ft 5 1 Nl rn 44 9 lbf in See tightening sequence 24 5 3 5 Nl rn 18 3Ibf ft 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 ...

Page 344: ...STEERING ALIGNMENT 1 Place vehicle on a level surface 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...

Page 345: ...s not touch the first spacer of tool TYPICAL 14 Slowly move rope back until it makes contact with spacer 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 TYPICAL AT THE FRONT OF RIM TYPICAL AT THE REAR OF RIM 17 Calculate the difference between the rear and the front measurement 18 The difference mus...

Page 346: ...IC TIPS Turning Radius Unequal If vehicle turns more on one side than the other check rack and pinion center to center Refer to STEERING ALIGNMENTin this subsection PROCEDURES 50 Nom 5 Nom 37 lbf ft 4 lbfoft Check front wheel alignment Refer to STEERING ALIGNMENT in this subsection STEERING COLUMN Steering Column Removal 1 Center steering wheel 2 Remove bolt and nut securing upper universal joint ...

Page 347: ...ion 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 6 Carefully push steering column downwards to release it from steering support Install steering wheel and steering shaft Make sure steering wheel is properly centered Tighten steering column U joi...

Page 348: ... frame SOME PARTS REMOVED FOR CLARITY PURPOSE 6 From the LH side remove rack and pinion from vehicle Rack and Pinion Installation The installation is the reverse of the removal pro cedure However pay attention to the following Find rack and pinion center to center as follows Calculate the total pinion shaft rotations from side to side Position the pinion shaft at half the total rota tions Align pi...

Page 349: ...tall NEW cotter pin Both ends of cotter pins must be folded 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 DRIV...

Page 350: ...ove 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 Wheel Bearing Installation The installation is the reverse of the removal pro cedure However pay attention to the following To ease whe...

Page 351: ......

Page 352: ...35 4 lbf ft Suspension ____6 grease matu cLI 48 6 Nem 35 4 lbf ft ME D All except X I model I X model Cl Suspension grease 1 1 1 1 I233 Component must be replaced when removed tn 2011 075 100_a Section 07 CHASSIS Subsection 03 FRONT SUSPENSION FRONT SUSPENSION tmr2011 035 329 ...

Page 353: ...nd Refer to INTRODUCTION subsection 2 Remove bolts and nuts retaining shock ab sorber 1 Upper bolt 7 Lower bolt 3 Remove shock absorber Shock Absorber Inspection Remove spring from shock absorber Refer to SPRINGS in this subsection Secure the end of shock body in a vise with its rod upward 3 0 Al4F013A TYPICAL 1 Clamp here NOTICE Do not clamp directly on shock body Extend and compress the piston s...

Page 354: ...ocedures 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 1 Ball joint nut 4 Remove bolts and nuts securing suspension arm to frame 1 Suspen...

Page 355: ...iscard cotter pin retaining ball joint 1 Ball joint cotter pin 5 Remove ball joint nut and washer 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 d...

Page 356: ...ERIODIC MAINTENANCE PROCEDURES subsection Install a NEW cotter pin to secure ball joint nut Both end of cotter pin must be folded SHOCK ABSORBER NUTS TORQUE 48 NI rn 6 Nom 35 lbf ft 4 lbf ft SUSPENSION ARM BUSHINGS Suspension Arm Bushings Removal 1 Remove wear plates cushions and inner bush ing from suspension arm LOWER SUSPENSION ARM 1 Wear plate 2 Cushion 3 Inner bushing UPPER SUSPENSION ARM 1 W...

Page 357: ... appropriate ball joint remover 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 334 tmr2011 035 ...

Page 358: ...f ft 1 i i 1 I 3 w 3 111 I iI 110 10 Nom f N _ 48 6 Nom 35 4 lbf ft 4 I 35 4Ibf ft 48 6 Nom re tit 110 10 N m 81 7 Ib t Suspension grease Section 07 CHASSIS Subsection 04 REAR SUSPENSION REAR SUSPENSION SERVICE TOOLS Description Part Number Page SPRING COMPRESSOR 529 036 184 337 PEI Component must be replaced when removed 0 36 100a tmr2011 036 335 ...

Page 359: ... ground Refer to INTRODUCTION subsection 2 Open cargo box 3 Remove bolts and nuts retaining shock ab sorber 1 Upper bolt 1 Lower bolt 4 Remove shock absorber Shock Absorber Inspection Remove spring from shock absorber Refer to SPRINGS in this subsection Secure the end of shock body in a vise with its rod upward TYPICAL 1 Clamp here NOTICE Do not clamp directly on shock body Extend and compress the...

Page 360: ...TYPICAL 5 Install a NEW bushing as the reverse of re moval 6 Install shock absorber on vehicle SPRINGS Spring Removal 1 Remove shock absorber from vehicle Refer to SHOCK ABSORBERS in this subsection 2 Use SPRING COMPRESSOR P N 529 036 184 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 suff...

Page 361: ...e installation is the reverse of the removal pro cedure However pay attention to the following Install all retaining screws of anti sway bar loosely first Torque retaining screws of anti sway bar accord ing to the following sequence TRAILING ARM Trailing Arm Removal 1 Safely lift and support the vehicle off the ground Refer to INTRODUCTION subsection 2 Remove wheel refer to WHEELS AND TIRES subsec...

Page 362: ...t 10 Remove trailing arm from vehicle Trailing Arm Disassembly Drive Shaft Bearing Removal 1 Remove circlip securing bearing into trailing arm 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 Spacer 2 Seal 2 Install trailing arm...

Page 363: ...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 ...

Page 364: ...ERVICE 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 ...

Page 365: ...e 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 ...

Page 366: ...ed 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 ponen...

Page 367: ...onnector 2 Check switch operation as follows BRAKE LIGHT SWITCH POSITION PIN RESISTANCE Firmly pushed 1 2 Close to 0 52 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 NOTE If only the LH taillight does not work check brake relay R8 in fus...

Page 368: ...e light switch retaining rear brake hose 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 tmr2011 037 SOME PARTS REMOVED FOR CLARITY PURPOSE 1 Front brake hoses 2 Sealing washers 5 Remove protective rubber from underneath dashboard UNDERNEATH DASHBOARD 1 Protective rubber 6 Disconnect master cylinder r...

Page 369: ...nd down to check if there is a free play MASTER CYLINDER ROD REMOVED 3 Remove master cylinder retaining bolts and nuts 1 Master cylinder retaining bolts 4 Remove master cylinder from vehicle Master Cylinder Inspection Check boot for crack Check rod for wear and scratch Check master cylinder housing for leak or dam age Master Cylinder Installation The installation is the reverse of the removal pro ...

Page 370: ...n is the reverse of the removal pro cedure However pay attention to the following If caliper was removed for replacement Refill and bleed brake system refer to PERI ODIC MAINTENANCE PROCEDURES subsec tion Install NEW sealing washers Apply threadlocker on caliper retaining screws CALIPER RETAINING SCREWS THREADLOCKER LOCTITE 243 BLUE P N 293 800 060 Tighten caliper retaining screws to specification...

Page 371: ...ISC 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 4 Replace brake disc 5 Ins...

Page 372: ...5 000 070 359 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 ...

Page 373: ...Y 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 350 tmr2011 038 ...

Page 374: ...ER 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 ...

Page 375: ...in 2 5 0 5 N rn 22 4 lbf in 2 5 0 5 N rn 22 4 lbf in 41 4 5 0 5 N m 40 4 lbf in trnr2011 038 004_a 1 6 0 4 N rn 14 4 lbf in 1 1 6 0 4 N m 14 4 lbf in 44 9 Ibf in 5 1 N m L 1 6 0 4 N rn 14 4 lbf in Section 07 CHASSIS Subsection 06 BODY FRONT BODY PARTS Torques and Service Products 352 tmr2011 038 ...

Page 376: ...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 Section 07 CHASSIS Subsection 06 BODY SIDE BODY PARTS Torques and Service Products tmr2011 038 353 ...

Page 377: ...n 2 0 5 N m 18 4 lbf in 4 5 0 5 N rn 40 4 lbf in II C 1 4 1 i CE Model 2 5 0 5 N m 22 4 lbf in Section 07 CHASSIS Subsection 06 BODY COCKPIT TRIMS DRIVER SIDE Torques and Service Products tmr2011 038 006_a 354 tmr2011 038 ...

Page 378: ...18 4 Ib n 2 0 5 N rri 18 4 lbf in 2 5 0 5 Ni m 22 4 lbf in 2 5 0 5 f I m 22 4 lbf in Section 07 CHASSIS Subsection 06 BODY COCKPIT TRIMS PASSENGER SIDE Torques and Service Products tmr2011 038 016_a tmr2011 038 355 ...

Page 379: ... 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 Section 07 CHASSIS Subsection 06 BODY COCKPIT STRUCTURE PANELS PASSENGER SIDE Torques and Service Products tr 2011 038 007_e 356 tmr2011 038 ...

Page 380: ...I 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 5 5 0 5 N rn 49 4 lbf in Section 07 CHASSIS Subsection 06 BODY COCKPIT STRUCTURE PANELS DRIVER SIDE Torques and Service Products trnr2011 038 01 a tmr2011 038 357 ...

Page 381: ...Section 07 CHASSIS Subsection 06 BODY SEATS 358 tmr2011 038 ...

Page 382: ...l decal can roll off when rubbing with your finger Pull decal slowly and when necessary apply more heat to ease removal on the area that has to be peeled off If decal tears while pulling off it has to be heated for a few seconds longer If decal tends to stretch while pulling off stop heating and wait a few sec onds to let it cool then peel it off Decal Installation Using isopropyl alcohol clean th...

Page 383: ...lower console The installation is the reverse of the removal pro cedure LATERAL CONSOLE PANELS Lateral Console Panels Removal and 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 RH lateral console panel 2 Plastic rivets FRONT PORTION ...

Page 384: ...verse 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 ...

Page 385: ......

Page 386: ...BOX CARGO BOX TRIMS 1mr2011 043 001a 5 1 N rn 2 0 5 N m 44 9 lbf in 18 4 lbf in 411111 44 9 lbf in 5 1 N m c le wow lip itikomikii f Iiillilitt 0 i 18 4 Ibf in 7 2 0 5 N m 4111 alai tr 0 1 V 47 5 1 N rn 44 9 lbf in 5 1 N rn 44 9 lbf in tmr2011 043 363 ...

Page 387: ...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 Section 07 CHASSIS Subsection 07 CARGO BOX CARGO BOX TILT RELEASE MECHANISM 1mr2011 043 002_a 364 tmr2011 043 ...

Page 388: ...11 1 N rn 97 9 lbf in 11 1 N ni 97 9 lbf in 4 0 5 N ni 35 4 lbf in Section 07 CHASSIS Subsection 07 CARGO BOX CARGO BOX SUPPORT tm r201 1 043 003_a tmr2011 043 365 ...

Page 389: ...9 lbf in 5 1 N m 44 9 lbf in 2 2 0 2 N m 19 2 Ibf 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 5 1 N m 44 9 lbf in Section 07 CHASSIS Subsection 07 CARGO BOX UPPER TAIL GATE tmr2011 043 004_a 366 tm r20 1 1 043 ...

Page 390: ...2 5 0 5 N rn 22 4 lbf in 7 1 N rn 62 9 lbf n 5 1 N rri 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 Section 07 CHASSIS Subsection 07 CARGO BOX LOWER TAIL GATE tmr2011 043 005_a tmr2011 043 367 ...

Page 391: ...44 9 lbf in 5 1 N m 44 9 lbf in 2 0 5 N rn 18 4 lbf in T 1 5 1 N rn 44 9 lbf in 2 0 5 N rn 18 4 lbf in Section 07 CHASSIS Subsection 07 CARGO BOX CARGO BOX ACCESSORIES XT model tmr2011 043 006_a 368 tmr2011 043 ...

Page 392: ...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 the top of rear lateral panel GAP BETWEEN CARGO BOX AND REAR LATERAL PANEL 1 Cargo box side 2 Rear lateral panel A Approximately 19mm 3 4 in CARGO BOX HEIGHT GAP 1 Top of...

Page 393: ...go 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 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 1 No gap here 4 Check the tilt release handle stroke 4 1 Determine...

Page 394: ... new one 5 Remove supports and lower cargo box CARGO BOX Cargo Box Removal 1 Unlock and raise the cargo box 2 Unplug the cargo box harness connector 1 Cargo box harness connector 3 From the LH of vehicle cut all locking ties se curing harness to frame 4 Secure the cargo box with wooden blocks or an equivalent and remove the upper gas shock bolt 5 Remove supports and lower cargo box 6 From undernea...

Page 395: ...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 ...

Page 396: ...bsection 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 tmr2011 039 373 ...

Page 397: ...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 T4 XT Model T3 l7 7Ni CE Models only tmr2011 039 001a tmr2011 039 374 ...

Page 398: ...tion 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 25 3 N m 18 2 lbf ft op 13 1 N m 115 9 lbf in unr20114 39 002_a tmr2011 039 375 ...

Page 399: ... Cage Inspection Check cage for bending cracks weld damages or any other damage A WARNING Any damaged cage components must be re placed Cage Installation A WARNING When the cage mounting bolts are removed they must be replaced with new ones or have their threads cleaned then have LOCTITE 243 BLUE P N 293 800 060 applied Ensure to use only 8 8 grade fasteners 1 Loosely assemble the cage 2 Position ...

Page 400: ...n 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 T...

Page 401: ......

Page 402: ...iameter Intake New 4 966 mm to 4 980 mm 1955 in to 1961 in Service limit 4 930 mm 1941 in Exhaust New 4 956 mm to 4 970 mm 1951 in to 1957 in Service limit 4 930 mm 1941 in Valve out of round Intake and exhaust New 0 005 mm 0002 in Service limit 0 06 mm 0024 in Valve guide diameter New 4 998 mm to 5 018 mm 1968 in to 1976 in Service limit 5 050 mm 1988 in Valve spring free length New 40 81 mm 1 60...

Page 403: ...side New 34 959 mm to 34 975 mm 1 3763 in to 1 377 in Service limit 34 950 mm 1 376 in Spark plug side New 21 959 mm to 21 980 mm 8645 in to 8654 in Service limit 21 950 mm 8642 in Camshaft main bearing journal bore Timing chain side New 35 000 mm to 35 025 mm 1 378 in to 1 3789 in Service limit 35 040 mm 1 3795 in Spark plug side New 22 000 mm to 22 021 mm 8661 in to 867 in Wear limit 22 040 mm 8...

Page 404: ... 7898 in 22 050 mm 8681 in Piston pin diameter New 19 996 mm to 20 000 mm 7872 in to 7874 in 21 996 mm to 22 000 mm 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 pressu...

Page 405: ...ing 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 Spring sleeve length New 9 2 mm to 9 4 mm 362 in to 37 in Service limit 9 0 mm 354 in Driven pulley sliding half bushing New 30 060 mm to 30 100 mm 1 183 in to 1 185 in Service limit 30 200 mm 1 189 in Driven pulley sliding fixed bushing New 30 060 mm to 30 100 mm 1 183 in to...

Page 406: ...o 25 000 mm 9837 in to 9843 in Service limit 24 984 mm 9836 in Bearing journal MAG CVT side New 16 980 mm to 16 991 mm 6685 in to 6689 in 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 Spark plug Quantity 2 Make and type NGK DCPR8E Ga...

Page 407: ...Connectors DC3 and DC4 12 V power outlet Communication connector F12 15 A Relays coils R1 and R3 F13 5 A Connector DC6 F14 15 A Fuel pump F15 5 A FUEL SYSTEM Fuel delivery Type Electronic Fuel Injection ER 54 mm throttle body with iTC Intelligent Throttle Control 1 injector per cylinder Fuel pump Type Electrical in fuel tank Operating pressure 350 kPa 51 PSI Idle speed 1250 rpm 100 not adjustable ...

Page 408: ...t 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 Sho...

Page 409: ...am X Threaded spring retainer BRAKES Front brake Qty 2 Type 214 mm ventilated disc brakes with hydraulic twin piston calipers Rear brake Qty 1 Type 214 mm ventilated disc brake with hydraulic twin piston caliper Brake fluid Capacity 125 ml 4 2 U S oz Type DOT 4 Caliper Floating Brake pad material Front Metallic Rear Metallic Minimum brake pad thickness 1 mm 04 in Minimum brake disc thickness Front...

Page 410: ...in Overall width 148 9 cm 58 6 in Overall height 182 9 cm 72 in Wheel base 192 4 cm 75 7 in Wheel track Front 125 7 cm 49 5 in 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 Cargo box capacity Total upper lower 272 kg 600 lb Upper 181 kg 4001b Lower 272 kg 600 lb Total vehicle load all...

Page 411: ......

Page 412: ... BK is a YELLOW wire with a BLACK stripe Connector Housing Area The first number in the connector pin contact number represents the area in the vehicle where the connector is located AREA LOCATION 1 Steering dashboard and upper console area 2 Under dashboard and front bulkhead area 3 Front of vehicle 4 Engine seat and lower console area 5 Rear of vehicle Wire Gauge The number after wire color indi...

Page 413: ...1 and INJ2 Fuel injector MAPTS Manifold air pressure and 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 SM Starter motor SPK1 and SPK2 Spark plug SS Starter solenoid ABBREVIATION DESCRIPTION STSW Start...

Page 414: ...ors 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 Support 1 Insert a small flat screwdriver between the sup port and the Deutsch connector 2 Pry the connector away from the support slightly while sliding it out in the direction shown TYPICAL MALE CONNECTOR REMOVED F...

Page 415: ...L 1 Flat screwdriver 2 Deutsch connector TYPICAL DEUTSCH CONNECTOR 7 Male connector 2 Female 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 FEMALE CONNECTOR 1 Female lock 392 tmr2...

Page 416: ...k is removed 2 Insert terminal through the back of the connec tor in the appropriate position and push it in as far as it will go You should feel or hear the ter minal lock engage 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 CONNECTOR PIN OUT 1 Terminal position identification...

Page 417: ...n 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 Open housing by lifting 4 tabs TYPICAL 1 Tabs 2 on each side 394 trn r201 1 042 ...

Page 418: ...s 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 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 2 Press and hold the locking tab on the connector to be disc...

Page 419: ...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 p...

Page 420: ... 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 Remove rear protector from connector 2 Pull out the connector lock 3 Inse...

Page 421: ...e GM TERMINAL EXTRACTOR P N 12094430 between the lock and the pin to release the pin GM TERMINAL EXTRACTOR P N 12094430 Step 2 Insert GM extractor tool P N 12094430 3 Gently pull on the wire to extract the pin out the back of the connector 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 o...

Page 422: ...P N 529 035 730 to select the proper position of the tool NOTE Different wires require different crimping pliers settings POSITIONING THE CRIMPING PLIERS Step 1 Step 1 Press Step 2 Step 2 Rotate After positioning the crimping pliers crimp the ter minal already installed on wire PROPERLY CRIMPED WIRE To verify if the wire is properly crimped apply some pulling force on wire and the terminal at the ...

Page 423: ...ective 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 ...