2018 Can-Am Outlander 570 650 850 1000r Service Manual

SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to cor- NOTE: Indicates supplementary information re-
rectly service and repair the Can-Am™ Outlander™ quired to fully complete an instruction.
and Renegade™ ATV. Although the mere reading of such information
This edition was primarily published to be used does not eliminate the hazard, your understanding
by mechanics and technicians who are already of the information will promote its correct use.
familiar with all service procedures relating to Always observe common shop safety practice.
BRP products. Technicians should attend training
courses given by BRPTI. Unless otherwise noted, the engine must be
stopped and the key must be removed prior to
Please note that the instructions in this manual performing any services.
will apply only if proper hand tools and special ser-
vice tools are used. Torque wrench tightening specifications must be
strictly adhered to. Use the torque values and ser-
The contents of this manual depicts parts and vice products as in the exploded views or in the
procedures applicable to the particular product at procedures when noted.
the time of writing. Service and warranty bulletins
may be published to update the content of this Locking devices when removed must be replaced
manual. Dealer modifications that were carried (e.g.: locking tabs, elastic stop nuts, self-locking
out after manufacturing of the product, whether fasteners, cotter pins, etc.).
or not authorized by BRP, are not included. Hoses, cables and locking ties removed during a
In addition, the sole purpose of the illustrations procedure must be reinstalled as per factory stan-
throughout the manual, is to assist identification dards.
of the general configuration of the parts. They are When ordering parts always refer to the specific
not to be interpreted as technical drawings or ex- model PARTS CATALOGS.
act replicas of the parts. We strongly recommend that any services be car-
The use of BRP parts is most strongly recom- ried out and/or verified by a highly skilled profes-
mended when considering replacement of any sional mechanic.
component. Dealer and/or distributor assistance It is understood that this manual may be trans-
should be sought in case of doubt. lated into another language. In the event of any
The engines and the corresponding components discrepancy, the English version shall prevail.
identified in this document should not be utilized BRP disclaims liability for all damages and/or in-
on product(s) other than those mentioned in this juries resulting from the improper use of the con-
document. tents of this publication.
It is understood that certain modifications may
render use of the ATV illegal under existing fed-
eral, provincial and state regulations.
This manual emphasizes particular information de-
noted by the following wording and symbols:
WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.
CAUTION Indicates a hazardous situation

which, if not avoided, could result in minor or
moderate injury.
NOTICE Indicates an instruction which, if not
followed, could result in severe damage to ve-
hicle components or other property.
219100883-005 I
INTRODUCTION
INTRODUCTION
GENERAL INFORMATIONS VIN Decal Description
The information and component/system descrip-
tions contained in this manual are correct at time MANUFACTURED BY :
of publication. BRP however, maintains a policy of FABRIQUÉ PAR:
continuous improvement of its products without MFD. DATE FAB : 12/2003 MODEL: 1234 2
imposing upon itself any obligation to install them VIN / NIV: 2BPS1234X2V000123 1
on products previously manufactured. 3
Due to late changes, it may have some differ- MADE IN/FABRIQUÉ AU: TYPE: ATV / VTT
XXXXX
ences between the manufactured product and
the description and/or specifications in this docu- vmr2015-005-004_a
ment. TYPICAL — VEHICLE SERIAL NUMBER DECAL UNDER SEAT

1. VIN (Vehicle Identification Number)
BRP reserves the right at any time to discontinue 2. Vehicle manufacturing date and model number
3. VIN bar code
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
VEHICLE INFORMATION
VEHICLE IDENTIFICATION
NUMBER (VIN) LOCATIONS
vmr2015-005-003_a
1 TYPICAL — VEHICLE SERIAL NUMBER DECAL ON RH SIDE

OF FRAME
2. Vehicle manufacturing date and model number
ENGINE IDENTIFICATION
NUMBER (EIN)
2 3
vmr2015-005-005_a
VIN LOCATIONS
1. VIN decal under seat
2. VIN decal on lower frame member, RH side
3. VIN stamped on lower frame member, RH side
vmr2015-005-001_a
BACK OF 450 ENGINE

1. EIN (Engine Identification Number)
II 219100883-005
INTRODUCTION
Replacement or repair of any emission related

component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sion levels to exceed their predetermined factory
specifications.
Exceptions include manufacturer's prescribed
changes.
vmr2016-005-001_a
OWNER RESPONSIBILITY
LH SIDE OF 570 ENGINE The owner/operator is required to have engine
maintenance performed to maintain emission
levels within prescribed certification standards.
The owner/operator is not to, and should not al-
low anyone else to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.
EMISSION REGULATIONS
The vehicle you are servicing may have been
certified to applicable emission regulations in
your country or state. Not as an exhaustive list;
this may include standards for engine exhaust
tmr2011-002-002_a
emissions, crankcase emissions, permeation
TYPICAL - RH SIDE OF OTHER ENGINES
emissions and evaporative emissions. Servic-
1. Engine Identification Number (EIN) ing procedures in this manual must be strictly
followed in order to keep the vehicle within the
ENGINE EMISSIONS factory specifications. Failure to follow servicing
procedures in this manual may lead a vehicle to
INFORMATION be out of compliance with applicable emission
regulations.
MANUFACTURER'S When servicing any vehicle; adjustments must be
RESPONSIBILITY kept within published factory specifications. Re-
Manufacturers of engines must determine the placement or repair of any emission related com-
exhaust emission levels for each engine horse- ponent must be executed in a manner that main-
power family and certify these engines with tains emission levels within the applicable certifi-
the United States of America Environmental cation standards. Nobody is allowed to modify the
Protection Agency (EPA). An emissions control engine in any manner that would alter the horse-
information label, showing emission levels and power or allow emission levels to exceed their
engine specifications, must be placed on each predetermined factory specifications. Exceptions
vehicle at the time of manufacture. include manufacturer’s prescribed changes.
The owner/operator is required to have engine
DEALER RESPONSIBILITY maintenance performed to maintain emission lev-
els within the prescribed certification standards.
When servicing any vehicle that carry an emis- The owner/operator is allowed and should not
sions control information label, adjustments must allow anyone else to modify the engine in any
be kept within published factory specifications. manner that would alter the horsepower or allow
emissions levels to exceed their predetermined
factory specifications.
219100883-005 III
INTRODUCTION
MANUAL INFORMATION MANUAL LAYOUT

This manual is divided into many major sections as
MANUAL PROCEDURES can be seen in the main table of contents at the
Many of the procedures in this manual are inter- beginning of the manual.
related. Before undertaking any task, you should Each section is divided into various subsections,
read and thoroughly understand the entire section and again, each subsection has one or more divi-
or subsection in which the procedure is contained. sions.
Illustrations and photos show the typical construc-
WARNING tion of various assemblies and, in all cases, may
Unless otherwise specified, the engine not reproduce the full detail or exact shape of the
should be turned OFF and cold for all main- parts used in a particular model vehicle. However,
tenance and repair procedures. they represent parts which have the same or a
similar function.
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).
vmr2015-005-006_a
TYPICAL
1. Left
2. Right
This manual uses technical terms which may be

different from the ones of the parts catalogs.
When ordering parts always refer to the specific
model PARTS CATALOGS.
NOTICE Most fasteners are metric, and most
components are built with parts dimensioned
using the metric system. Consult the appropri-
ate PARTS CATALOG to obtain and use the cor-
rect parts and fasteners. Mismatched or incor-
rect fasteners could cause damage to the vehi-
cle.
IV 219100883-005
INTRODUCTION
TYPICAL PAGE
Section 06 ENGINE Page heading

Subsection 01 (MAGNETO) indicates section
and subsection.
Subsection title MAGNETO

Indicates applicable Models
models.
Loctite 243 Drop represents a

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

1 is used to identify
a part referred to
the text.
NEW indicates that the
part must be replaced NEW
with a new one.
5 Nm
(44 lbfin)
Illustration number
for publishing process. XXX0000
Document number for 55 Page number

publishing process.
mmr2008-001
NOTICE Pay attention to torque specifications.

Some of these are in lbf in instead of lbf ft.
Use appropriate torque wrench.
Typical_iso_2008_en
219100883-005 V
INTRODUCTION
TYPICAL PAGE
Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)
Tittle in bold
indicates category
of information to be GENERAL
carried out. NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Reference to a Clean threads before applying a threadlocker. Re-
specific section fer to the SELF-LOCKING FASTENERS and LOC-
or subsection. TITE APPLICATION sections at the beginning of
this manual for complete procedure. TYPICAL
WARNING indicates a general
Torque wrench tightening specifications
view which may
must be strictly adhered to. not represent exact
Locking devices (e.g.: locking tabs, elastic 1 details.
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones. TYPICAL
1. Starting pulley
PROCEDURES NOTE: To remove starting pulley bolts, hold mag- Call-outs pertaining
Indicates component neto flywheel with a socket as shown. to above illustration.
procedures apply to. MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
Indicates specific a clean cloth. Illustration always
procedure to be Magneto Flywheel Removal follows text to which
carried out. Remove muffler, refer to the EXHAUST SYSTEM it applies.
section.
Remove acoustic panel.
Remove rewind starter. mmr2007-016-002
Remove starting pulley no. 2. TYPICAL Italic bold face type-

Models
setting indicates a
Remove the connecting flange retaining the
procedure applicable
rewind starter to the engine housing. to a specific
model(s).
mmr2008-001 57
Bold face number following part

name refers to exploded view
at beginning of subsection.
typical_txt_2008_en
VI 219100883-005
INTRODUCTION
TIGHTENING TORQUE
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, refer to the following table.
WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices must be replaced when removed (e.g.: locking tabs, elastic stop nuts, self-lock-
ing fasteners, cotter pins, etc.).
In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce-
dure:
1. Manually screw in all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.
NOTICE Be sure to use the recommended tightening torque for the specified fastener used.
Whenever possible, always apply torque on the nut.
Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are used to
secure a part (eg. a cylinder head). Some parts must be torqued according to a specific sequence and
torque pattern as detailed in the installation procedure.
4.8 8.8 9.8 10.9 12.9

Property
class and
head 4.8 8.8 9.8 10.9 12.9
markings
4.8 8.8 9.8 10.9 12.9 12.9
5 8 10 12
Property
class and
12
10
nut
5
markings
A00A8BS
FASTENER FASTENER GRADE/TORQUE

SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5 – 2 N•m 2.5 – 3 N•m 3.5 N•m - 4 N•m 4 N•m - 5 N•m
M4
(13 – 18 lbf•in) (22 – 27 lbf•in) (31 lbf•in - 35 lbf•in) (35 lbf•in - 44 lbf•in)
3 N•m - 3.5 N•m 4.5 N•m - 5.5 N•m 7 N•m - 8.5 N•m 8 N•m - 10 N•m
M5
(27 lbf•in - 31 lbf•in) (40 lbf•in - 49 lbf•in) (62 lbf•in - 75 lbf•in) (71 lbf•in - 89 lbf•in)
6.5 N•m - 8.5 N•m 8 N•m - 12 N•m 10.5 – 15 N•m
M6 16 N•m (142 lbf•in)
(58 lbf•in - 75 lbf•in) (71 lbf•in - 106 lbf•in) (93 – 133 lbf•in)
M8 15 N•m (133 lbf•in) 25 N•m (18 lbf•ft) 32 N•m (24 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 73 N•m (54 lbf•ft)
219100883-005 VII
INTRODUCTION
FASTENER INFORMATION Threadlocker Application for

Uncovered Holes (Bolts and Nuts)
NOTICE Most components in the vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners 1
could cause damage to the vehicle or possible
personal injury.
SELF-LOCKING FASTENER
PROCEDURE
2
A00A3LA
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.

2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
A00A6LA on threads and allow to dry.
TYPICAL — SELF-LOCKING FASTENER 3. Choose proper strength Loctite threadlocker.
The following describes common procedures 4. Fit bolt in the hole.
used when working with self-locking fasteners. 5. Apply a few drops of threadlocker at proposed
Use a metal brush or a tap to properly clean a tightened nut engagement area.
threaded hole, then use a solvent. Allow the sol- 6. Position nut and tighten as required.
vent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper Threadlocker Application for Blind
adhesion of the product used for locking the fas- Holes
tener.
LOCTITE® THREADLOCKER 1
APPLICATION PROCEDURE
The following describes common procedures 2
used when working with Loctite products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.
lmr2007-040-004_a
1. On fastener threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.

2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
on threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
VIII 219100883-005
INTRODUCTION
4. Apply several drops along the threaded hole Threadlocker Application for
and at the bottom of the hole. Pre-Assembled Parts
5. Apply several drops on bolt threads.
6. Tighten as required.
Threadlocker Application for Stud

Installation in Blind Holes 1
1 3
2
A00A3OA
1. Apply here
lmr2007-040-005_a 2. Do not apply
1. On stud threads
2. On threads and in the hole 1. Clean bolts and nuts with solvent.
3. On retaining nut threads
2. Assemble components.
1. Clean threads (stud and hole) with solvent. 3. Tighten nuts.
2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041) 4. Apply a few drops of proper strength Loctite on
on threads and allow to dry. bolt/nut contact surfaces.
3. Apply 2 or 3 drops of proper strength Loctite 5. Avoid touching metal with tip of flask.
threadlocker on female threads and in hole.
NOTE: For preventive maintenance on exist-
NOTE: To avoid a hydro lock situation, do not ap- ing equipment, retighten nuts and apply proper
ply too much Loctite. strength Loctite on bolt/nut contact surfaces.
4. Apply several drops of proper strength Loctite
on stud threads. Threadlocker Application for an
5. Install stud. Adjustment Screw
6. Install cover, part, etc.
7. Apply a few drops of proper strength Loctite on 2
1
uncovered stud threads.
8. Install and tighten retaining nut(s) as required.
A00A3PA
1. Apply here
2. Plunger
1. Adjust screw to proper setting.

2. Apply a few drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
219100883-005 IX
INTRODUCTION
NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

a soldering iron (232°C (450°F)).
Application for Stripped Thread Repair 1 2
5
1
6
8
2
1
A00A3QA 4 7
1. Release agent
2. Stripped threads 1 3
3. Form-A-Thread
lmr2007-040-006_a
4. Tape
5. Cleaned bolt 1. Proper strength Loctite
6. Plate 2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
7. New threads (P/N 293 800 038) on both sides of gasket
8. Threadlocker 3. Loctite Primer N only
Standard Thread Repair 1. Remove old gasket and other contaminants us-
Follow instructions on Loctite FORM-A-THREAD ing LOCTITE CHISEL (GASKET REMOVER) (P/N 413
81668 package. 708 500). Use a mechanical means only if nec-
essary.
If a plate is used to align bolt:
NOTE: Avoid grinding.
1. Apply release agent on mating surfaces.
2. Clean both mating surfaces with solvent.
2. Put waxed paper or similar film on the surfaces.
3. Spray Loctite Primer N on both mating surfaces
3. Twist bolt when inserting it to improve thread and on both sides of gasket and allow to dry 1
conformation. or 2 minutes.
NOTE: NOT intended for engine stud repairs. 4. Apply LOCTITE 518 (P/N 293 800 038) on both
Repair of Small Holes/Fine Threads sides of gasket, using a clean applicator.
Option 1: Enlarge damaged hole, then follow 5. Place gasket on mating surfaces and assemble
STANDARD THREAD REPAIR procedure. parts immediately.
Option 2: Apply FORM-A-THREAD on the screw NOTE: If the cover is bolted to blind holes, apply
and insert in damaged hole. proper strength Loctite in the hole and on threads.
Permanent Stud Installation (Light Duty) Tighten fastener.
1. Use a stud of the desired thread length. NOTE: If holes are sunken, apply proper strength
Loctite on bolt threads.
NOTE: DO NOT apply release agent on stud.
6. Tighten as usual.
2. Follow Standard Thread Repair procedure.
3. Allow 30 minutes for Loctite FORM-A-THREAD
to cure.
4. Complete part assembly.
X 219100883-005
INTRODUCTION
Threadlocker Application for Mounting 2. Spray housing and gasket with LOCTITE 7649
on a Shaft (PRIMER) (P/N 293 800 041).
Mounting with a Press 3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
4. Install according to standard procedure.
1
5. Wipe off excess product.
2 6. Allow 30 minutes for product to cure.
NOTE: Normally used on worn-out housings to
3 prevent leaking or sliding.
A00A3UA
It is generally not necessary to remove gasket
1. Bearing compound applied on outer gasket diameter.
2. Proper strength Loctite
3. Shaft
1. Clean shaft external contact surface.

2. Clean internal contact surface of part to be in-
stalled on shaft.
3. Apply a strip of proper strength Loctite on cir-
cumference of shaft contact surface at inser-
tion or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft. DO NOT use Loctite an-
tiseize or any similar product. No curing period is
required.
Mounting in Tandem
1. Apply retaining compound on internal contact
surface (bore) of parts to be installed.
2. Continue parts assembly in the prescribed or-
der.
Threadlocker Application for Case-In

Components (Metallic Gaskets)
A00A3VA 1
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket

diameter.
219100883-005 XI
Subsection 02 (PERIODIC MAINTENANCE SCHEDULE)
PERIODIC MAINTENANCE SCHEDULE

GENERAL
Maintenance is very important for keeping your vehicle in safe operating condition. The vehicle should
be serviced as per the maintenance schedule.
The maintenance schedule does not exempt the pre-ride inspection.
A repair shop or person of the owner's choosing may maintain, replace, or repair emission control
devices and systems. These instructions do not require components or service by BRP or authorized
Can-Am dealers. Although an authorized Can-Am dealer has an in-depth technical knowledge and tools
to service the Can-Am ATV, the emission-related warranty is not conditioned on the use of an authorized
Can-Am dealer or any other establishment with which BRP has a commercial relationship. For
emission-related warranty claims, BRP is limiting the diagnosis and repair of emission-related parts to
the authorized Can-Am dealers. For more information, please refer to the US EPA EMISSION-RELATED
WARRANTY contained herein. Proper maintenance is the owner’s responsibility. A warranty claim
may be denied if, among other things, the owner or operator caused the problem through improper
maintenance or use.
You must follow the instructions for fuel requirements in the fueling section of this manual. Even if gaso-
line containing greater than ten volume percent ethanol is readily available, the US EPA issued a prohibi-
tion against the use of gasoline containing greater than 10 vol% ethanol that applies to this vehicle. The
use of gasoline containing greater than 10 vol% ethanol with this engine may harm the emission control
system.
WARNING
Failure to properly maintain the vehicle according to the maintenance schedule and procedures
can make it unsafe to operate.
SEVERE DUSTY CONDITIONS

Engine Air Filter Maintenance Guideline
Air filter maintenance should be adjusted according to riding conditions.
Air filter maintenance must be increased in frequency in the following dusty conditions:
– Riding on dry sand
– Riding on dry dirt covered surfaces
– Riding on dry gravel roads or similar conditions.
NOTE: Riding in a group in these conditions would increase even more the air filter maintenance.
MAINTENANCE SCHEDULE LEGEND

Operation in trail riding conditions
Operation in severe riding conditions (dusty or muddy) or carrying heavy loads condition
MAINTENANCE SCHEDULE
Make sure to perform proper maintenance at recommended intervals as indicated in the tables. Some
items of the maintenance schedule must be performed in function of the calendar, regardless of the
distance or time of operation.
vmr2017-102 1
EVERY 1 500 KM (1,000 MI) OR 50 HOURS (whichever comes first)

EVERY 750 KM (500 MI) OR 25 HOURS (whichever comes first)
Verify and clean engine air filter. Replace as needed
Verify battery connections
Lubricate rear propeller shaft joint
Inspect tie rod ends and ball joints for play and boots condition
Lubricate front suspension arm bushings
Lubricate rear stabilizer bar bushings
Inspect the drive shaft boots and protectors
Inspect brake pads. Replace as needed
Inspect wheel bearings for abnormal play
Inspect and clean CVT air filter. Replace as needed. (If equipped)
Tighten wheel beadlock bolts (If equipped)
Lubricate lower shock absorber spherical bearings (Outlander LTD and XT-P and Renegade Xxc)
Lubricate upper shock absorber spherical bearings (Outlander LTD)

Adjust valve clearance
Clean muffler spark arrester
Verify and clean throttle body
Replace fuel vent breather filter
Verify CVT drive belt and clean CVT pulleys
Lubricate the one way bearing of the drive pulley
Inspect ACS suspension hoses condition (LTD)
The following must be performed at least once a year:
Change engine oil and filter
Lubricate throttle cable
Inspect and clean brake system
Inspect battery condition
Verify steering system for abnormal play
Verify front differential and rear final drive oil level and look for contamination
Verify gearbox oil level and look for contamination (except 450)
2 vmr2017-102
PERFORM AT THE FIRST 3 000 KM (2,000 MI)AND AT 6 000 KM (4,000 MI) THEN
FOLLOW THE REGULAR SCHEDULE
PERFORM AT THE FIRST 1 500 KM (1,000 MI) AND AT 3 000 KM (2,000 MI) THEN
FOLLOW THE REGULAR SCHEDULE
Replace gearbox oil (except 450)
Clean the vehicle speed sensor (VSS) (except 450)

Verify the cooling system
Test engine coolant strength
Verify fuel system for leaks
Verify fuel pump pressure
Replace spark plugs
Replace front differential oil
Replace rear final drive oil
Replace gearbox oil (except 450)
Inspect input and output shaft seals (gearbox, differential and final drive)
Clean vehicle speed sensor
Clean and lubricate lower and upper steering column half bushings
The following must be performed every 2 years:
Replace the brake fluid
EVERY 12 000 KM (8,000 MI) OR 5 YEARS (whichever comes first)

Replace engine coolant
vmr2017-102 3
Subsection XX (PERIODIC MAINTENANCE PROCEDURES (OUTLANDER))
PERIODIC MAINTENANCE
PROCEDURES (OUTLANDER)
SERVICE TOOLS
Description Part Number Page
TEST CAP ...................................................................................... 529 035 991 ............................................. 9
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ....................................... 9, 22
SERVICE PRODUCTS
AIR FILTER OIL ............................................................................. 219 700 340 ............................................. 3
BRAKE FLUID GTLMA DOT4........................................................ 293 600 131 ..................................... 20, 22
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ........................................... 16
LONG LIFE ANTIFREEZE(F) .......................................................... 619 590 204 ............................................. 7
LONG LIFE ANTIFREEZE .............................................................. 219 702 685 ............................................. 7
SUSPENSION GREASE ................................................................. 293 550 033 ..................................... 18–19
XPS 4-STROKE SYNTH. BLEND OIL (F)........................................ 619 590 109 ............................................. 5
XPS 4-STROKE SYNTH. BLEND OIL............................................. 293 600 121 ............................................. 5
XPS 4-STROKE SYNTHETIC OIL (F).............................................. 619 590 114 ............................................. 5
XPS 4-STROKE SYNTHETIC OIL ................................................... 293 600 112 ............................................. 5
XPS BRAKES AND PARTS CLEANER (USA) ................................. 219 701 705 ........................................... 20
XPS BRAKES AND PARTS CLEANER ........................................... 219 701 776 ........................................... 20
XPS SYNTHETIC GEAR OIL (75W 140) ........................................ 293 600 140 ..................................... 12, 17
XPS SYNTHETIC GEAR OIL (75W 90) .......................................... 293 600 043 ........................................... 16
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 21
GENERAL – Riding on dry dirt covered surfaces

This subsection provides: – Riding on dry gravel trails or similar conditions.
– Fluid level verifications NOTE: Riding in a group in these conditions
– Maintenance procedures. would increase even more the air filter mainte-
nance.
The following systems should be serviced accord-
ing to the PERIODIC MAINTENANCE SCHED- Removing the Engine Air Filter
ULE.
NOTICE Never remove or modify any com-
PROCEDURES ponent in the air filter housing. Otherwise,
engine performance degradation or damage
can occur. The engine is calibrated to operate
AIR INTAKE SYSTEM specifically with these components.
Engine Air Filter Maintenance 1. Remove seat.
Guideline
2. Remove console. Refer to BODY subsection.
As with any ATV, air filter maintenance is critical to
ensure proper engine performance and life span. 3. Rotate air filter cover counterclockwise to re-
move it.
Air filter maintenance should be adjusted accord-
ing to riding conditions. NOTE: A socket wrench may be used to ease re-
moval of the air filter cover.
Air filter maintenance must be increased in fre-
quency and oil must be added to the foam filter
for the following dusty conditions:
vmr2017-103 1
3. Check air filter dirty chamber for cleanliness.

– If any debris or water are found, clean air fil-
ter chamber using a vacuum cleaner.
NOTICE Do not blow compressed air into air
filter chamber.
4. Check air filter housing drain tube (clean cham-
ber).
– If any debris or water are found, refer to SPE-
CIAL PROCEDURES subsection.
– Investigate for contamination source.
vmo2015-005-014_a
1. Air filter cover
4. Remove air filter.
vmr2012-010-017_b
TYPICAL - SOME PARTS REMOVED FOR CLARITY

1. Air filter drain tube
vmo2015-005-015_a Cleaning the Paper Filter

AIR FILTER REMOVAL
1. Ensure that the foam filter is removed from pa-
per filter.
Inspecting and Draining the Engine Air
Filter Housing 2. Tap out heavy dust from the paper filter.
1. Remove LH side panel and extension. Refer to This will allow dirt and dust to get out of the paper
BODY subsection. filter.
2. Drain air filter housing drain tube. NOTE: Paper filter have a limited life span; re-
place filter if too dirty or clogged.
NOTICE It is not recommended to blow com-
pressed air on the paper filter; this could dam-
age the paper fibers and reduce its filtration
ability when used in dusty environments.
NOTICE Do not wash the paper filter with any
cleaning solution.
Cleaning the Foam Filter

1. Spray the foam filter inside and out with air filter
cleaner and follow manufacturer's instructions.
2. Dry the foam filter completely.
vmr2012-010-017_a

1. Air filter housing drain tube
2 vmr2017-103
vbs2009-012-005 vmo2015-005-014_b
TYPICAL - DRY 1. Cover position arrow
2. Locked
NOTE: A second application may be necessary 3. Unlocked
for heavily soiled elements.
Reinstall the console.
Oiling the Foam Filter
1. Spray the recommended air filter oil on the EXHAUST SYSTEM
foam filter previously cleaned and dried. Fol- Cleaning and Inspecting the Muffler
low manufacturer's informations. Spark Arrester
RECOMMENDED PRODUCT The muffler must be periodically purged of accu-
mulated carbon.
AIR FILTER OIL WARNING
(P/N 219 700 340)
Never run engine in an enclosed area. Never
perform this operation immediately after the
engine has been run because exhaust sys-
tem is very hot. Make sure that there are no
combustible materials in the area. Wear eye
protection and gloves. Never stand behind
the vehicle while purging exhaust system.
Respect all applicable laws and regulations.
Select a well-ventilated area and make sure the

muffler is cool.
CAUTION Never perform this operation

immediately after the engine has been running
as exhaust system is very hot.
vbs2009-012-014 Muffler (Transversal Mounting)
TYPICAL - OIL THE FOAM FILTER 1. Place transmission on PARK position.
Reinstall oiled foam filter over the paper filter. 2. Remove the clean out plug of the muffler.
Installing the Engine Air Filter

Slightly grease O-ring seal and plastic body of air
filter. Refer to AIR INTAKE SYSTEM exploded
view.
Install filter assembly in air filter housing.
Ensure air filter cover is properly locked onto the
air filter housing. See indications on filter cover
and housing.
vmr2017-103 3
vmo2015-005-037_a
TYPICAL
1. Muffler
2. Clean out plug
3. Block the end of the muffler with a shop rag and vmr2012-0005-051_a
start engine. TYPICAL — ALL MODELS

1. Screws
4. Momentarily increase engine RPM several 2. Tail pipe
times to purge accumulated carbon out of the
muffler. 3. Remove exhaust tail pipe, gasket (discard) and
spark arrester.
5. Stop engine and allow muffler to cool.
6. Reinstall the clean out plug.
Muffler (Longitudinal Mounting)
1. Remove the muffler cover and discard the
screws.
tmo2011-001-041_a
1. Spark arrester
2. Gasket
3. Exhaust tail pipe
4. Remove carbon deposits from the spark ar-

rester using a brush.
vmr2012-0005-050_a
TYPICAL NOTICE Use a soft brush and be careful to

1. Remove and discard screws avoid damaging spark arrester mesh.
2. Cover
2. Remove and discard the tail pipe retaining

screws.
4 vmr2017-103
Verifying the Engine Oil Level

NOTICE Operating the engine with an im-
proper level may severely damage engine.
NOTE: While checking the oil level, visually in-
spect engine area for leaks.
tmo2011-001-043_a
1. Clean spark arrester
5. Inspect mesh of spark arrester for any damage.

Replace as required.
6. Inspect spark arrester chamber in muffler.
Clean as required. vmr2015-063-100_a
For installation, reverse the removal procedure. TYPICAL - RH SIDE OF ENGINE

1. Dipstick
However pay attention to the following.
Install new gasket and new retaining screws. NOTE: Do not lose the O-ring placed on the dip-
stick.
TIGHTENING TORQUE
With vehicle on a level surface and engine cold,
11 N•m ± 1 N•m not running, check the oil level as follows:
Tail pipe retaining screws
(97 lbf•in ± 9 lbf•in)
1. Unscrew dipstick then remove it and wipe
clean.
LUBRICATION SYSTEM 2. Reinstall dipstick, screw in it completely.
3. Remove and check oil level. It should be near
Recommended Engine Oil or equal to the upper mark.
For the summer season, use:
RECOMMENDED SERVICE PRODUCT
Outside of XPS 4-STROKE SYNTH. BLEND
the U.S. OIL (F) (P/N 619 590 109)
Within the XPS 4-STROKE SYNTH. BLEND
U.S. OIL (P/N 293 600 121)
For all season, use:

RECOMMENDED SERVICE PRODUCT
Outside of XPS 4-STROKE SYNTHETIC OIL
the U.S. (F) (P/N 619 590 114)
Within the XPS 4-STROKE SYNTHETIC OIL
U.S. (P/N 293 600 112)
vmr2015-063-001_a
1. Full
If recommended XPS oil is not available, use a 2. Add
4-stroke SAE 5W 40 engine oil that meets or ex-
ceeds the requirements for API service classifica- To add oil, remove the dipstick. Place a funnel into
tion SJ, SL, SM or SN. Always check the API ser- the dipstick orifice.
vice label certification on the oil container, it must Add a small amount of recommended oil and
contain at least one of the above standards. recheck oil level.
vmr2017-103 5
Repeat the above procedures until oil level 11. Replace oil filter. Refer to ENGINE OIL FILTER
reaches the dipstick's upper mark. Do not over- REPLACEMENT in this subsection.
fill. Wipe off any spillage. 12. Refill engine with recommended engine oil.
Properly tighten dipstick.
MODEL ENGINE OIL CAPACITY
Changing the Engine Oil 450 engines 3 L (3.2 qt (U.S. liq.))
1. Start and warm-up engine. All engines except 450 2 L (2.1 qt (U.S. liq.))
2. Stop engine.
13. After filling, check the oil level, refer to EN-
3. Ensure vehicle is on a level surface. GINE OIL LEVEL VERIFICATION in this sub-
4. Remove dipstick. section.
5. Place a drain pan under the engine drain plug 14. Start engine and let it idle for a few minutes.
area. 15. Ensure oil filter and drain plug areas are not
6. Clean the magnetic drain plug area. leaking.
7. Unscrew magnetic drain plug and discard the 16. Stop engine.
gasket ring. 17. Wait a while to allow oil to flow down to
crankcase, then check oil level again.
CAUTION The engine oil can be very hot.
18. Refill as necessary.
19. Dispose oil and filter as per your local environ-
mental regulations.
Replacing the Engine Oil Filter

Engine Oil Filter Access
To reach oil filter, refer to BODY subsection and
remove the following parts:
– Seat
– Console
– RH side panel and extension
– RH inner fender panel.
vmr2015-063-101_a

1. Magnetic drain plug
2. Access through frame
Allow oil to drain completely from the crankcase.

8. Clean the magnetic drain plug from metal shav-
ings and residue. Presence of debris gives an
indication of internal engine damage.
9. Install a NEW gasket ring on the magnetic drain
plug.
NOTICE Never use the gasket ring a second
time. Always replace by a new one.
vmr2015-029-200_a
10. Install and tighten magnetic drain plug to the 1. Oil filter cover
recommended torque.
Removing the Engine Oil Filter
TIGHTENING TORQUE 1. Clean oil filter area.
20 N•m ± 1 N•m 2. Remove oil filter cover.
Magnetic drain plug
(15 lbf•ft ± 1 lbf•ft)
3. Remove oil filter.
6 vmr2017-103
vmr2016-009-001_a
vmr2006-008-001_a
1. Oil filter screw
2. Oil filter cover 1. O-ring - slightly oil
3. O-ring 2. End of filter - slightly oil
4. Oil filter
5. Install the cover on the engine.
Installing the Engine Oil Filter
6. Tighten oil filter cover screws to recommended
1. Check and clean the oil filter inlet and outlet
torque.
area of dirt and other contaminations.
TIGHTENING TORQUE
10 N•m ± 1 N•m
Oil filter cover screws
7. Reinstall remaining parts if applicable.
COOLING SYSTEM
Recommended Engine Coolant
COOLANT
Finland, LONG LIFE
Norway and ANTIFREEZE(F)
BRP Sweden (P/N 619 590 204)
recommended
product LONG LIFE
vmr2015-063-003_a
All Other
1. Outlet bore to the engine oil providing system ANTIFREEZE
Countries
2. Inlet bore from the oil pump to the oil filter (P/N 219 702 685)
2. Install a NEW O-ring on oil filter cover. Distilled water and
antifreeze solution
3. Install the filter into the cover. Alternative, or _ (50% distilled
if not available
4. Apply engine oil on O-ring and on end of filter. water,
50% antifreeze)
NOTICE Always use ethylene-glycol an-

tifreeze containing corrosion inhibitors specif-
ically formulated for internal combustion
aluminum engines.
To prevent antifreeze deterioration, always use
the same brand. Never mix different brands or
type of antifreeze. Always use the same an-
tifreeze unless cooling system is completely
flushed and refilled.
vmr2017-103 7
Do not use tap water, straight antifreeze or 2. Remove pressure cap.

straight water in the system. Tap water contains
minerals and impurities which build up in the sys- WARNING
tem. During cold weather, straight water causes To avoid potential burns, do not remove the
the system to freeze while straight antifreeze pressure cap if the engine is hot.
thickens and does not have the same efficiency.
3. Using an antifreeze tester, test coolant
Verifying the Engine Coolant Level strength.
WARNING MINIMUM RECOMMENDED COOLANT
In order to avoid potential burns, check STRENGTH
coolant level with engine cold. Do not re- -30°C (-22°F)
move the radiator cap if the engine is hot.
Inspecting the Engine Cooling System
1. Place vehicle on a level surface.
1. Check general condition of hoses and clamps
2. Remove gauge support. Refer to BODY sub- for tightness.
section.
2. Check the leak indicator hose for oil or coolant.
With the vehicle on a level surface, coolant level
should be between the MIN. and MAX. marks of Leaking coolant indicates a defective rotary seal.
the reservoir. Leaking oil indicates a defective oil seal. If either
seal is leaking, both seals must be replaced at the
same time. Refer to WATER PUMP SHAFT AND
SEALS in the COOLING SYSTEM subsection.
vmo2012-012-042_a
TYPICAL
1. Engine coolant reservoir vmr2016-009-002_a
1. Leak indicator hose

NOTE: When checking level at temperature 2. Water pump
lower than 20°C (68°F), it may be slightly lower
than MIN. mark. Another leak indicator hole is visible on the PTO
side. It provides an indication of the PTO gasket
3. Add coolant up to MAX. mark if required. condition. If a liquid leaks from this hole, PTO gas-
4. Use a funnel to avoid spillage. Do not overfill. ket replacement is necessary.
5. Properly reinstall and tighten reservoir cap.
6. Reinstall gauge support.
NOTICE Do not store any objects under the
gauge support.
Checking the Engine Coolant Specific

Gravity
1. Remove gauge support. Refer to BODY sub-
section.
8 vmr2017-103
REQUIRED TOOLS
TEST CAP
(P/N 529 035 991)
VACUUM/PRESSURE
PUMP
(P/N 529 021 800)
COOLING SYSTEM LEAK TEST

vmr2015-063-004_a 110 kPa (16 PSI)
TYPICAL
1. Leak indicator hole If there is no pressure drop after 10 minutes, there
2. PTO cover
3. Crankcase PTO, front side is no leak in the cooling system.
If the pressure drops, check all hoses, radiator,
3. Ensure vent hose on coolant expansion tank is
cylinders and engine base for coolant leaks or air
not obstructed.
bubbles.
Testing the Engine Cooling System Pressure
Cap Replacing the Engine Coolant
1. Remove gauge support. Refer to BODY sub- Draining the Engine Cooling System
section.
2. Remove pressure cap. CAUTION Engine coolant can be very hot.
Coolant draining should be carried out on a
WARNING cold engine.
To avoid potential burns, do not remove the 1. Remove gauge support. Refer to BODY sub-
pressure cap if the engine is hot. section.
2. Remove cooling system pressure cap.
3. Test the pressure cap using a cooling system
tester.
4. Replace the cap if it does not hold the pressure,
or if it opens at a relief pressure that is too low
or too high.
PRESSURE CAP RELIEF PRESSURE
Approximately 110 kPa (16 PSI)
Testing the Engine Cooling System Leak

1. Remove gauge support. Refer to BODY sub-
section.
2. Remove pressure cap.
WARNING vmo2012-012-042_a
TYPICAL
To avoid potential burns, do not remove the 1. Cooling system pressure cap
pressure cap if the engine is hot.
3. Unscrew coolant drain plug.
3. Pressurize cooling system as follows. NOTE: Coolant drain plug is accessible from un-
derneath RH footrest panel.
vmr2017-103 9
vmr2015-029-202_a
vmr2012-013-010_a
TYPICAL - SOME PARTS REMOVED FOR CLARITY 1. Outer exhaust heat shield
1. Coolant drain plug
4. Remove CVT duct outlet.
4. Drain cooling system into a suitable container.
5. Disconnect the lower radiator hose and drain
the remaining coolant.
NOTE: Take note of the hose clamp position be-
fore it is loosened for hose removal.
6. Reinstall coolant drain plug with a NEW sealing
washer.
7. Tighten coolant drain plug to specification.
TIGHTENING TORQUE
10 N•m ± 1 N•m
Coolant drain plug
8. Fill cooling system with recommended coolant,

refer to COOLING SYSTEM FILLING AND
vmr2015-029-203_a
BLEEDING procedure.
1. CVT duct outlet
Filling and Bleeding the Engine Cooling
System 5. Unscrew bleed screws on thermostat housing
covers of both front and rear cylinders.
1. Remove cooling system pressure cap.
2. Remove RH and LH side panels. Refer to
BODY subsection.
3. On LH side of engine, remove outer exhaust
heat shield. Refer to EXHAUST SYSTEM sub-
section.
vmr2015-029-201_a
RH SIDE
1. Front cylinder bleed screw
10 vmr2017-103
2. Before checking or adjusting the valve clear-

ance, turn crankshaft clockwise to TDC ignition
of the respective cylinder, refer to CAMSHAFT
TIMING GEAR in the TIMING CHAIN subsec-
tion.
NOTICE Crankshaft must be turned clock-
wise only to avoid loosening the magneto
retaining bolt.
3. Using a feeler gauge, check the valve clear-
ance.
VALVE CLEARANCE
0.11 mm to 0.19 mm
EXHAUST
(.0043 in to .0075 in)
vmr2015-029-204_a
LH SIDE 0.06 mm to 0.14 mm

INTAKE
1. Rear cylinder bleed screw (.0024 in to .0055 in)
6. Fill cooling system until coolant comes out of If the valve clearance is out of specification, adjust
bleed screws. valves as follows.
7. Squeeze the top of the coolant hose between NOTE: Use the center value of exhaust/intake
the radiator and coolant pump several times to specification to ensure a proper valve adjustment.
bleed all air from the highest point of the hose.
4. Hold the adjustment screw at the proper posi-
8. Install bleed screws using NEW gasket rings. tion and torque the locking nut.
9. Tighten bleed screws.
TIGHTENING TORQUE
5.0 N•m ± 0.6 N•m
Bleed screws
10. Refill coolant tank up to MAX level mark.

11. Install cooling system pressure cap.
12. Run engine at idle until the cooling fan cycles
on for a second time.
13. Stop the engine and let it cool down.
WARNING
Do not remove the pressure cap if the engine
is hot.
14. Check coolant level in the coolant tank. Refer

to VERIFYING THE ENGINE COOLANT LEVEL
vmr2007-036-003_a
in this subsection. 1. Adjustment screw
15. Add coolant if required. 2. Locking nut
3. Feeler gauge
CYLINDER HEAD 5. Repeat the procedure for each valve.

6. Before installing valve covers, recheck valve
Inspecting and Adjusting the Engine clearance.
Valve Clearance
NOTE: Check and adjust valve clearance only
when engine is cold.
1. Remove valve covers, refer to TOP END sub-
section.
vmr2017-103 11
GEARBOX
Recommended Gearbox Oil (Except
450 Engines)
RECOMMENDED
QUANTITY
PRODUCT
XPS SYNTHETIC
Approximately 450 ml
GEAR OIL (75W 140)
(15.2 U.S. oz)
(P/N 293 600 140)
If the recommended oil is not available, use a vmo2012-012-056_a
75W140 gearbox oil that meets the API GL-5 1. Drain plug
2. Oil level plug
specification.
3. Check oil level.
Verifying the Gearbox Oil Level
The oil should be level with the bottom of the oil
NOTE: Prior checking the gearbox oil level, en- level hole.
sure vehicle is on a level surface.
1. To access gearbox oil level plug, refer to BODY NOTICE Operating the gearbox with an im-
subsection and remove the following parts: proper oil level may severely damage gearbox.
– Seat 4. Install the oil level plug with its O-ring. Tighten
– Console plug as per table.
– RH side panel and extension(s) TIGHTENING TORQUE
– RH footrest panel.
5 N•m ± 0.6 N•m
Oil level plug
Replacing the Gearbox Oil

Draining the Gearbox Oil
1. Start engine and operate vehicle to warm-up
the gearbox oil.
NOTE: Running engine at idle is not sufficient, ve-
hicle transmission must be operated.
2. Position vehicle on a level surface.
3. Place a drain pan under the gearbox drain plug
area.
4. Clean drain plug area.
5. Remove magnetic drain plug and sealing
vmr2015-063-102_a
washer. Discard sealing washer.
TYPICAL
1. Oil level plug
WARNING
2. Remove the gearbox oil level plug. The gearbox oil can be very hot.
6. Remove oil level plug and its O-ring.

NOTE: Allow oil to completely flow out of gear-
box.
12 vmr2017-103
2. Inspect and clean the air inlet and outlet open-

ings from inside the CVT cover.
3. Inspect and clean the air outlet duct connected
to the exhaust system heat shield under the
seat.
NOTE: If a lot of debris or grime are found in the
CVT system, it may be necessary to remove the
ducts and thoroughly clean them.
4. Reinstall CVT cover.
vmo2012-012-056_a
Inspecting the Drive Belt
2. Oil level plug 1. Inspect belt for cracks, fraying or abnormal
wear. Replace if necessary.
7. Clean magnetic drain plug and pay attention to
any debris present on drain plug. 2. Check drive belt width at cord level. Replace if
it is out of specification.
NOTE: Presence of excessive debris provides an
indication of a gearbox problem. DRIVE BELT WIDTH
8. Reinstall magnetic drain plug with a NEW seal- SERVICE LIMIT 30 mm (1.181 in)
ing washer.
TIGHTENING TORQUE
20 N•m ± 2 N•m
Magnetic drain plug
9. Dispose gearbox oil as per your local environ-

mental regulations.
Filling the Gearbox Oil
1. Fill the gearbox through the oil level hole until
the oil reaches the bottom of the oil level hole.
2. Install the oil level plug with its O-ring. Tighten vmr2006-021-005_a
plug as per table. 1. Drive belt
2. Cord in drive belt
TIGHTENING TORQUE
5 N•m ± 0.6 N•m Drive Pulley, Driven Pulley and
Oil level plug
(44 lbf•in ± 5 lbf•in) One-Way Bearing Maintenance
Refer to CONTINUOUSLY VARIABLE TRANSMIS-
Cleaning the Vehicle Speed Sensor SION (CVT) subsection.
(VSS)
Remove the VSS. Refer to GEARBOX AND 4X4 FUEL SYSTEM
COUPLING UNIT subsection. Inspecting and Cleaning the Throttle
Remove all metal particles and oil from the VSS Body
magnet.
1. Remove the air intake housing, refer to AIR IN-
NOTE: A dirty VSS will cause erratic speedometer TAKE SYSTEM subsection.
readings.
2. Visually inspect throttle plate and throttle body
venturi for cleanliness.
CONTINUOUSLY VARIABLE
3. Clean inside throttle body if necessary. Refer to
TRANSMISSION (CVT) ELECTRONIC FUEL INJECTION (EFI) subsec-
Cleaning the CVT Air Inlet/Outlet tion.
1. Remove CVT cover, refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT) subsection.
vmr2017-103 13
Lubricating the Throttle Cable

The throttle cable must be lubricated with a sili-
cone based lubricant.
WARNING
Always use a silicone-based lubricant. Using
another lubricant (like a water-based lubri-
cant) could cause the throttle lever/cable to
become sticky and stiff.
Open the throttle lever housing.
V07I0HA 1
1. Inner housing protector
Remove the cable from the throttle lever housing.

NOTE: Slide cable in clip slot and remove the end
of cable from clip.
V07I0FY
V07I0FB
1. Remove these screws
Separate the housing.

Slide rubber protector back to expose throttle ca-
ble adjuster.
V07I0IA
Remove the throttle body side cover.
V07I0GA 1 2 3 4
1. Cable protector
2. Throttle cable adjuster
3. Lock nut
4. Throttle lever housing
Screw in the throttle cable adjuster.

Remove inner housing protector.
14 vmr2017-103
vmo2006-007-032_a
vmr2015-043-019_d
1. Throttle body
2. Side cover screws 1. Vent breather filter
2. Vent inlet check valve
Insert the needle of the lubricant can in the end of
throttle cable adjuster. Inspecting the Fuel System
1. Visually inspect fuel tank for cracks, wear
marks, signs of leakage or any other damages.
2. Visually inspect fuel system hoses for proper
rooting, cracking, wear marks, signs of leakage
or any other damages.
3. Carry out a FUEL TANK LEAK TEST, refer to
FUEL TANK AND FUEL PUMP subsection.
WARNING
All fuel system leaks must be repaired. Dam-
aged, worn or leaking fuel system com-
ponents should be replaced to ensure fuel
system tightness.
V07I0JA
Testing the Fuel Pump Pressure
Refer to FUEL TANK AND FUEL PUMP subsec-
TYPICAL
tion for procedure.
NOTE: Place a rag around the throttle cable ad-
juster to prevent the lubricant from splashing. ELECTRICAL SYSTEM
Add lubricant until it runs out at throttle body end Inspecting the Battery
of the throttle cable.
Visually inspect battery casing for cracks or other
Reinstall and adjust the cable. Refer to ELEC- damage. If casing is damaged, replace battery
TRONIC FUEL INJECTION subsection. and thoroughly clean battery rack with water and
sodium bicarbonate (baking soda).
Replacing the Fuel Tank Vent Breather
Filter Inspect battery posts condition and battery re-
tainer plate.
Ensure breather filter is installed with the flow ar-
row pointing towards the vent inlet check valve. For battery testing, refer to CHARGING SYSTEM
subsection.
vmr2017-103 15
Replacing the Spark Plug 2. With vehicle on a level surface, check oil level
by removing filler plug. Oil level must reach the
Spark Plug Access lower edge.
For access to the LH spark plug, remove the LH 3. Reinstall filler plug with a NEW sealing washer.
inner fender panel.
For access to the RH spark plug, remove the RH TIGHTENING TORQUE
side panel and extension(s). 22.5 N•m ± 2.5 N•m
Filler plug
Removing the Spark Plug
1. Remove spark plug cable from spark plug. Replacing the Front Differential Oil
2. Clean the spark plug area using pressurized air. 1. Place vehicle on a level surface. Set transmis-
3. Remove spark plug. sion in park position.
Installing the Spark Plug 2. Clean filler and drain plug areas.
Prior to installation, ensure that contact surfaces 3. Place a drain pan under the front differential.
of the cylinder head and spark plug are free of 4. Remove filler plug.
grime.
5. Remove drain plug.
1. Using a wire feeler gauge, set electrode gap as
specified in TECHNICAL SPECIFICATIONS.
2. Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) over the spark plug threads to
prevent possible seizure.
NOTICE Do not apply antiseize lubricant on
the first 2 spark plug threads.
3. Hand screw spark plug into cylinder head, then
tighten to specification using a torque wrench
and an appropriate socket.
TIGHTENING TORQUE
20 N•m ± 2 N•m
Spark plug
(15 lbf•ft ± 1 lbf•ft) vmr2016-107-002_a
BOTTOM VIEW OF VEHICLE
DRIVE SYSTEM NOTE: Allow enough time for oil to flow out.
6. Install and tighten drain plug to specification.
Verifying the Front Differential Oil
Level TIGHTENING TORQUE
1. Clean filler plug prior to checking oil level. Drain plug
7.5 N•m ± 0.5 N•m
7. Refill front differential with recommended oil.

CAPACITY RECOMMENDED OIL
XPS SYNTHETIC
GEAR OIL (75W 90)
500 ml (17 U.S. oz)
(P/N 293 600 043) or a
75W 90 (API GL-5) gear oil
8. Reinstall filler plug with a NEW sealing washer.

9. Tighten filler plug to specification.
vmr2016-107-001_a
RH SIDE OF VEHICLE
16 vmr2017-103
TIGHTENING TORQUE
22.5 N•m ± 2.5 N•m
Filler plug
Verifying the Rear Final Drive Oil Level

1. Ensure vehicle is on a level surface.
2. Clean filler plug area.
3. Remove filler plug.
vmr2016-009-004_b
LH REAR SIDE OF VEHICLE

1. Filler plug
2. Drain plug
NOTE: Allow enough time for oil to flow out.

6. Install drain plug.
TIGHTENING TORQUE
7.5 N•m ± 0.5 N•m
Drain plug
vmr2016-009-004_a 7. Refill the rear final drive.

LH REAR SIDE OF VEHICLE
1. Filler plug QUANTITY RECOMMENDED OIL
XPS SYNTHETIC
4. Verify the oil level by inserting a wire with a 90°
GEAR OIL (75W 140)
bend through the oil filler hole. 250 ml
(P/N 293 600 140)
(8 U.S. oz)
5. Oil level must be within the following specifica- or a 75W 140
tion from the bottom of oil filler hole. (API GL-5) gear oil
OIL LEVEL 8. Reinstall filler plug with a NEW sealing washer.
20 mm ± 5 mm (9/16 in ± 3/16 in) TIGHTENING TORQUE
6. Reinstall filler plug with a NEW sealing washer. 22.5 N•m ± 2.5 N•m
Filler plug
TIGHTENING TORQUE
Filler plug
22.5 N•m ± 2.5 N•m Inspecting Drive Shaft Boot and
(17 lbf•ft ± 2 lbf•ft) Protector
1. Visually inspect each drive shaft boot for grease
Replacing the Rear Final Drive Oil leak, cracks or opening.
1. Ensure vehicle is on a level surface. 2. Check if the drive shaft boot protectors are
2. Clean filler and drain plug areas. fixed firmly, not torn or otherwise damaged.
3. Place a drain pan under rear final drive. 3. Replace if necessary.
4. Unscrew filler plug.
Inspecting Drive Shaft Joint
5. Remove drain plug.
Turn and move drive shaft back and forth to detect
excessive play.
Inspecting Rear Propeller Shaft U-Joint

Check yoke U-joints for wear, backlash or axial
play. Replace if necessary.
vmr2017-103 17
Lubricating Rear Propeller Shaft STEERING SYSTEM

U-Joint
Inspecting the Steering System
PROPELLER SHAFT U-JOINT LUBRICATION
Steering Column
Use Hi-temp bearing grease NLGI-2 or an equivalent
Turn and move steering column back and forth to
detect any abnormal play.
WHEELS AND TIRES If abnormal play is detected, inspect upper and
Checking the Wheel Lug Nut Torque lower steering column half bushings. Replace
halve bushings and O-rings as necessary, refer to
Tighten wheel lug nuts to the specified torque us- STEERING SYSTEM subsection.
ing the illustrated sequence.
If steering column feels stiff, refer to STEERING
TIGHTENING TORQUE COLUMN HALF BUSHING CLEANING AND LU-
100 N•m ± 10 N•m BRICATION in this subsection.
Wheel lug nuts
(74 lbf•ft ± 7 lbf•ft) Tie-Rod End
Check tie-rod end ball joint for:
– Damage
– Pitting
– Abnormal play.
Replace if necessary.
Cleaning and Lubricating Steering

Column Half Bushing
Clean, inspect and lubricate upper and lower
steering column half bushings and O-rings. Refer
to STEERING SYSTEM subsection.
SUSPENSION
Inspecting Shock Absorber
vmr2012-038-004_a Check shock absorber for any leaks, replace if nec-
TIGHTENING SEQUENCE essary.
Inspecting Wheel Bearing HPG Shock Absorber (without Remote

Reservoir)
1. Safely lift and support the vehicle.
Check shock absorber for abnormal play:
2. Hold wheel by the top and the bottom and try – Front to back
to move it by pulling and push alternately with
both hands. Check for any play. – Up and down.
3. If there is any looseness detected, replace the If any play is detected, replace shock absorber
wheel bearing. refer to STEERING SYSTEM bushings. Refer to REAR SUSPENSION subsec-
subsection. tion.
NOTE: To properly locate play during this inspec- Lubricating Front Suspension Arm
tion, be sure to check other components for wear
Lubricate suspension arm at grease fittings.
or looseness (ball joints, suspension pivots, etc).
If necessary repair or replace all defective parts SUSPENSION ARM LUBRICATION
before checking the wheel bearing condition. Be
SUSPENSION GREASE (P/N 293 550 033)
careful not to misinterpret a loose ball joint as a
loose wheel bearing.
18 vmr2017-103
5. Check ball joint bellows for:

– Damage
– Cracks.
Inspecting Rear Suspension Trailing

Arm
1. Check trailing arms for:
– Cracks
– Pitting
– Bending
– Distortion.
vmr2012-040-012_a 2. Check trailing arm for abnormal play:
TYPICAL
1. Grease fittings – Side to side
– Up and down.
3. If any play is detected, inspect:
– Spacers
– Bearings
– Inner spacers.
Inspecting and Lubricating Rear

Stabilizer Bar Bushing
Rear Stabilizer Bar Bushing Inspection
Inspect bushings for:
– Cracks
– Damage
vmr2012-040-013_a – Abnormal wear.
TYPICAL
1. Grease fittings Lubricating Rear Stabilizer Bar Bushing
Lubricate bushings at grease fittings.
Inspecting Front Suspension Arm
LUBRICATION
1. Check suspension arm for:
– Cracks SUSPENSION GREASE
Stabilizer bar bushing
(P/N 293 550 033)
– Pitting
– Bending
– Distortion.
2. Check suspension arm for abnormal play:
– Side to side
– Up and down.
3. If any play is detected, inspect:
– Wear plates
– Bushings
– Sleeves.
4. Check ball joint for:
– Damage
– Pitting
– Play. vmr2012-041-018_a
TYPICAL
1. Grease fittings
vmr2017-103 19
BRAKES
Recommended Brake Fluid
Always use brake fluid meeting the specification
DOT 4 only such as the BRAKE FLUID GTLMA DOT4
(P/N 293 600 131) or an equivalent.
WARNING
To avoid damage to the braking system, do
not use other brake fluid types.
vmo2015-005-026_b
Verifying the Brake Fluid Reservoir 1. Rear brake fluid reservoir
Level
With vehicle on a level surface, check brake fluid Adding Brake Fluid
in reservoirs for proper level. Clean filler cap.
NOTE: A low level may indicate leaks or worn
brake pads. WARNING
Clean filler cap before removing.
Front Brake Reservoir
Turn steering in the straight-ahead position to en- Remove screws retaining the reservoir cap.
sure reservoir is level.
Remove reservoir cap.
Check the brake fluid level, the reservoir is full
when the fluid reaches of the top of window. Add fluid as required using a clean funnel. Do not
overfill.
Visually inspect lever boot condition.
Check for cracks, tears, etc. Replace if damaged. NOTICE Brake fluid can damage plastic
and painted surface. Wipe off and clean any
spillage.
Reinstall reservoir cap and tighten screws.
NOTE: Ensure filler cap diaphragm is pushed in-
side the cap before closing the brake fluid reser-
voir.
Inspecting and Cleaning Brake System

NOTICE Do not clean brake components in
petroleum based solvent. Use brake system
cleaner only. Soiled brake pads must be re-
placed with new ones.
To clean parts from the brake system, use the fol-
lowing recommended products or an equivalent.
vmo2012-012-046_a
TYPICAL RECOMMENDED PRODUCT

Rear Brake Reservoir XPS BRAKES AND
For United States of
PARTS CLEANER (USA)
Remove the seat. America
(P/N 219 701 705)
With vehicle on a level surface, liquid should be XPS BRAKES AND
between MIN. and MAX. level marks of brake For all other countries PARTS CLEANER
pedal fluid reservoir. (P/N 219 701 776)
Brake Pads
1. Measure brake pad lining thickness.
20 vmr2017-103
BRAKE PAD MINIMUM THICKNESS – Check cleanliness of master cylinder rod and
boot.
1 mm (1/32 in)
– Check master cylinder boot for cracks or
NOTE: The brake pad grooves are wear indica- damage. Replace as necessary.
tors. Hand Lever
Check hand lever as follows:
– Lever pivot bolt cleanliness
– Lever pivot bolt movement.
Brake Pedal
1. Check brake pedal as follows:
– Brake pedal pivot movement
tmr2011-037-008_a
BRAKE PAD GROOVE

– Brake pedal pivot cleanliness.
2. If required, clean then lubricate brake pedal
NOTICE Brake pads must always be replaced pivot using XPS SYNTHETIC GREASE (P/N 293
in pairs. 550 010).
Brake Caliper Brake Hoses
1. Remove caliper then check the following com- 1. Check hoses for leaks, crushed, deformations,
ponents: cracking or scrapes.
– Check brake pad pin NOTE: Any deformation can restrict the proper
– Check caliper boots for cracks flow of fluid and cause braking problems.
– Check caliper movement on its support
– Check pistons movement Replacing the Brake Fluid
– Check pistons for scratches, rust or other Draining the Brake Fluid
damages.
1. Clean and remove reservoir cover with its di-
2. Clean the following components using the rec- aphragm.
ommended product or an equivalent:
2. Connect a clear hose onto bleeder.
– Brake pads
– Caliper support and slider
– Caliper pistons and pin.
NOTE: Do not remove pistons from caliper for
cleaning them.
3. Lubricate caliper slider 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 tmr2011-037-101_a
TYPICAL
BRAKES subsection for details. 1. Caliper bleeder
2. Clean brake disc using the recommended prod-
uct or an equivalent. 3. Loosen bleeder.
4. Pump brake lever(s) and/or brake pedal until no
Master Cylinder more fluid flows out.
1. Check master cylinder as follows: 5. Repeat draining procedure for the other bleed-
– Leaks or damages. ers.
– Brake fluid level.
vmr2017-103 21
NOTE: To locate all bleeders according to ve- Bleeding the Brake System (Using a Vacuum
hicle configuration, refer to EXPLODED VIEW Pump)
and BRAKE CIRCUIT CONFIGURATIONS. See NOTE: Brake fluid reservoir must be kept full to
BRAKES subsection. prevent air from being pumped into the system.
Filling the Brake Fluid 1. Unscrew all bleeders until brake fluid comes
1. Add recommended brake fluid to MAX. mark. out then close it.
Do not overfill. NOTE: To locate all bleeders according to ve-
hicle configuration, refer to EXPLODED VIEW
and BRAKE CIRCUIT CONFIGURATIONS. See
BRAKES subsection.
2. Install the Vacuum/pressure pump onto
bleeder.
REQUIRED TOOL
VACUUM/PRESSURE
PUMP
(P/N 529 021 800)
3. Place pump to vacuum position.

4. Pump vacuum pump a few times.
vmo2012-012-046_a 5. Loosen bleeder.
TYPICAL - BRAKE FLUID RESERVOIR
6. Continue to pump until no more air bubbles ap-
pear in clear hose.
7. Close then tighten bleeder.
TIGHTENING TORQUE
5.5 N•m ± 1.5 N•m
Bleeder
8. Add recommended brake fluid to MAX. mark.

Do not overfill.
9. Perform bleeding procedure for the other bleed-
ers.
10. Check brakes operation:
– If brakes feel spongy, bleed system again
then carry out the BRAKE SYSTEM PRES-
vmo2012-012-035_a SURE VALIDATION as detailed in BRAKES
TYPICAL - UNDER THE SEAT subsection.
1. Brake fluid reservoir
Bleeding the Brake System (Manual
NOTE: If applicable, ensure filler cap diaphragm is Procedure)
fully retracted before closing the cap.
NOTE: Brake fluid reservoir must be kept full to
RECOMMENDED BRAKE FLUID prevent air from being pumped into the system.
BRAKE FLUID GTLMA DOT4 (P/N 293 600 131) 1. Connect a clear hose onto bleeder.
2. Pump up system pressure slowly using brake
WARNING pedal and/or lever(s) until resistance is felt.
Use only DOT 4 brake fluid from a sealed con- 3. Depress and hold brake pedal and/or lever(s).
tainer. 4. Open bleeder and then close it.
Do not use brake fluid from an old or already
opened container. 5. Release brake pedal and/or lever(s) slowly.
22 vmr2017-103
NOTE: Do not release brake pedal and/or lever(s)

until bleeder has been closed.
6. Repeat procedure until fluid flows out without
any air bubbles.
7. Tighten bleeder.
TIGHTENING TORQUE
5.5 N•m ± 1.5 N•m
Bleeder
8. Perform bleeding procedure for the other bleed-

ers.
NOTE: To locate all bleeders according to ve-
hicle configuration, refer to EXPLODED VIEW
and BRAKE CIRCUIT CONFIGURATIONS. See
BRAKES subsection.
9. Check brakes operation:
– If brakes feel spongy, bleed system again
then carry out the BRAKE SYSTEM PRES-
SURE VALIDATION as detailed in BRAKES
subsection.
BODY
Inspecting Seat Latch Operation
Ensure seat latch functions properly and that seat
is properly secured when latched.
FRAME
Inspecting the Frame
Inspect frame for damages such as:
– Cracks
– Dents
– Twisting
– Deformation
– Corrosion
– Loose fasteners.
Pay particular attention to:
– Front and rear frame extensions (body mod-
ules)
– Underside of frame
– Suspension attachment points
– Engine attachment points.
Inspecting the Tow Hitch

1. Ensure tow hitch receptacle module is solidly
mounted.
2. Inspect hitch for cracks and other damages.
3. Repair or replace if necessary.
vmr2017-103 23
Subsection XX (STORAGE PROCEDURE)
STORAGE PROCEDURE
SERVICE PRODUCTS
BRP HEAVY DUTY CLEANER ....................................................... 293 110 001 ............................................. 3
XPS FUEL STABILIZER.................................................................. 413 408 601 ............................................. 1
XPS LUBE...................................................................................... 293 600 016 ......................................... 1, 3
XPS MULTI-PURPOSE CLEANER ................................................. 219 701 709 ............................................. 3
XPS STORAGE OIL (EXCEPT U.S. COUNTRY) ............................. 413 711 600 ............................................. 1
XPS STORAGE OIL (U.S. COUNTRY ONLY) ................................. 413 711 900 ............................................. 1
GENERAL Proceed as follows:

If the ATV is not used or is to be stored for an 1. Remove side body panels.
extended period of time, more than 4 months, be 2. Remove spark plugs.
sure to perform the storage procedures described 3. Spray storage oil into each cylinder (see follow-
below. ing table).
Where applicable, refer to the appropriate sub- NOTE: Use the storage oil as per country availabil-
sections in this manual for details of the required ity.
tasks as outlined in these procedures.
RECOMMENDED PRODUCTS
PROCEDURES XPS STORAGE OIL (EXCEPT U.S. COUNTRY)
(P/N 413 711 600)
NOTE: To facilitate the inspection and ensure
adequate lubrication of components, it is rec- XPS STORAGE OIL (U.S. COUNTRY ONLY)
ommended to clean the entire vehicle. Refer to (P/N 413 711 900)
VEHICLE CLEANING in this subsection.
4. Press start button, 1 or 2 seconds maximum, to
lubricate cylinders.
FUEL SYSTEM
5. Reinstall spark plugs.
Fuel System Protection NOTE: Do not run engine during storage period.
Pour fuel stabilizer in fuel tank and fill up fuel tank.
Start vehicle to allow for fuel stabilizer to spread Engine Air Intake System
through the fuel system. Remove parts required for access to engine air in-
Follow the manufacturer's instructions for proper let hose, refer to AIR INTAKE SYSTEM subsec-
use. tion.
RECOMMENDED FUEL SYSTEM PROTECTION
Block engine air inlet hose using a rag to prevent
intrusion of small animals.
XPS FUEL STABILIZER (P/N 413 408 601)
CVT Protection
NOTICE Fuel stabilizer should be added 1. Remove drive belt. Refer to CONTINUOUSLY
prior to engine lubrication to ensure fuel sys- VAIABLE TRANSMISSION (CVT).
tem components protection against varnish
deposits. 2. Inspect and clean pulleys.
3. Protect pulleys by spraying XPS LUBE (P/N 293
ENGINE 600 016) on pulley faces.
NOTE: Do not reinstall drive belt.
Engine Internal Lubrication
4. Close CVT cover.
Engine internal parts must be lubricated to protect
them from rust formation during the storage pe- 5. Remove CVT outlet from exhaust system heat
riod. shield and from CVT outlet hose.
vmr2012-006 1
vmr2012-007-001_a
TYPICAL
vmr2012-011-007_c
1. CVT cover
2. Exhaust system heat shield TYPICAL - RENEGADE MODEL ILLUSTRATED
3. CVT outlet 1. Muffler
2. Block with rag here
6. Block CVT outlet hose using a rag.
ELECTRICAL SYSTEM
Battery Removal
Remove battery from ATV.
Store and charge battery as per battery manufac-
turer's recommendations.
DRIVE SYSTEM
Lubricate rear propeller shaft U-joints.
CHASSIS
Lubrication
vmr2012-007-002_a
Lubricate front and rear suspension.
TYPICAL
1. CVT outlet hose
Tire Pressure
Exhaust System Inflate tires to recommended pressure.
Block muffler outlet using a rag to avoid intrusion
of small animals. Vehicle Cleaning
Wash and dry the vehicle.
NOTICE Never use a high pressure washer to
clean the vehicle. USE LOW PRESSURE ONLY
(such as a garden hose). The high pressure can
cause electrical or mechanical damages.
Remove any dirt or rust.
To clean plastic parts, use only flannel cloths and
XPS ATV Wash (P/N 219 701 702) or soapy water.
To clean vinyl parts, use only flannel cloths and a
mild non abrasive multipurpose cleaner.
2 vmr2012-006
RECOMMENDED PRODUCT FOR PLASTIC PARTS

XPS ATV Wash
(P/N 219 701 702)
Soapy water
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 avoid
damaging the glossy finish on Polypropylene
body parts, never use:
– Petroleum based cleaning products
– XP-S ATV Finishing Spray (P/N 219 701 704)
– XP-S ATV Cleaning Kit (P/N 219 701 713).
RECOMMENDED PRODUCT FOR VINYL PARTS
XPS MULTI-PURPOSE CLEANER (P/N 219 701 709)
To clean heavily soiled parts of the vehicle, includ-

ing metallic parts use the following.
RECOMMENDED PRODUCT FOR HEAVILY
SOILED PARTS
BRP HEAVY DUTY CLEANER (P/N 293 110 001)
Inspect the vehicle and repair any damage. Touch

up all metal spots where paint has been scratched
off.
Spray all metal parts with an appropriate lubricant
for rust protection.
RECOMMENDED RUST PROTECTION
XPS LUBE (P/N 293 600 016)
Vehicle Protection
Protect the vehicle with a cover to prevent dust
accumulation during storage.
NOTICE The vehicle has to be stored in a cool
and dry place, and covered with an opaque
tarpaulin. This will prevent sun rays and grime
from affecting plastic components and vehicle
finish.
vmr2012-006 3
Subsection 05 (PRESEASON PREPARATION)
PRESEASON PREPARATION
Proper vehicle preparation is required after a stor-
age period.
Any worn, broken or damaged parts found must
be replaced.
Remove rags that were installed for storage: en-
gine air inlet hose, CVT outlet hose and muffler.
Clean drive and driven pulleys to remove storage
protective lubricant, then reinstall drive belt. Refer
to CONTINUOUSLY VARIABLE TRANSMISSION
(CVT).
Remove parts required to allow inspection of
entire engine air inlet system. Check for animal
nests and other foreign material. Reinstall re-
moved parts.
Drain fuel tank and fill with fresh fuel if a fuel sta-
bilizer was not used for storage.
Reinstall battery. Refer to CHARGING SYSTEM
subsection.
Inflate tires to the recommended pressure.
Do each items indicated in the table entitled:
EVERY 3 000 KM (2,000 MI) OR 100 HOURS
(whichever comes first)
EVERY 1 500 KM (1,000 MI) OR 50 HOURS
(whichever comes first)
NOTE: If the EVERY 6 000 km (4,000 mi) OR 200

HOURS OF OPERATION maintenance service is
due, also perform the related items as per the
MAINTENANCE SCHEDULE.
Test drive vehicle.
vmr2016-109 1
Subsection XX (SPECIAL PROCEDURES)
SPECIAL PROCEDURES
SERVICE PRODUCTS
XPS LUBE...................................................................................... 293 600 016 ........................................... 2
GENERAL WHAT TO DO IF WATER IS IN

NOTE: Component failures resulting from these THE AIR FILTER HOUSING
events are not warrantable. Inspect the drain reservoir underneath the air filter
Refer to the appropriate subsections in this man- housing to validate if water is present.
ual for details of the required tasks as outlined in
these procedures.
WHAT TO DO IF WATER IS IN
THE CVT
The CVT drain plug is located on the rear portion
of the CVT cover. It is accessible from the rear LH
fender.
Inspect the CVT drain plug to validate if water is
present.
vmo2012-012-054_a
TYPICAL
1. Air filter housing drain reservoir
If water is present, press clamp and remove reser-

voir to drain water from air filter housing.
If one of the following conditions is met, refer to
WHAT TO DO IF VEHICLE IS IMMERSED IN WA-
TER:
– If more than 50 ml (2 U.S. oz) of water (approxi-
mately 5 drain reservoirs) is found in the air filter
vmo2013-007-012_a housing.
1. Drain plug – If any deposits are present in the drain reservoir.
2. Spring clamp
NOTICE Failure to service vehicle properly
NOTICE If water is present in the CVT, it could may lead to component permanent damage.
result in belt slippage. The engine will acceler-
ate but the vehicle will remain still.
WHAT TO DO IF VEHICLE IS
If water is present, remove CVT drain plug to ex- TURNED OVER
pel water.
In the event the vehicle was rolled over tilted on
Reinstall the drain plug and secure it using the it's side; put the vehicle back on its wheel, wait 3
spring clamp. to 5 minutes, then check the following:
NOTE: Make sure hose is properly inserted on – Inspect air filter housing for oil accumulation,
CVT cover nipple. if any oil is found, clean air filter and air filter
If an appreciable amount of water is drained from housing.
the CVT cover, remove the cover and properly ser- – Check engine oil level and refill if necessary.
vice the CVT. – Check engine coolant level and refill if neces-
sary.
– Check gearbox oil level and refill if necessary.
vmr2013-008 1
Subsection XX (SPECIAL PROCEDURES)
– Check rear final drive oil level and refill if neces- Replace the engine oil (without starting the en-
sary. gine).
– Inspect suspension components and steering Replace gearbox oil.
system components.
Inspect fuel tank for water intrusion. If in doubt,
– Inspect body and chassis for any damages. flush fuel tank and refill with new fuel.
– Start engine. If the oil pressure light stays on,
Inspect fuel tank vent system for water intrusion.
stop engine immediately and investigate the
Clean as required. Replace breather filter. Carry
problem.
out a fuel pump pressure test.
– After restarting engine, check for indicator
lights or messages displayed in the multifunc- Inspect brake system for water intrusion. Replace
tion gauge. Correct as required. brake fluid as required.
Limited model: Inspect ACS intake hose for any Inspect all lights for water intrusion. Dry as re-
trace of oil. Clean thoroughly if oil is found in hose. quired.
If oil reached compressor, disassemble compres- Inspect multifunction switch for water intrusion.
sor and clean thoroughly. Dry as required.
Remove spark plugs. Crank engine in drowned
WARNING mode to expel any water.
Do not use vehicle if any of the controls,
steering, suspension or brakes are damaged CAUTION Keep away from spark plug
or inoperative. holes to avoid being splashed when cranking
engine.
WHAT TO DO IF VEHICLE IS Add a small quantity of engine oil in cylinders (ap-
IMMERSED IN WATER proximately 2 teaspoonfuls).
In the event the vehicle was immersed, proceed Install spark plugs (replace if required).
with the following.
WARNING
NOTICE A vehicle that was immersed may Before starting engine, use B.U.D.S. and
be damaged or prone to malfunctions (short check vehicle for fault codes.
and long term) if not serviced promptly and ap-
propriately. Do not crank or start engine. Start the engine and allow it to run at idle speed
Drain the entire air intake system. Inspect the until the engine reaches its operating tempera-
throttle body. Remove parts as required. ture.
Inspect and clean air box as needed. Remove Stop the engine.
parts as required. Change engine oil and filter.
Replace the air filter. NOTE: Change oil as many times as necessary,
Drain, inspect and clean the CVT. until there is no whitish appearance in engine oil.
Limited model: Inspect ACS hose. If water is Replace front differential oil.
present, disassemble and dry compressor. Replace rear final drive oil.
Inspect front differential and rear final drive vents. Lubricate front and rear suspensions and propeller
Clean or replace as necessary shaft joints.
Drain muffler and exhaust pipes (removal re- Spray all metal parts with XPS LUBE (P/N 293 600 016).
quired). Test drive to confirm proper operation.
Clean muffler spark arrester..
Remove fuse box covers. Check for presence of
water. Dry as necessary.
Disconnect, clean and dry the following electrical
connectors:
– ECM
– Multifunction gauge
– DPS.
2 vmr2013-008
Subsection XX (ENGINE REMOVAL AND INSTALLATION)
ENGINE REMOVAL AND INSTALLATION

SERVICE TOOLS
ENGINE LIFTING TOOL ................................................................ 529 036 022 ........................................... 5
Outlander models
13 ± 2 N•m
(115 ± 18 lbf•in)
7 ± 1 N•m
(62 ± 9 lbf• in)
NEW
4 ± 1 N•m
(35 ± 9 lbf•in)
4.9 ± 0.4 N•m
(43 ± 4 lbf•in)
1000
1000
62.5 ± 7.5 N•m
(46 ± 6 lbf•ft)
62.5 ± 7.5 N•m
(46 ± 6 lbf•ft)
NEW = Component must be replaced when removed.
vmr2013-009-100_a
vmr2013-009 1
PROCEDURES
ENGINE REMOVAL
1. Place vehicle on a workstation equipped with
an engine-lifting hoist.
2. Disconnect negative (-) cable from battery.
3. Carry out the following operations. Refer to ta-
ble.
REFERENCES
OPERATIONS
(SUBSECTION)
Safely lift and support vmr2012-009-003_a
INTRODUCTION
the vehicle TYPICAL - OUTLANDER SHOWN
1. RH footrest support
FUEL TANK AND
Release fuel pressure 5. Move throttle body aside to make room.
FUEL PUMP
PERIODIC
Drain engine coolant MAINTENANCE
PROCEDURES
Remove front body module
BODY
Remove RH footrest panel
Remove air filter housing AIR INTAKE SYSTEM
Remove muffler
EXHAUST SYSTEM
Remove exhaust pipes
Remove CVT air inlet CONTINUOUSLY
VARIABLE
Remove CVT air outlet TRANSMISSION (CVT)
Disconnect positive (+) vmr2012-009-001
STARTING SYSTEM
starter cable TYPICAL - THROTTLE BODY ATTACHED ON FRAME
Disconnect TPS connector 6. Move master cylinder aside to make room.

ELECTRONIC FUEL
Disconnect MAPTS INJECTION (EFI)
connector
Remove intake manifold INTAKE MANIFOLD
Remove spark plug cables IGNITION SYSTEM
4. Remove RH footrest support.
vmr2012-009-002
TYPICAL - MASTER CYLINDER ATTACHED ON REAR FENDER
7. Move crankcase vent hose as illustrated.
2 vmr2013-009
11. Disconnect ignition coil connector.
vmr2012-009-004_a
TYPICAL
1. Crankcase vent hose
vmr2012-009-007_a
8. Disconnect both engine harness connectors TYPICAL - FROM LH SIDE

(HIC). 1. Ignition coil connector
12. Remove the following locking ties.
vmr2012-009-005_a
TYPICAL
1. Engine harness connectors (HIC) vmr2012-009-008_a
TYPICAL
9. Move ECM as illustrated. 1. Locking ties
13. Remove plastic cover from engine.
vmr2012-009-006
TYPICAL
10. Cut locking ties from ignition coil harness.

vmr2013-009 3
16. Remove magneto harness from its location

along vehicle and gather it in a bundle near
engine.
NOTE: It may be necessary to slightly lift the rear
body module to ease magneto harness removal.
Refer to BODY subsection.
vmr2012-009-009_a
TYPICAL
1. Plastic cover
14. Remove harnesses support from engine.
vmr2012-009-011_a
MAGNETO HARNESS (SOME PARTS REMOVED FOR CLARITY)
17. Disconnect vent hose from gearbox.
vmr2012-009-010_a
TYPICAL
1. Harnesses support
15. Disconnect magneto connector from voltage

regulator rectifier.
vmr2012-009-012_a
TYPICAL - OUTLANDER SHOWN

1. Vent hose
18. Disconnect coolant hoses as illustrated.
vmr2012-043-013_b

1. Magneto connector
4 vmr2013-009
Engine Lifting
1. Install the ENGINE LIFTING TOOL (P/N 529 036
022) on engine.
529036022
vmr2012-009-025_a
500/650/800R ENGINES - SOME PARTS REMOVED FOR CLARITY

1. Disconnect the following coolant hoses
vmr2012-009-015
TYPICAL
2. Remove upper retaining screws from engine.
vmr2012-009-013_a
1000 ENGINE - SOME PARTS REMOVED FOR CLARITY

1. Disconnect the following coolant hoses
19. Remove main ground wire from engine.
vmr2012-009-016_a
LH SIDE
1. Upper retaining screws
3. Remove rear retaining bolt from engine.
vmr2012-009-014_a

1. Main ground wire
vmr2013-009 5
vmr2012-009-020_a
1. Oetiker clamps
vmr2012-009-017_a
LH SIDE
7. Move front propeller shaft bellows forward.
1. Rear retaining bolt
4. Remove front retaining bolt from engine.
vmr2012-009-021_a
1. Front propeller shaft bellows

vmr2012-009-018_a
8. Remove propeller shaft screw from gearbox
LH SIDE
1. Front retaining bolt output shaft.
5. Remove engine support plate from frame.
vmr2012-009-022_a
vmr2012-009-019_a 1. Rear propeller shaft screw

RH SIDE
1. Engine support plate screws 9. Slightly lift engine and move it forward to dis-
connect rear propeller shaft from engine.
6. Remove the following Oetiker clamps from
front propeller shaft.
6 vmr2013-009
10. Move propeller shaft yoke downwards to TORQUE

make room.
62.5 N•m ± 7.5 N•m
Engine retaining bolts
6. If applicable, fill engine as per specification. Re-

fer to LUBRICATION SYSTEM subsection.
7. Fill and bleed cooling system. Refer to PERI-
ODIC MAINTENANCE PROCEDURE subsec-
tion.
8. Check for any leaks.
9. Reinstall all the remaining parts as the reverse
of removal procedure. Refer to exploded views
and proper subsections.
10. Test drive vehicle to confirm proper operation.
vmr2012-009-023
TYPICAL
ENGINE MOUNTS
REPLACEMENT
11. Move engine rearward to disconnect front pro-
peller shaft from engine. NOTE: Use the same procedure for the front and
rear engine mounts.
12. Remove engine by the RH side.
Engine Mount Removal
Insert a punch into engine mount bushing and
push the opposite engine mount out.
tmr2011-007-011
vmr2012-009-024
TYPICAL
TYPICAL
Engine Mount Installation
ENGINE INSTALLATION The installation is the reverse of the removal pro-
The installation is the reverse of the removal procedure.
cedure. However, pay attention to the following.
1. Inspect condition of engine mounts.
2. Install engine on vehicle.
3. Install all engine retaining bolts loosely.
4. Install and tighten propeller shaft screw. Refer
to REAR DRIVE subsection.
5. Tighten engine retaining bolts to specification.
vmr2013-009 7
Subsection XX (AIR INTAKE SYSTEM)
AIR INTAKE SYSTEM

AIR FILTER HOUSING
Loctite 5150 1.6 ± 0.4 Nm

(silicone sealant) (14 ± 4 lbfin)
6 ± 1 Nm
(53 ± 9 lbfin)
Suspension
grease
6 ± 1 Nm
(53 ± 9 lbfin)
Loctite 5150
(silicone sealant)
2.5 ± 0.5 Nm

(22 ± 4 lbfin)
To throttle body
To engine
vmr2012-010-100_a
vmr2013-010 1
GENERAL
NOTICE Never modify the air intake system.
Otherwise, engine performance degradation
or damage can occur. The engine is calibrated
to operate specifically with these components.
PROCEDURES
AIR FILTER
For air filter servicing, refer to PERIODIC MAIN-
TENANCE PROCEDURES subsection.
vmr2012-033-001_a
AIR FILTER HOUSING TYPICAL

1. Dashboard support
Air Filter Housing Removal
4. Remove screws securing CVT air inlet to air fil-
1. Remove front body module. Refer to BODY ter housing.
subsection.
2. On applicable models, remove the following
plastic rivets.
vmr2012-010-002_a
TYPICAL
1. CVT air inlet screws
vmr2012-013-005_a
5. Remove ECM retaining screws.
TYPICAL
1. Plastic rivets
3. On applicable models, move dashboard support

toward front.
vmr2012-010-001_a
1. ECM retaining screws
6. Disconnect both engine harness connectors

(HIC).
2 vmr2013-010
7. Move ECM aside.
vmr2012-010-004_a
AIR INTAKE TUBE MOVED TO GAIN ACCESS

1. Coolant tank LH retaining screw
vmr2012-009-005_a
TYPICAL
1. Engine harness connectors (HIC)
8. Remove air intake tube retaining screw.
vmr2012-010-005_a
1. Coolant tank RH retaining screw
11. Detach link rod from shift lever.

vmr2012-010-003_a
1. Air intake tube retaining screw
9. Move air intake tube to gain access to coolant

tank LH screw.
10. Remove coolant tank retaining screws.
vmr2012-010-006_a

1. Link rod retaining bolt
12. Carefully move link rod downward.
vmr2013-010 3
vmr2012-010-007
vmr2012-010-010_a
TYPICAL - OUTLANDER SHOWN TYPICAL
1. Gearbox vent hose
13. Remove the following locking ties.
15. Detach crankcase vent hose from air filter
housing.
vmr2013-010-001_a

1. Locking tie to remove - location shown
vmr2012-010-011_a
TYPICAL
1. Crankcase vent hose
16. Remove air filter housing retaining screws.
vmr2012-010-009_a

1. Locking ties to remove
14. Detach gearbox vent hose from air filter hous-

ing.
vmr2012-010-012_a
SCREWS LOCATED NEAR SEAT ANCHORAGE

1. Air filter housing retaining screws
4 vmr2013-010
vmr2012-010-013_a
vmr2012-010-015_a
SCREW LOCATED UNDER COOLANT TANK
1. Air filter housing retaining screw
1. Throttle body
20. Remove air filter housing by pulling it towards

rear.
vmr2012-010-014_a
SCREW LOCATED ON LH SIDE - ACCESS FROM UNDER SHIFT

LEVER vmr2012-010-016_a
1. Air filter housing retaining screw
AIR FILTER HOUSING REMOVAL
17. Detach throttle body from intake adapters.
21. Remove remaining components from air filter
18. Slightly lift air filter housing upward. housing.
19. Move throttle body aside to make room.
Air Filter Housing Inspection
Check air filter housing for cracks or other dam-
age. Replace if necessary.
Air Filter Housing Installation

The installation is the reverse of the removal pro-
Refer to applicable exploded views for tightening
torque.
vmr2013-010 5
Subsection XX (EXHAUST SYSTEM (TRANSVERSAL MOUNTING))
EXHAUST SYSTEM (TRANSVERSAL

MOUNTING)
Single Cylinder Models
Max Models
10 ± 2 N•m
(89 ± 18 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
NEW
Bolt down,
nut facing outwards
40 ± 1 N•m NEW
(30 ± 1 lbf•ft) 13 ± 1 N•m
(115 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
See tightening
sequence
vmr2017-130-101_a
vmr2017-130 1
Twin Cylinder Models
Max Models
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
13 ± 1 N•m
(115 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
NEW
Bolt down,
nut facing outwards
40 ± 1 N•m
(30 ± 1 lbf•ft)
10 ± 2 N•m
(89 ± 18 lbf•in) See tightening
sequence
9 ± 1 N•m
(80 ± 9 lbf•in) 9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
See tightening PRO series

sequence
vmr2017-130-102_a
2 vmr2017-130
GENERAL
WARNING
Never touch exhaust system components im-
mediately after the engine has run.
PROCEDURES
MUFFLER
Removing the Muffler vmr2015-014-503_a
1. Loosen exhaust pipe clamp.

Inspecting the Muffler
Check muffler and cover for cracks or other dam-
ages. Replace if necessary.
Check if the rubbers support are brittle, hard or
otherwise damaged. Replace if needed.
Installing the Muffler

Reverse the removal procedure.
vmr2015-014-501_a
HEAT SHIELD
1. Clamp nut
Removing the Heat Shield
2. Remove muffler retaining bolts. 1. Refer to BODY and remove following LH body
panels.
vmr2015-014-502_a
1. Bolt
2. Washer
3. Nut
vmr2015-027-002_a
3. Remove the muffler. LH SIDE

1. Side panel
2. Side panel extension
3. Rear panel extension (Max models)
2. Remove outer heat shield retaining bolts.

NOTICE Do not use an impact tool to remove
or install heat shield bolts.
vmr2017-130 3
MAX Models
4. Remove heat shield extension retaining bolts.
vmr2015-014-505_a
TYPICAL - OUTER HEAT SHIELD - SHORT MODEL SHOWN

1. Heat shield bolts
3. Remove muffler for rear and inner heat shield

removal.
vmr2013-011-002_a
1. Outer heat shield extension

2. M6 x 16 bolts
vmr2015-014-509_a
vmr2015-014-511_a
TYPICAL - REAR HEAT SHIELD REMOVAL
1. Rear heat shield TYPICAL
2. M6 x 25 bolt 1. Inner heat shield extension
3. M6 elastic nut 2. M6 x 16 bolts
4. M6 x 16 bolts with washers
Installing the Heat Shield

Reverse the removal procedure. However, pay at-
tention to the following.
Refer to exploded view for torque specifications,
and following illustration for rear heat shield tight-
ening sequence.
vmr2015-014-512_a
TYPICAL - INNER HEAT SHIELD REMOVAL

1. Inner heat shield
2. M6 x 16 bolts
4 vmr2017-130
vmr2015-027-101_a
REAR HEAT SHIELD TIGHTENING SEQUENCE
HEAD PIPE (SINGLE CYLINDER vmr2015-014-508_a
1. Retaining nuts
MODELS)
4. Remove front head pipe from vehicle.
Removing the Head Pipe
NOTE: The space to remove the front head pipe
1. Remove MUFFLER See procedure in this sub- is limited. Remove it without forcing it.
section.
2. Refer to BODY and remove RH and LH inner Inspecting the Head Pipe
fender panels. Check head pipe for cracks, bending or other dam-
ages. Replace if needed.
Installing the Head Pipe

Install NEW exhaust gasket and pipe exhaust re-
taining nuts.
TIGHTENING TORQUE
13 N•m ± 1 N•m
Head pipe nuts
Exhaust System Tightening Sequence

vmr2015-027-003_a
Install all nuts and bolts loosely.
LH ILLUSTRATED, RH SIMILAR Install springs.
1. Remove inner fender panel (both sides)
Tighten all fasteners as per following tightening
3. From RH side of vehicle, remove head pipe re- sequence. Refer to exploded view for torque
taining nuts. specifications.
vmr2015-014-002_a
EXHAUST SYSTEM TIGHTENING SYSTEM SEQUENCE
vmr2017-130 5
Y-PIPE (TWIN CYLINDER HEAD PIPE (TWIN CYLINDER

MODELS) MODELS - FRONT CYLINDER)
Removing the Y-Pipe Removing the Front Head Pipe
1. Remove MUFFLER. See procedure in this sub- 1. Remove Y-PIPE See procedure in this subsec-
section. tion.
2. Remove OUTER HEAT SHIELD. See procedure 2. Refer to BODY and remove LH and RH inner
in this subsection. fenders.
3. Remove the following parts:
– Springs from head pipe
– Y-pipe retaining nuts on rear cylinder
– Y-pipe from vehicle.
vmr2015-027-003_a
1. Remove inner fender panel (both sides)
3. From RH side of vehicle, remove head pipe re-

taining nuts.
vmr2015-027-005_a
1. Springs (4)
2. Y-pipe retaining nuts on rear cylinder (2)
Inspecting the Y-Pipe

Check Y-pipe for cracks, bending or other dam-
Installing the Y-Pipe

Install NEW exhaust gasket and exhaust pipe re-
taining nuts.
Properly position exhaust pipe before tightening.
vmr2015-027-004_a
Refer to EXHAUST SYSTEM TIGHTENING SE- 1. Head pipe retaining nuts
QUENCE.
4. Remove front head pipe from vehicle.
TIGHTENING TORQUE
Head pipe nuts 13 N•m ± 1 N•m
(rear cylinder) (115 lbf•in ± 9 lbf•in)
6 vmr2017-130
vmr2015-027-100_a
vmr2015-027-006_a
1. Head pipe

is limited. Remove it without forcing it.
Inspecting the Front Head Pipe

Check head pipe for cracks, bending or other dam-
Installing the Front Head Pipe

Install NEW exhaust gaskets and nuts.
Refer to EXHAUST SYSTEM TIGHTENING SE-
QUENCE.
TIGHTENING TORQUE
13 N•m ± 1 N•m
Head pipe nuts
Exhaust System Tightening Sequence

Install springs.
sequence. Refer to exploded view for torque
specifications.
vmr2017-130 7
Subsection XX (EXHAUST SYSTEM (LONGITUDINAL MOUNTING))
EXHAUST SYSTEM (LONGITUDINAL

MOUNTING)
Max models
9 ± 1 N•m
(80 ± 9 lbf•in) 9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
13 ± 1 N•m
(115 ± 9 lbf•in)
40 ± 1 N•m
(30 ± 1 lbf•ft)
Bolt down,
nut facing outwards NEW
NEW
NEW
13 ± 1 N•m
(115 ± 9 lbf•in)
10 ± 2 N•m
(89 ± 18 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m PRO series
(80 ± 9 lbf•in)

vmr2017-130-100_a
vmr2017-131 1
GENERAL 3. Remove the muffler.
WARNING Inspecting the Muffler

Never touch exhaust system components im- Check muffler and cover for cracks or other dam-
mediately after the engine has run. ages. Replace if necessary.
Check if the rubber support is brittle, hard or oth-
PROCEDURES erwise damaged. Replace if needed.
SPARK ARRESTER Installing the Muffler

For the installation, reverse the removal proce-
For spark arrester servicing, refer to PERIODIC dure. However, pay attention to the following.
MAINTENANCE PROCEDURES subsection.
Install new exhaust gasket.
MUFFLER
HEAT SHIELD
Removing the Muffler
Removing the Heat Shield
1. Loosen exhaust pipe clamp.
1. Refer to BODY and remove LH panel.
2. Remove heat shield retaining bolts.
NOTICE Do not use an impact tool to remove
or install heat shield bolts.
vmr2012-011-003_a
LH SIDE — PARTS REMOVED FOR CLARITY

1. Muffler
2. Loosen clamp
2. Remove muffler retaining bolts. vmr2012-011-008_a
TYPICAL LH SIDE — PARTS REMOVED FOR CLARITY

1. Heat shield
2. Remove bolts
3. Remove muffler for rear and inner heat shield

removal.
vmr2012-011-002_a

1. Muffler
2. Remove bolts
2 vmr2017-131
vmr2015-014-511_a
TYPICAL
vmr2015-014-509_a 1. Inner heat shield extension
TYPICAL - REAR HEAT SHIELD REMOVAL 2. M6 x 16 bolts
1. Rear heat shield
2. M6 x 25 bolt Installing the Heat Shield
3. M6 elastic nut
4. M6 x 16 bolts with washers
dure. However, pay attention to the following.
Refer to exploded view for torque specifications,
and following illustration for rear heat shield tight-
ening sequence.
vmr2015-014-512_a
TYPICAL - INNER HEAT SHIELD REMOVAL

1. Inner heat shield
2. M6 x 16 bolts
vmr2015-027-101_a
Max Models REAR HEAT SHIELD TIGHTENING SEQUENCE
4. Remove heat shield extensions retaining bolts.

Y-PIPE
Removing the Y-Pipe
1. Remove MUFFLER. See procedure in this sub-
section.
2. Remove HEAT SHIELD. See procedure in this
subsection.
– Springs from head pipe
– Y-pipe retaining nuts on rear cylinder.
– Y-pipe from vehicle.
vmr2013-011-002_a

1. Outer heat shield extension
2. M6 x 16 bolts
vmr2017-131 3
vmr2012-011-010_a
vmr2012-011-012_a
TYPICAL LH SIDE — PARTS REMOVED FOR CLARITY TYPICAL
1. Y-pipe 1. Remove
2. Springs
3. From RH side of vehicle, remove head pipe re-
Inspecting the Y-Pipe taining nuts.
Check Y-pipe for cracks, bending or other dam-
Installing the Y-Pipe

cedure.
Install NEW exhaust gaskets and exhaust pipe re-
taining nuts.
Properly position exhaust pipe before tightening.
TIGHTENING TORQUE
Head pipe nuts 13 N•m ± 1 N•m
(rear cylinder) (115 lbf•in ± 9 lbf•in)
HEAD PIPE (FRONT CYLINDER)

vmr2015-027-004_a
Removing the Front Head Pipe TYPICAL

1. Head pipe retaining nuts
1. Remove Y-PIPE See procedure in this subsec-
tion. 4. Remove front head pipe from vehicle.
2. Refer to BODY and remove rear part of RH
inner fender to reach head pipe screws (Out-
lander series only).
4 vmr2017-131
vmr2016-113-002_a
vmr2012-011-011_a
TYPICAL LH SIDE — PARTS REMOVED FOR CLARITY

1. Head pipe

is limited. Remove it without force.
Inspecting the Front Head Pipe

Check head pipe for cracks, bending or other dam-
Installing the Front Head Pipe

Install NEW exhaust gaskets.
Refer to EXHAUST SYSTEM TIGHTENING SE-
QUENCE.
TIGHTENING TORQUE
13 N•m ± 1 N•m
Head pipe nuts
Exhaust System Tightening System

Sequence
Install springs.
sequence. Refer to exploded view for torque
specifications.
vmr2017-131 5
Subsection 04 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM
SERVICE TOOLS
ADAPTER HOSE ........................................................................... 529 035 652 ............................................. 5
DISCONNECT TOOL ..................................................................... 529 035 714 ............................................. 5
PRESSURE GAUGE....................................................................... 529 035 709 ............................................. 5
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ....................................... 8, 12
vmr2016-114 1
COMPONENTS
Outlander 570/650 (except PRO package)
20 ± 2 N•m
(15 ± 1,5 lbf•ft)
NEW
Loctite 243
12 ± 1 N•m
(106 ± 9 lbf•in)
NEW
10 ± 1 N•m
(89 ± 9 lbf•in)
Engine oil
Engine oil
NEW
6 ± 0,7 N•m
(53 ± 6 lbf•in) Loctite 243 20 ± 2 N•m
(15 ± 1,5 lbf•ft)
Engine oil
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
7 ± 0,5 N•m
(62 ± 4 lbf•in)
Engine oil
Engine oil

vmr2015-028-001_a
2 vmr2016-114
COMPONENTS
Outlander 850/1000R and all models with PRO Package
20 ± 2 N•m
(15 ± 1.5 lbf•ft)
Loctite 243
12 ± 1 N•m
NEW (106 ± 9 lbf•in)
10 ± 1 N•m
(89 ± 9 lbf•in)
NEW
Engine oil
NEW
30 ± 2 N•m
(22 ± 1.5 lbf•ft)
Loctite 243
6 ± 0,7 N•m
(53 ± 6 lbf•in)
Engine oil
NEW
10 ± 1 N•m
(89 ± 9 lbf•in)
8 ± 1 N•m
(70 ± 9 lbf•in) Engine oil
Loctite 243
Loctite 243
7 ± 0,5 N•m
NEW = Component must be replaced when removed. (62 ± 4 lbf•in)
vmr2015-114-001_a
vmr2016-114 3
ENGINE LUBRICATION CIRCUIT
vmr2007-033-001_a
1. Camshaft bearings
2. Oil pressure switch
3. Oil filter
4. Oil pressure regulator valve
5. Oil strainer
6. Oil pump
7. Crankshaft main bearings
8. Crankshaft support bearing
9. Connecting rod bearings
4 vmr2016-114
INSPECTION Remove oil pressure gauge and adapter hose.

NOTE: To remove adapter hose from oil pressure
TESTING THE ENGINE OIL gauge, use the disconnect tool.
PRESSURE REQUIRED TOOL
NOTE: The engine oil pressure test should be DISCONNECT TOOL
done with a warm engine 100°C (212°F) and the (P/N 529 035 714)
recommended oil.
Remove the oil pressure switch. Refer to OIL Reinstall the oil pressure switch and remaining
PRESSURE SWITCH in this subsection. components.
Install the pressure test gauge with the proper
adapter hose in the OPS engine bore. TROUBLESHOOTING
REQUIRED TOOL LOW OR NO OIL PRESSURE
1. Oil level is too low.
PRESSURE GAUGE
(P/N 529 035 709) - Refill engine with recommended engine oil. Re-
fer to OIL LEVEL VERIFICATION in the PERIODIC
ADAPTER HOSE - Check for high oil consumption, refer to HIGH OIL
(P/N 529 035 652) CONSUMPTION in thisTROUBLESHOOTING.
- Check for engine oil leaks. For leak indicator
hose and leak indicator hole, refer to COOLING
SYSTEM INSPECTION in the PERIODIC MAIN-
TENANCE PROCEDURES subsection. Repair if
necessary.
2. Use of unsuitable engine oil type.
- Replace engine oil by the recommended engine
oil.
3. Clogged oil filter.
- Replace oil and oil filter at the same time.
4. Defective oil pressure switch.
- Test oil pressure switch, see procedure in this
subsection.
5. Defective or worn oil pump.
- Check oil pump, see procedure in this subsection.
vmr2015-028-100_a 6. Defective engine oil pressure regulator.
TYPICAL
1. Gauge connected in OPS engine bore - Check engine oil pressure regulator, see proce-
dure in this subsection.
The engine oil pressure should be within the fol- 7. Worn plain bearings in crankcase.
lowing values.
- Check plain bearing clearance, refer to BOTTOM
OIL PRESSURE 1250 RPM 6000 RPM END subsection.
300 kPa 8. Clogged engine oil strainer.
MINIMAL 70 kPa (10 PSI)
(44 PSI) - Clean engine oil strainer, see procedure in this
subsection.
150 kPa 350 kPa
NOMINAL
(22 PSI) (51 PSI)
OIL CONTAMINATION
250 kPa 450 kPa
MAXIMAL 1. Defective water pump seal ring or rotary seal.
(36 PSI) (65 PSI)
- Check for oil or coolant leak from indicator near
If the engine oil pressure is out of specifications, water pump, refer to COOLING SYSTEM IN-
SPECTION in the PERIODIC MAINTENANCE
check the points described in TROUBLESHOOT- PROCEDURES subsection. Replace seal if nec-
ING in this subsection. essary.
vmr2016-114 5
2. Cylinder head or cylinder base gasket leak. Removing the Oil Cooler
- Retighten cylinder head to specified torque, refer Refer to PERIODIC MAINTENANCE PROCE-
to TOP END subsection. Replace gasket if tight- DURES subsection to:
ening does not solve the problem.
– Drain engine oil. Refer to ENGINE OIL
3. Engine internal damage. CHANGE
- Repair engine. – Drain coolant. Refer to ENGINE COOLANT RE-
4. Oil cooler gasket leak. PLACEMENT.
- Replace oil cooler gasket and change engine oil. Remove oil cooler retaining screws.
HIGH OIL CONSUMPTION

1. Leaking breather oil seal.
- Check if the oil seal of the breather is brittle, hard
or damaged. Refer to BOTTOM END subsection.
2. Valve stem seals worn or damaged.
- Replace valve stem seals.
3. Worn piston rings (blue exhaust smoke).
- Replace piston rings.
PROCEDURES tmr2011-010-006_a
1. Retaining screws
OIL COOLER 2. Oil cooler
Outlander 850/1000R and all models Place rags or towels under oil cooler to catch re-
with PRO Package maining oil and coolant.
Remove oil cooler and discard gasket.
Oil Cooler Access
Refer to BODY and remove rear part of RH inner
fender panel.
tmr2011-010-007_a
1. Oil cooler
2. Gasket
vmr2016-114-001_a Inspecting the Oil Cooler

1. Remove Check oil cooler for cracks or other damage.
Installing the Oil Cooler

For installation, reverse the removal procedure.
Pay attention to the following details.
Wipe off any oil and coolant spillage.
6 vmr2016-114
Install a NEW gasket. Oil Pressure Switch Activation

Refer to PERIODIC MAINTENANCE PROCE- The oil pressure switch activates when the engine
DURES subsection and carry out the following: oil pressure is lower than following specified pres-
– Refill engine with recommended oil. See EN- sure range.
GINE OIL CHANGE. OIL PRESSURE SWITCH ACTIVATION RANGE
– Refill and bleed cooling system. See ENGINE
COOLANT REPLACEMENT. 30 kPa ± 10 kPa (4.35 PSI ± 1.45 PSI)
To check the function of the oil pressure switch,

OIL PRESSURE SWITCH (OPS) an oil pressure test has to be performed. Refer to
Oil Pressure Switch Location ENGINE OIL PRESSURE in this subsection.
If the engine oil pressure is good, perform the oil
pressure switch resistance test.
Testing the Oil Pressure Switch

Resistance
Disconnect the connector from the oil pressure
switch.
Check resistance as per following tables.
OPS ENGINE NOT
ENGINE
CONNECTOR RUNNING
PIN RESISTANCE ( )
Close to 0
Engine
1 (normally closed
ground
switch)
vmr2015-114-002_a
1. Oil pressure switch OPS

ENGINE ENGINE RUNNING
CONNECTOR
Oil Pressure Switch Access
PIN RESISTANCE ( )
Refer to BODY subsection and remove the fol-
lowing Infinite (open) when
– Seat Engine pressure reaches
1
ground 30 kPa ± 10 kPa
– Console (4.35 PSI ± 1.45 PSI)
– RH side panel and extension.
Remove OPS cover.
vmr2006-014-009_a
vmr2012-012-003_a
TYPICAL
1. Remove If resistance values are incorrect, replace the oil
pressure switch.
vmr2016-114 7
If the values are correct, check wiring.
Removing the Oil Pressure Switch

Unplug the oil pressure switch connector.
Unscrew and remove oil pressure switch.
Installing the Oil Pressure Switch
vmr2015-028-002_a
1. Engine oil pressure regulator
NOTE: The oil pressure regulator system works

when the oil pressure exceeds 400 kPa (58 PSI).
Oil Pressure Regulator Access

Refer to BODY subsection and remove the fol-
lowing:
vmr2015-114-002_a
– Seat
1. Oil pressure switch
– Console
Apply required service product on threads of oil – RH side panel and extension
pressure switch. – RH footboard panel.
Tighten oil pressure switch to specification.
Removing the Oil Pressure Regulator
TIGHTENING TORQUE
Remove plug screw and pull oil pressure regulator
LOCTITE 243 (BLUE) out.
Service product
(P/N 293 800 060)
12 N•m ± 1 N•m
Oil pressure switch
ENGINE OIL PRESSURE

REGULATOR
Oil Pressure Regulator Location
The oil pressure regulator is located on the engine
magneto side, integrated in the magneto cover.
vmr2015-028-003_a
1. Plug screw
2. Gasket ring
3. Pressure regulator housing
4. Spring
5. Pressure regulator valve
8 vmr2016-114
Inspecting the Oil Pressure Regulator

Inspect pressure regulator housing and valve for
scoring or other damages.
Check spring for free length.
SPRING FREE LENGTH
NEW NOMINAL 39 mm (1.535 in)
SERVICE LIMIT 37 mm (1.457 in)
NOTE: Replace worn or damaged components.

Clean bore and thread in the magneto housing
from metal shavings and other contaminations.
tmr2011-010-011_a
Installing the Oil Pressure Regulator 1.

2.
Thrust washer
Needle pin
For installation, reverse the removal procedure. 3. Oil pump gear
4. Retaining ring
NOTE: At installation always replace the gasket 2. Remove oil pump cover screws and pull oil
ring of the plug screw by a NEW one. pump cover out.
OIL PUMP
Oil Pump Location
The oil pump is located on the engine PTO side
(behind PTO cover).
vmr2006-042-011_a
1. Retaining screws
2. Oil pump cover
3. Remove oil pump shaft with needle pin and in-

ner rotor.
4. Remove outer rotor.
vmr2006-042-009_a
1. Oil pump
Removing the Oil Pump

Remove the PTO cover. Refer to PTO COVER in
the BOTTOM END subsection.
1. Remove:
– Retaining ring
– Oil pump gear
– Needle pin
– Thrust washer.
vmr2016-114 9
vmr2006-042-013_a
1. Pittings on the teeth
Using a feeler gauge, measure the clearance of

tmr2011-010-012_a inner and outer rotors as shown.
1. Outer rotor
2. Needle pin CLEARANCE OF INNER AND OUTER ROTOR
3. Oil pump shaft
4. Inner rotor SERVICE LIMIT 0.25 mm (.0098 in)
Inspecting the Oil Pump

Inspect oil pump and oil pump cover bore for
marks, scratches or other damages. Check for A
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.
A
A
2 1
vmr2006-042-014_a
1. Outer rotor
2. Inner rotor
A. 0.25 mm (.0098 in)
If clearance of inner and outer rotors exceeds the

tolerance, replace oil pump rotors. Ensure to also
check oil pump cover. If damaged, replace the
complete oil pump assembly.
If clearance between outer rotor and its bore in
crankcase exceeds the tolerance, replace the
complete oil pump rotors and/or the crankcase.
vmr2006-042-012_a Using a depth gauge, measure the axial clearance
1. Oil pump bore of the oil pump as shown.
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.
10 vmr2016-114
vmr2015-114-005_a
1. Markings
vmr2006-042-015
OIL PUMP — MEASUREMENT “A” After reinstallation of the remaining parts, check
for smooth operation of the oil pump assembly.
Testing the Oil Pump Function

After engine is completely reassembled, start en-
gine and make sure oil pressure is within specifi-
cations (refer to ENGINE OIL PRESSURE in this
subsection).
ENGINE OIL STRAINER

Oil Strainer Location
The engine oil strainer is located between both
crankcase halves.
vmr2006-042-016
Removing the Oil Strainer
OIL PUMP COVER — MEASUREMENT “B” Remove engine from vehicle.
Substract measurement B from measurement A Separate crankcase halves. Refer to BOTTOM
to obtain axial clearance. END subsection.
Remove screws and retaining plate.
OIL PUMP AXIAL CLEARANCE
Pull out engine oil strainer.
SERVICE LIMIT 0.20 mm (.008 in)
NOTE: When the axial clearance of the oil pump

assembly increases, the oil pressure decreases.
Installing the Oil Pump

NOTE: When installing the oil pump rotors, make
sure both markings are on the outer side.
vmr2016-114 11
vmr2006-042-018_a
1. Reed valve
2. Stopper
vmr2006-042-017_a 3. Screws
1. Engine oil strainer
2. Retaining plate
3. Screws
Removing the Reed Valve
Remove:
Cleaning and Inspecting the Oil – Engine from vehicle
Strainer – PTO cover (refer to PTO COVER in the BOT-
Clean engine oil strainer with a part cleaner then TOM END subsection)
use an air gun to dry it. – Reed valve retaining screws
– Stopper plate
WARNING – Reed valve.
Always wear eye protector. Chemicals can
cause a rash break out and injure your eyes. Inspecting the Reed Valve
Check reed valve for cracks or other damage.
Check engine oil strainer for cracks or other dam-
age. Replace if damaged. Replace reed valve if damaged.
Installing the Oil Strainer Installing the Reed Valve

The installation is the reverse of the removal pro- The installation is the reverse of the removal pro-
cedure. cedure.
SERVICE PRODUCT
LOCTITE 243 (BLUE)
Oil Strainer screws
(P/N 293 800 060)
TIGHTENING TORQUE
6 N•m ± 0.7 N•m
Oil strainer screws
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.
12 vmr2016-114
Subsection 05 (COOLING SYSTEM)
COOLING SYSTEM
SERVICE TOOLS
HANDLE ........................................................................................ 420 877 650 ........................................... 17
OIL SEAL PUSHER........................................................................ 529 035 757 ........................................... 17
ROTARY SEAL PUSHER PLATE.................................................... 529 036 130 ........................................... 14
SEAL PUSHER .............................................................................. 529 035 766 ..................................... 14, 17
SERVICE PRODUCTS
DOW CORNING 111 ..................................................................... 413 707 000 ........................................... 17
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 7
vmr2016-115 1
RADIATOR
570 and 650 Engines
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
NEW
10 ± 2 N•m
(89 ± 18 lbf•ft)
10 ± 2 N•m
(89 ± 18 lbf•ft)

vmr2016-417-100_a
2 vmr2016-115
RADIATOR AND THERMOSTAT

850 and 1000R Engines
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
NEW
NEW
10 ± 2 N•m
NEW (89 ± 18 lbf•ft) 1000R
850
NEW

vmr2016-115-100_a
vmr2016-115 3
WATER PUMP AND THERMOSTAT

570 and 650 Engines
NEW
3,5 ± 0,4 N•m 6 ± 0.7 N•m

(53 ± 6 lbf•in) 3,5 ± 0,4 N•m
(31 ± 4 lbf•in) NEW (31 ± 4 lbf•in)
NEW
Loctite
243 6 ± 0.7 N•m
(53 ± 6 lbf•in)
Loctite
243
CTS See Electronic
Fuel Injection (EFI)
16 ± 2 N•m
(142 ± 18 lbf•in)
NEW
20 ± 2 N•m
(15 ± 1 lbf•ft)
10 ± 1 N•m
(89 ± 9 lbf•in)
NEW
NEW
2.5 ± 0.3 N•m

(22 ± 3 lbf•in) Engine
oil
Molycote NEW
111
NEW
Engine oil

vmr2013-013-002_b
4 vmr2016-115
WATER PUMP
3,5 ± 0,4 N•m
(31 ± 4 lbf•in) NEW
NEW
6 ± 0.7 N•m
Loctite 243
16 ± 2 N•m
(142 ± 18 lbf•in)
3,5 ± 0,4 N•m
(31 ± 4 lbf•in)
6 ± 0.7 N•m CTS, see ELECTRONIC FUEL
20 ± 2 N•m (53 ± 6 lbf•in) INJECTION (EFI)
(15 ± 1.5 lbf•ft)
Loctite
243
NEW
NEW
10 ± 1 N•m
(89 ± 9 lbf•in)
NEW
NEW NEW
See
BOTTOM END
2.5 ± 0.3 N•m
(22 ± 3 lbf•in) Engine
oil
Molycote
111 Engine
oil
vmr2013-013-001_b
vmr2016-115 5
GENERAL 570 and 650 Engines

NOTICE Never start engine without coolant. 1. Remove thermostat housing screws and re-
Some engine parts such as the rotary seal on move thermostat cover.
the water pump shaft can be damaged.
PROCEDURES
THERMOSTAT
Thermostat Location
570 and 650 Engines
The thermostat is located in the thermostat hous-
ing at the top of the front cylinder (RH side).
vmr2015-115-003_a
1. Thermostat cover
2. Thermostat housing
3. Cover screws
4. Bleed screw
2. Pull thermostat and gasket.
vmr2015-029-002_a
1. Front cylinder
2. Thermostat housing

The thermostat is located between the front cylin-
der and the radiator, behind the RH front inner
fender.
vmr2016-030-001_a
1. Thermostat with gasket

1. Remove the RH front inner fender.
2. Remove Oetiker clamps.
vmr2016-417-001_a
Removing the Thermostat

Drain engine coolant, refer to PERIODIC MAINTE-
NANCE PROCEDURES subsection.
6 vmr2016-115
RADIATOR
Inspecting the Radiator
Check radiator fins for clogging or damage.
Remove insects, mud or other obstructions with
compressed air or low pressure water.
Removing the Radiator

1. Drain engine coolant. Refer to PERIODIC
2. Remove front body module. Refer to BODY
vmr2016-417-003_a
subsection.
3. Remove the thermostat and its housing as a 3. Disconnect radiator and fan assembly.
unit.
Testing the Thermostat

To check thermostat, put it in water and heat the
water.
THERMOSTAT OPENING TEMPERATURE
STARTS TO OPEN FULLY OPEN
65°C (149°F) 75°C (167°F)
Replace thermostat if it does not begin to open at

specified temperature.
Check if gasket is brittle, hard or damaged. If so,
replace gasket.
vmr2015-029-102_a
Installing the Thermostat 1. Radiator hoses

570 and 650 Engines
SERVICE PRODUCT
Thermostat cover LOCTITE 243 (BLUE)
retaining screws (P/N 293 800 060)
TIGHTENING TORQUE
Thermostat cover 6 N•m ± 0.7 N•m
retaining screws (53 lbf•in ± 6 lbf•in)

Install NEW Oetiker clamps.
vmr2015-029-104_a
All Models Step 1: Disconnect cooling fan connector
Step 2: Remove the harness connector from the fan shroud
Refill and bleed cooling system, refer to PERI-
ODIC MAINTENANCE PROCEDURES subsec-
tion.
Check cooling system for leaks.
vmr2016-115 7
TIGHTENING TORQUE
Radiator upper retaining 10 N•m ± 2 N•m
bolts (89 lbf•in ± 18 lbf•in)
Refill and bleed cooling system, refer to PERI-

tion.
Check cooling system for leaks.
COOLANT TEMPERATURE
SENSOR (CTS)
Refer to ELECTRONIC FUEL INJECTION (EFI)
vmr2015-029-105_a subsection.
1. Remove fan motor vent hose (if so equipped)
NOTE: Take note of the rooting of vent hose on

RADIATOR COOLING FAN
vehicle to ease reinstallation. Radiator Cooling Fan Operation
The ECM controls the radiator cooling fan via the
input of the coolant temperature sensor (CTS). Re-
fer to the following table.
CHECK
ENGINE COOLING GAUGE
ENGINE
TEMP. FAN MESSAGE
LIGHT
95°C __ __
Turns ON
(203°F)
93°C __ __
Turn OFF
(199°F)
Check
115°C
ON Turns ON engine
(239°F)
Hi Temp
vmr2015-029-103_a
118°C Limp
Step 1: Remove upper retaining bolts ON Flashes
Step 2: Remove radiator from bushings (244°F) Home
Installing the Radiator Radiator Cooling Fan Fuse Location

Reverse the removal procedure. However, pay at- The radiator cooling fan fuse (F9) is located in the
tention to the following. front fuse box, under the gauge support.
Ensure that rubber bushings are properly installed
between frame and fan shroud.
Ensure that vent hose of the cooling fan mo-
tor is properly rooted as prior to removal (if so
equipped).
NOTICE If the vent hose of the cooling fan
motor is not properly rooted, the fan motor
may be damaged due to improper venting.
Tighten radiator upper retaining bolts to specifica- vmr2015-044-006_a
tion.
Testing the Radiator Cooling Fan
1. Disconnect radiator cooling fan connector.
8 vmr2016-115
COOLING FAN TROUBLESHOOTING CHART

Is fan working? YES  Everything is OK
NO 
Check FAN fuse (F9) Replace fuse
Is fuse burnt?
YES  Is fan working?
NO 
Bypass fan relay R1
(refer to RELAY
OPERATION TEST)

vmr2015-029-101_a
Replace relay
1. Cooling fan connector Fan turns? YES  Is fan working?
2. Connect cooling fan connector pin B to a suit-
able 20 A fuse jumper and then directly to the NO 
positive battery post. Apply 12 Vdc
3. Connect cooling fan connector pin A (BK wire) and a ground to
directly to the negative battery post. fan connector
(refer to RADIATOR
4. Check if cooling fan works properly. COOLING FAN TEST)
– If cooling fan does not work, replace it.
– If cooling fan works properly, refer to RADI-

Replace fan
ATOR COOLING FAN TROUBLESHOOTING Fan turns? NO  Is fan working?
CHART.
5. Reconnect radiator cooling fan connector. YES 
Troubleshooting the Radiator Cooling Check CTS
(refer to
Fan ELECTRONIC FUEL
NOTE: The following troubleshooting chart as- INJECTION (EFI)
sumes that the engine is operating in the fan subsection)
activation temperature range. Refer to RADIA-
TOR COOLING FAN OPERATION. 
CTS works? NO  Replace CTS
Is fan working?
YES 
Check wiring harness
and connectors
(refer to WIRING
DIAGRAM)

Harness and Repair or replace
connectors good?
NO  defective part(s)
YES 
Try a new ECM  Is fan working?
Removing the Radiator Cooling Fan

1. Proceed with RADIATOR REMOVAL. See pro-
cedure in this subsection.
vmr2016-115 9
2. Remove radiator cooling fan retaining screws. 3. If the radiator cooling fan is activated, replace
the relay.
Relay Continuity Test
Refer to POWER DISTRIBUTION AND GROUNDS
subsection.
WATER PUMP HOUSING

Water Pump Housing Location
The water pump housing is located on the engine
MAG side.
Water Pump Housing Access

Remove RH footrest panel, refer to BODY sub-
section.
vmr2012-013-008_a
1. Cooling fan retaining screws Removing the Water Pump Housing

3. Remove radiator cooling fan. WARNING
To avoid potential burns, do not remove the
Installing the Radiator Cooling Fan radiator cap or loosen the coolant drain plug
The installation is the reverse of the removal pro- if the engine is hot.
Tighten cooling fan retaining screws to specifica- 1. Drain engine coolant. Refer to PERIODIC
tion. MAINTENANCE PROCEDURES subsection.
TIGHTENING TORQUE 2. Remove radiator outlet hose from water pump
housing.
Radiator cooling fan 10 N•m ± 2 N•m
screws (89 lbf•in ± 18 lbf•in) 3. Remove screws retaining water pump housing.
RADIATOR COOLING FAN RELAY

(R1)
Relay Location (Radiator Cooling Fan)
The radiator cooling fan relay (R1) is located in the
front fuse box, under the gauge support.
vmr2016-030-002_a

2. Sealing ring
3. Screws
vmr2015-044-006_a 4. Water pump housing
Testing the Radiator Cooling Fan Relay 4. Pull water pump housing to remove it.
Relay Operation Test Inspecting the Water Pump Housing
1. Remove relay (R1). Check if gasket is brittle, hard or damaged and re-
2. Bypass relay using a jumper. Refer to WIRING place as necessary.
DIAGRAM to locate proper terminals.
10 vmr2016-115
NOTICE Water pump shaft and impeller have

right-hand threads.
Inspecting the Water Pump Impeller

Check impeller for cracks or other damage. Re-
place impeller if damaged.
Installing the Water Pump Impeller

NOTICE Be careful not to damage impeller
fins during installation.
tmr2015-016-003_a
1. Gasket WATER PUMP SHAFT AND

Installing the Water Pump Housing
SEALS
The installation is the reverse of the removal pro- Use these guidelines to service these parts.
cedure. However, pay attention to the following. DEFECTIVE PART ACTION
NOTICE To prevent leaking, take care that the Replace:
gasket is exactly in groove when you reinstall - Rotary seal
Rotary seal
the water pump housing. - Oil seal
(assembled engine)
Tighten screws of water pump housing in a criss-
Replace:
cross sequence to specification. - Rotary seal
Oil seal
TIGHTENING TORQUE - Oil seal
(assembled engine)
Water pump housing 10 N•m ± 1 N•m
screws (89 lbf•in ± 9 lbf•in) Replace:
- Water pump
shaft assembly
Water pump shaft
WATER PUMP IMPELLER (including rotary seal)
- Oil seal
Removing the Water Pump Impeller (engine disassembled)
1. Proceed with WATER PUMP HOUSING RE-
MOVAL. See procedure in this subsection. Water Pump Seals Replacement
2. Remove impeller by unscrewing it counter- (Assembled Engine)
clockwise. NOTE: Read and thoroughly understand the en-
tire procedure before starting it.
Seals Removal
1. Remove the following parts, see procedure in
this subsection.
– WATER PUMP HOUSING
– WATER PUMP IMPELLER.
2. Carefully pry out inner part of the rotary seal
using 2 screwdrivers.
vmr2015-115-002_a
1. Turn counterclockwise to unscrew
vmr2016-115 11
tmr2011-011-050_a
1. Inner part of rotary seal
tmr2011-011-051_a
1. Small chisel
4. Use 2 screwdrivers and carefully remove the

outer part of the rotary seal.
vbs2008-011-005
TYPICAL - INNER PART OF ROTARY SEAL REMOVED
3. Carefully bend down the outer part of rotary

seal lip using a small chisel.
tmr2011-011-052_a
1. Screwdrivers
NOTICE Be careful not to damage the

crankcase while removing outer part of the
rotary seal.
12 vmr2016-115
5. Thoroughly remove sealing residue and burr of

rotary seal using a scraper.
NOTICE Be careful not to damage water
pump shaft.
tmr2011-011-055_a
1. Pull on screws to remove seal
8. Check water pump shaft axial play.

NOTE: If axial play is not adequate, engine must
be disassembled to replace water pump shaft.
9. Clean oil seal seat.
tmr2011-011-053_a
1. Scraper
6. Install 2 wooden screws in the seal.
tmr2011-011-056_a
Seals Installation
1. Apply engine oil on water pump shaft.
tmr2011-011-054_a 2. Apply grease on the lips of the oil seal.
1. Wooden screws 3. Carefully install oil seal over the water pump
2. Oil seal
shaft.
7. Remove oil seal from crankcase by pulling 4. Push oil seal into the water pump cavity.
screws with pliers.
REQUIRED TOOL
17 mm (11/16 in) deep socket
vmr2016-115 13
vbs2008-011-034
tmr2011-011-057_a
OIL SEAL INSTALLATION
1. Rotary seal
5. Ensure that the oil seal is properly seated in wa- 2. M8 robust flat washer (P/N 420 227 935)
3. M8 x 1.25 nut (P/N 233 281 414)
ter pump cavity.
11. Remove M8 nut.
NOTE: The robust M8 flat washer must remain on
water pump shaft.
REQUIRED TOOLS
ROTARY SEAL PUSHER PLATE (P/N 529 036 130)
4x M6 x 85 screws (P/N 420 440 347)
4x tubes 70 mm (2.75 in)
SEAL PUSHER (P/N 529 035 766)
vbs2008-011-035_a
TYPICAL
1. Oil seal properly seated
6. Apply engine oil on water pump shaft.

7. Place rotary seal onto water pump shaft and pull
out water pump shaft by hand.
NOTICE Do not install the rotary seal com-
pletely into the crankcase to prevent the water
529036130
pump shaft plastic gear from breaking. Push it
ROTARY SEAL PUSHER PLATE (P/N 529 036 130)
partially in, then pull the shaft.
8. Place a robust M8 flat washer (P/N 420 227
935) onto water pump shaft.
9. Install a M8 x 1.25 nut (P/N 233 281 414) onto
water pump shaft by hand.
10. Thread nut 1-1/2 turns to pull the shaft into
rotary seal.
529035766
SEAL PUSHER (P/N 529 035 766)
14 vmr2016-115
tmr2011-011-060_a
SEAL PUSHER INSTALLATION

tmr2011-011-058_a 1. Seal pusher aligned with pusher bolt
ROTARY SEAL PUSHER PLATE ASSEMBLY
1. 4 x tubes (70 mm (2.75 in) length) 12.5 Tighten the pusher bolt by hand until it
2. 4 x screws M6 x 85
3. Plane surface on pusher bolt stops against the seal pusher.
13. Carefully thread the pusher bolt 1-1/2 turns.
12. Install rotary seal installation tools on
crankcase as follows. 14. Ensure that the rotary seal is going straight
into crankcase.
NOTE: Make sure pusher bolt has a plane
surface. 15. Remove rotary seal installation tools from
crankcase.
12.1 Apply a little grease at the end of tool
pusher bolt. 16. Repeat steps 9 TO 15 until rotary seal is com-
pletely seated in the crankcase.
12.2 Ensure that pusher bolt is completely un-
screwed.
12.3 Install rotary seal pusher plate on
crankcase by tightening M6 screws.
NOTICE Do not use pneumatic or elec-
tric tools for tightening screws.
vbs2008-011-037
ROTARY SEAL PROPERLY SEATED ON CRANKCASE
17. Carry out the final adjustment of the water

pump shaft as follows.
17.1 Install M8 x 1.25 nut (P/N 233 281 414)
onto water pump shaft.
tmr2011-011-059_a
ROTARY SEAL PUSHER PLATE INSTALLATION 17.2 Carefully thread M8 nut until the rotary
1. Rotary seal pusher plate seal is flush with the end of water pump
2. Tube (70 mm (2.75 in) length)
3. M6 x 85 screw shaft threads.
4. Pusher bolt
12.4 Install seal pusher between rotary seal

pusher plate and water pump shaft.
vmr2016-115 15
vbs2008-011-040
WATER PUMP SHAFT PROPERLY ADJUSTED WITH ROTARY tmr2011-011-010_a

SEAL 1. Water pump shaft
2. Crankcase MAG side
NOTICE The water pump shaft must
be properly adjusted with rotary seal. 3. Install a blind hole puller expander snugly
The water pump shaft must move freely against outer part of rotary seal and pull seal
while pushing it toward the crankcase. out.
18. Install the following parts, see procedure in
this subsection.
– WATER PUMP IMPELLER
– WATER PUMP HOUSING.
19. Refill and bleed cooling system. Refer to PE-
RIODIC MAINTENANCE PROCEDURES sub-
section.
20. Check cooling system for leaks.
Water Pump Shaft and Seals

Replacement (Disassembled Engine)
Water Pump Shaft and Seals Removal
1. Remove the following parts, see procedure in
this subsection: vmr2007-034-105_a
– WATER PUMP HOUSING

– WATER PUMP IMPELLER 4. Remove oil seal from inside of crankcase MAG
side using a pusher tool.
– WATER PUMP GEARS.
2. Push out water pump shaft with inner portion of NOTICE Be careful not to damage the rotary
rotary seal from inside of crankcase MAG side. seal surface in crankcase.
REQUIRED TOOL
Soft hammer
16 vmr2016-115
Push NEW oil seal in place.
tmr2011-011-011_a
1. Oil seal
2. Machined surface for rotary seal
tmr2011-011-014_a
1. Oil seal
2. Installer handle with oil seal pusher
Lubricate sealing lip of the oil seal.

SERVICE PRODUCT
DOW CORNING 111
Sealing lip of the oil seal
(P/N 413 707 000)
tmr2011-011-012_a
OIL SEAL REMOVAL - VIEW FROM INSIDE CRANKCASE MAG

SIDE
1. Orifices for oil seal removal
Water Pump Shaft and Seals Installation

Use tightening torque values specified in the ex-
ploded view.
tmr2011-011-011_b
NOTE: Never apply oil on the press fit area of the 1. Sealing lip
oil seal and rotary seal. 2. Oil seal properly installed
Clean rotary seal surface of any old sealant. Apply engine oil on the water pump shaft and in-
Install oil seal. termediate shaft.
REQUIRED TOOL Slide NEW water pump shaft assembly into
crankcase.
OIL SEAL PUSHER
(P/N 529 035 757) REQUIRED TOOL
HANDLE
SEAL PUSHER
(P/N 420 877 650)
(P/N 529 035 766)
When installing the oil seal on the pusher, make
sure the sealing lip points outwards.
vmr2016-115 17
WATER PUMP GEARS

Water Pump Gears Identification
mmr2009-112-028_a
WATER PUMP SHAFT ASSEMBLY

1. Surface where rotary seal is pushed by tool
NOTICE Never use a hammer for rotary seal

installation. Only use a press to avoid damag-
ing the ceramic component.
vmr2012-013-009_a
1. Water pump shaft

2. Water pump gear
3. Water pump intermediate drive gear
4. Water pump intermediate shaft
5. Water pump drive gear (See BOTTOM END subsection)
Inspecting the Water Pump Gears

Water Pump Gear
Inspect water pump gear for wear and damage on
the snap mechanism to the needle pin. Replace if
damaged.
tmr2011-011-015_a
1. Water pump shaft with rotary seal

2. Water pump seal installer
NOTICE After installation, water pump shaft

with rotary seal must rotate freely.
tmr2011-011-008_a
CRANKCASE MAG SIDE

1. Circlip
2. Water pump gear
Water Pump Intermediate Drive Gear

Check water pump intermediate drive gear for
wear or broken teeth. Replace if damaged.
18 vmr2016-115
vmr2015-029-001_a
CRANKCASE PTO SIDE tmr2011-011-009_a

2. Circlip CRANKCASE MAG SIDE
3. Water pump intermediate shaft 1. Water pump gear
4. Crankcase PTO side 2. Needle pin
3. Thrust washer
Water Pump Drive Gear Water Pump Intermediate Drive Gear
See BOTTOM END subsection. 1. Remove circlip retaining water pump interme-
diate drive gear and discard it.
Removing the Water Pump Gears
Water Pump Gear
1. Remove circlip retaining water pump gear and
discard it.
vmr2015-029-001_a
CRANKCASE PTO SIDE

2. Circlip
4. Crankcase PTO side

tmr2011-011-008_a
– Water pump intermediate drive gear
CRANKCASE MAG SIDE
1. Circlip – Needle pin.
2. Water pump gear
Water Pump Drive Gear
2. Remove the following parts: See BOTTOM END subsection.
– Water pump gear
– Needle pin Installing the Water Pump Gears
– Thrust washer. Water Pump Gear
Install the following parts on water pump shaft.
– Thrust washer
– Needle pin
– Water pump gear.
vmr2016-115 19
NOTICE A missing thrust washer will cause a Water Pump Drive Gear
leaking rotary seal. See BOTTOM END subsection.
tmr2011-011-009_a
1. Water pump gear

2. Needle pin
3. Thrust washer
NOTE: Ensure water pump gear snaps properly

onto needle pin.
Install NEW circlip to retain water pump gear.
NOTICE Never use the circlip a second time.
Always install a NEW one.
tmr2011-011-008_a
1. Circlip
2. Water pump gear
Water Pump Intermediate Drive Gear

Install the following parts on water pump interme-
diate shaft.
– Needle pin
– Water pump intermediate drive gear.
Install NEW circlip to retain water pump interme-
diate drive gear.
NOTICE Never use the circlip a second time.
Always install a NEW one.
20 vmr2016-115
Subsection 06 (MAGNETO AND STARTER)
MAGNETO AND STARTER

SERVICE TOOLS
CRANKSHAFT LOCKING BOLT..................................................... 529 035 617 ............................................. 6
CRANKSHAFT PROTECTOR ......................................................... 529 036 034 ............................................. 6
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 4–5
MAGNETO PULLER ...................................................................... 529 035 748 ............................................. 6
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ........................................... 11
DREI BOND SEALING COMPOUND ............................................ 420 297 906 ............................................. 3
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 6
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ......................................... 7–8
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ..................................... 10–11
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ............................................. 3
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ......................................... 7–8
vmr2016-116 1
6 ± 0,7 N•m
(53 ± 6 lbf•in)
Engine oil See ELECTRONIC FUEL
INJECTION (EFI)
10 ± 1 N•m
(89 ± 9 lbf•in)
5 ± 0,6 N•m
(44 ± 5 lbf•in)
Drei Bond sealing compound

Loctite 243
Multi Purpose Grease BP LS3 Loctite 243
10 ± 1 N•m 4 ± 0,5 N•m

(89 ± 9 lbf•in) (35 ± 4 lbf•in)
NEW 10 ± 1 N•m
150 ± 10 N•m (89 ± 9 lbf•in)
(111 ± 7 lbf•ft)
Engine oil
Loctite 648
30 ± 2 N•m
(22 ± 1,5 lbf•ft) Loctite 767 (antiseize lubricant)
Engine oil
25 ± 3 N•m
(18 ± 2 lbf•ft)

vmr2015-030-001_a
2 vmr2016-116
PROCEDURES
MAGNETO COVER
Magneto Cover Access
Refer to BODY subsection and remove the follow-
ing:
– Seat
– Console
– RH side panel and extension panel
– RH footboard panel.
Removing the Magneto Cover

Drain engine oil (refer to ENGINE OIL CHANGE vmr2015-030-003_a
in the PERIODIC MAINTENANCE PROCEDURES 1. Magneto cover
subsection). 2. Retaining screws
Remove crankshaft position sensor (CPS) and cut Pull out magneto cover.
tie raps.
Disconnect the stator connector on the voltage Inspecting and Cleaning the Magneto
regulator/rectifier, refer to STATOR CONNECTOR Cover
ACCESS in this subsection. Check magneto cover for cracks or other damage.
Remove dipstick with O-ring. Replace if necessary.
NOTE: Clean all metal components in a non-
ferrous metal cleaner. Use LOCTITE CHISEL (GAS-
KET REMOVER) (P/N 413 708 500), or suitable
equivalent.
WARNING
Wear safety glasses and work in a well
ventilated area when working with strong
chemical products. Also wear suitable
non-absorbent gloves to protect your hands.
Installing the Magneto Cover

However, pay attention to the following.
Install a NEW magneto cover gasket.
vmr2015-030-002_a
1. Dipstick Apply DREI BOND SEALING COMPOUND (P/N 420

2. O-ring 297 906) on stator cable grommet as shown in next
3. Crank position sensor (CPS)
illustration.
Remove magneto cover retaining screws.
vmr2016-116 3
vmr2012-032-003_a
TYPICAL
tmr2011-012-006_a
1. Voltage regulator/rectifier location
1. Stator cable grommet (apply Drei Bond sealing compound)
Tighten screws using the following sequence.
vmr2012-014-020_a
1. Voltage regulator/rectifier
2. Three YELLOW wires
Testing the Stator Static Continuity

vmr2015-030-003_b
1. Disconnect the stator connector on the voltage
TIGHTENING SEQUENCE
regulator/rectifier.
TIGHTENING TORQUE REQUIRED TOOL
10 N•m ± 1 N•m
Magneto cover screws FLUKE 115 MULTIMETER
(P/N 529 035 868)
Refill engine with recommended oil.
2. Set multimeter to .
STATOR 3. Connect multimeter between YELLOW wires.
Stator Connector Access 4. Read resistance.
NOTE: The stator is directly connected to the volt- RESISTANCE @
age regulator/rectifier. TERMINAL
20°C (68°F)
1 and 2
1 and 3 0.15 - 0.30
2 and 3
4 vmr2016-116
4. If there is a resistance or continuity, the stator

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

Remove MAGNETO COVER. See procedure in
this subsection.
Remove screws securing the wire holding strip.
YL
YL Remove stator retaining screws then the stator.
YL
V07G05A
TYPICAL
5. If any reading is out of specification, replace sta-

tor.
6. Re-plug connectors properly.
Testing the Stator Insulation

REQUIRED TOOL
FLUKE 115 MULTIMETER

(P/N 529 035 868)
1. Set multimeter to . tmr2013-014-001_a
2. Connect multimeter between any YELLOW 1. Holding strip screws

wire (on stator connector) and engine ground. 2. Wire holding strip
3. Stator retaining screws
3. Read resistance. 4. Stator
TEST PROBES
RESISTANCE @ Inspecting the Stator
20°C (68°F)
Check stator windings and insulation for cracks or
Any YELLOW wire and
Infinite (open circuit)
other damages. If damaged replace it.
engine ground
Check if stator wires are brittle, hard or otherwise
damaged.
Installing the Stator

NOTICE When installing the stator take care
to route wires properly and install retaining
strip.
NOTE: There is only one position for the stator
YL (notch in the magneto housing cover).
YL
YL
V07G07A
TYPICAL
vmr2016-116 5
vmr2006-041-007_a
1. Screw M16
vmr2015-030-004_a 2. Washer
3. Rotor
1. Threads for cable holding strip
2. Notch for stator
Remove rotor.
TIGHTENING TORQUE REQUIRED TOOL
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060) CRANKSHAFT PROTECTOR
(P/N 529 036 034)
4 N•m ± 0.5 N•m
Holding strip screws
MAGNETO PULLER
(P/N 529 035 748)
TIGHTENING TORQUE
10 N•m ± 1 N•m NOTE: Use grease to place protector on crank-
Stator retaining screws
(89 lbf•in ± 9 lbf•in) shaft end prior to screw on the magneto puller.
ROTOR
Removing the Rotor
this subsection.
Lock crankshaft (refer to CRANKSHAFT LOCKING
PROCEDURE in the BOTTOM END subsection).
REQUIRED TOOL
CRANKSHAFT LOCKING BOLT
(P/N 529 035 617)
Heat screw in order to break the Loctite.

Remove screw and washer securing rotor to vmr2006-041-010_a
crankshaft. 1. Rotor
2. Magneto puller
Screw magneto puller bolt to remove rotor.
Inspecting the Rotor

Check inner side of rotor for scratches or other
damage.
Blow pressurized air in the rotor oil bore and make
sure it is not clogged.
6 vmr2016-116
Oil sprag clutch and install sprag clutch gear.
tmr2011-012-007_a
1. Rotor
vmr2006-041-015_b
2. Oil bore
1. Sprag clutch
Check keyway of the rotor for wear or damages. 2. Sprag clutch housing
3. Sprag clutch gear
Check if trigger wheel teeth are bent or otherwise 4. Apply engine oil here
damaged. Slide rotor onto crankshaft. The woodruff key and
Check woodruff key and keyway on the crank- the keyway must be aligned.
shaft for wear or damages. Rotate starter double gear counterclockwise to
Replace parts as necessary. align intermediate gear teeth with sprag clutch
gear.
Installing the Rotor
Use PULLEY FLANGE CLEANER (P/N 413 711 809) to
clean following parts:
– Crankshaft taper
– Oil passage in crankshaft taper
– Thread in crankshaft
– Rotor taper
– Oil bore in rotor.
NOTICE Taper on crankshaft and rotor must
be free of grease.
vmr2006-041-012_b
1. Starter double gear

3. Intermediate gear
TIGHTENING TORQUE
LOCTITE 648 (GREEN)
Service product
(P/N 413 711 400)
150 N•m ± 10 N•m
Rotor retaining screw
tmr2011-012-008_a
1. Crankshaft (MAG side)

2. Oil passage
3. Threads
vmr2016-116 7
SPRAG CLUTCH NOTE: Sprag clutch must lock in counterclock-

wise direction.
Removing the Sprag Clutch
this subsection.
Heat screws in order to break the Loctite.
Loosen sprag clutch housing screws located in-
side rotor.
vmr2006-041-014_a
SPRAG CLUTCH FUNCTIONAL TEST

1. Lock
NOTE: Sprag clutch, housing and gear must be

replaced at the same time, if damaged.
tmr2011-012-004_a
1. Rotor
Installing the Sprag Clutch
2. Sprag clutch housing screws For installation, reverse the removal procedure.
Remove rotor (refer to ROTOR in this subsection). However, pay attention to the following details.
Remove sprag clutch gear. Use PULLEY FLANGE CLEANER (P/N 413 711 809)to
clean following:
Remove sprag clutch housing screws and sprag
– Threads in sprag clutch housing
clutch housing.
– Threads of sprag clutch housing screws.
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 sprag clutch
gear needle bearing.
vmr2006-041-013_a
1. Sprag clutch housing screws

2. Rotor
3. Sprag clutch
4. Sprag clutch housing
Inspecting the Sprag Clutch

Inspect sprag clutch and sprag clutch housing for
wear and damage.
Also check the collar of the sprag clutch gear. vmr2006-041-015_b
1. Sprag clutch
Rotate sprag clutch gear in sprag clutch. 2. Sprag clutch housing
4. Apply engine oil here
8 vmr2016-116
Install rotor, refer to ROTOR in this subsection.

Tighten sprag clutch housing screws to specifica-
tion.
TIGHTENING TORQUE
Sprag clutch housing 30 N•m ± 2 N•m
screws (22 lbf•ft ± 1 lbf•ft)
SPRAG CLUTCH GEAR

Removing the Sprag Clutch Gear
Remove ROTOR. See procedure in this subsec-
tion.
Pull sprag clutch gear out of the rotor. vmr2006-041-016_a
1. Teeth
2. Collar
3. Needle bearing
Installing the Sprag Clutch Gear

NOTE: Apply engine oil on needle bearing and col-
lar of sprag clutch gear.
STARTER DRIVE GEARS

Starter Drive Gear Location
The starter drive gears are located on the engine
MAG side behind the magneto cover.
vmr2006-041-015_a
1. Rotor
2. Sprag clutch gear Removing the Starter Drive Gear
Inspecting the Sprag Clutch Gear this subsection.
Inspect gear, especially teeth and sprag clutch col- Remove location pins, starter double gear and in-
lar, for wear and other damage. termediate gear.
Check needle bearing condition. Replace sprag
clutch gear if necessary.
vmr2016-116 9
vmr2015-030-102_a
vmr2006-041-017_a
TYPICAL
1. Intermediate gear 1. Starter
2. Starter double gear 2. Starter power cable connection at starter
3. Starter gear 3. Starter power cable
4. Location pins 4. Starter power cable connection at solenoid
Inspecting the Starter Drive Gear

Inspect gears and location pins for wear and dam-
age.
Replace parts as necessary.
Installing the Starter Drive Gear

cedure. Pay attention to the following details.
Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) on starter gear before installing
the starter double gear.
Apply engine oil on location pins.
vmr2012-033-003_a
TYPICAL
ELECTRIC STARTER 1. Power cable from starter solenoid to starter
2. Power cable from battery to starter solenoid (not visible)
Starter Access for Testing 3. Fuel tank
4. RH rear fender
To access starter electrical terminal, refer to
BODY subsection and remove the following: 2. Using booster cables, carefully supply current
– Seat from a 12 volt battery directly to the starter
power cable.
– Console
– RH side panel and extension panel NOTICE First connect the red jumper cable
– RH footboard panel. from the booster battery to the starter cable.
Momentarily connect the BLACK (-) cable from
Testing the Starter Operation the booster battery to engine ground last.
1. Disconnect starter power cable from starter so- If the starter turns, test other starting system
lenoid and pull cable out to RH side of the vehi- components.
cle.
Removing the Starter
1. Ensure ignition switch is set to OFF.
2. Disconnect BLACK (-) cable from battery.
10 vmr2016-116
WARNING Bring starter close to its location. Rotate it so

that its mounting ear allows installation in engine
Always disconnect BLACK (-) cable first and crankcase and on its alignment pin.
reconnect last.
Push starter in place and align mounting ear to in-
3. Remove body parts as listed in STARTER AC- stall screw.
CESS. TIGHTENING TORQUE
4. For models using the gearbox with GBPS, re- 25 N•m ± 3 N•m
fer to CONTINUOUSLY VARIABLE TRANSMIS- Starter mounting screw
SION (CVT) subsection and remove the:
– Drive pulley NOTICE When connecting the RED (+) cable
– Driven pulley to the starter motor, make sure the battery ca-
– CVT back cover. bles are disconnected.
5. Disconnect RED (+) cable from starter. TIGHTENING TORQUE
6. Clean starter area. DIELECTRIC GREASE
Service product
7. Remove starter retaining screw (from RH side (P/N 293 550 004)
of engine). Starter terminal and 6 N•m ± 0.5 N•m
retaining nut (53 lbf•in ± 4 lbf•in)
When installing remaining removed parts, refer to

applicable subsections.
Connect battery cables.
WARNING
Always connect RED (+) cable first then
BLACK (-) cable last.
Test starter operation.
vmr2015-030-103_a
1. Starter
2. Starter power cable to disconnect
3. Starter retaining screw to remove
8. Carefully pry the starter from the engine

crankcase.
Installing the Starter

Reverse the removal procedure. However, pay
particular attention to the following.
Make sure the starter and engine mating surfaces
are free of debris. Serious problems may arise if
the starter is not properly aligned.
Lubricate starter O-ring.
STARTER O-RING AND MATING SURFACE
LOCTITE 767
Service product (ANTISEIZE LUBRICANT)
(P/N 293 800 070)
vmr2016-116 11
Subsection 07 (INTAKE MANIFOLD)
INTAKE MANIFOLD
See ELECTRONIC FUEL

INJECTION (EFI)
0,7 ± 0,1 N•m

(6 ± 1 lbf•in)
10 ± 1 N•m
(89 ± 9 lbf•in)
6 ± 0,7 N•m
(53 ± 6 lbf•in)
See
Loctite 243 ELECTRONIC FUEL
INJECTION (EFI)
Engine oil
Engine oil
Engine oil
20 ± 2 N•m
(15 ± 1.5 lbf•ft)

vmr2016-117-001_a
vmr2016-117 1
PROCEDURES
INTAKE MANIFOLD
Intake Manifold Access
ing:
– Console
Removing the Intake Manifold

1. Release fuel pressure. Refer to FUEL TANK
AND FUEL PUMP subsection.
2. Disconnect top of shift rod. vmr2015-031-002_a
1. Forward fuel rail disconnect

2. Rear fuel rail disconnect
4. Disconnect fuel injector electrical connectors.

5. Disconnect MAPTS connector.
vmr2012-015-006_a
TYPICAL - SHIFT ROD DISCONNECT

1. Remove screw, nut, and bushing
3. Disconnect the fuel hoses from fuel rails, refer

to ELECTRONIC FUEL INJECTION (EFI) sub-
vmr2015-031-003_a
section.
1. Forward fuel injector connector
2. Rear fuel injector connector
CAUTION The fuel hose may still be un- 3. MAPTS connector
der pressure.
6. Disconnect throttle body from intake manifold
and air intake silencer. Refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
NOTE: Do not disconnect throttle cable need-
lessly.
7. Remove wiring harness support from engine.
2 vmr2016-117
vmr2012-015-005_a
1. Remove
8. Remove intake manifold from engine.
vmr2015-031-004_a
1. Manifold retaining screws (4x)
Inspecting the Intake Manifold

Check intake manifold for cracks, warping at
flanges or any other damage. Replace if neces-
sary.
Installing the Intake Manifold

Tighten intake manifold retaining screws to spec-
ified torque one cylinder at a time.
TIGHTENING TORQUE
Intake manifold 20 N•m ± 2 N•m
retaining screws (15 lbf•ft ± 1 lbf•ft)
Enable fuel pump using B.U.D.S.
vmr2016-117 3
Subsection 08 (TOP END)
TOP END
SERVICE TOOLS
CRANKSHAFT LOCKING BOLT..................................................... 529 035 617 ........................................... 21
DIAL INDICATOR ADAPTER ......................................................... 529 036 159 ............................................. 6
ENGINE LEAK DOWN TEST KIT ................................................... 529 035 661 ............................................. 6
PISTON CIRCLIP INSTALLER........................................................ 529 035 921 ........................................... 25
TDC DIAL INDICATOR .................................................................. 414 104 700 ............................................. 6
VALVE GUIDE INSTALLER ............................................................ 529 036 140 ........................................... 19
VALVE GUIDE INSTALLER ............................................................ 529 036 269 ........................................... 19
VALVE GUIDE REMOVER (6 MM) ................................................ 529 036 074 ........................................... 18
VALVE GUIDE REMOVER 5 MM .................................................. 529 035 924 ........................................... 18
VALVE SPRING COMPRESSOR CUP............................................ 529 035 764 ........................................... 14
VALVE SPRING COMPRESSOR CUP............................................ 529 036 270 ........................................... 14
VALVE SPRING COMPRESSOR .................................................... 529 035 724 ........................................... 14
SERVICE TOOLS – OTHER SUPPLIER

SNAP-ON PLIERS.......................................................................... YA 8230 ........................................... 16
SERVICE PRODUCTS
vmr2016-118 1
CYLINDER HEAD NO. 1
7 ± 0,8 N•m
(62 ± 7 lbf•in)
12 ± 1 N•m
(106 ± 9 lbf•in)
Engine oil
See tightening
procedure
Engine oil
10 ± 1 N•m NEW
(89 ± 9 lbf•in)
Engine oil
Engine
oil
See ignition
system
12 ± 1 N•m
(106 ± 9 lbf•in)
NEW
Engine oil
Loctite 648 NEW

10 ± 1 N•m
(89 ± 9 lbf•in)
tmr2013-068-001_b
2 vmr2016-118
CYLINDER HEAD NO. 2
7 ± 0,8 N•m
12 ± 1 N•m (62 ± 7 lbf•in)
Engine oil (106 ± 9 lbf•in)
See ignition
system
Engine oil Engine oil

NEW
See tightening NEW

procedure
10 ± 1 N•m
(89 ± 9 lbf•in)
Engine oil
Engine oil
NEW 10 ± 1 N•m
Loctite 648 (89 ± 9 lbf•in)
10 ± 1 N•m
(89 ± 9 lbf•in)

tmr2013-068-002_b
vmr2016-118 3
CYLINDERS AND PISTONS
Engine oil
Engine oil
Engine oil
NEW
NEW
Engine oil NEW
NEW
NEW
Engine
oil
vmr2006-043-003_d
4 vmr2016-118
GENERAL WARNING
Special reference are made in the text for proce- Always respect this order for disassembly;
dures which are different for cylinder no. 1 and disconnect BLACK (-) cable first.
cylinder no. 2.
2. Remove radiator cap.
WARNING
To prevent being burned, ensure the radiator
is cool and wear the appropriate safety equip-
ment before removing the radiator cap.
3. Unplug spark plug cable.

4. Clean spark plug area and remove spark plug
from cylinder head.
Vmr2012-015-002_a
TYPICAL
1. Cylinder 1 (front)
2. Cylinder 2 (rear)
When diagnosing an engine problem, always per-

form a cylinder leak test.
NOTE: Even though the following procedures do
not require the engine removal, many illustrations
show the engine out of the vehicle for more clar-
ity. tmr2011-013-005_a
IMPORTANT: Note position of parts upon disas- 1. Spark plug cable

2. Spark plug
sembly. This may help to find the root cause of a
problem. A component that is not replaced should 5. Remove VALVE COVER. See procedure in this
be reinstalled in the same position as originally subsection.
mounted.
6. Rotate crankshaft until piston is at ignition TDC.
INSPECTION 7. Turn crankshaft using one of the following two
procedures.
LEAK TEST First Procedure
Before performing the cylinder leak test, verify the Turn the drive pulley.
following: Second Procedure
– Clamp(s) tightness
1. Remove plug screw with O-ring from magneto
– Radiator and hoses. cover.
NOTE: For best accuracy, the leak test should be 2. Use a 14 mm Allen key and turn crankshaft.
done with the engine at normal operating temper-
ature. NOTICE Turn only clockwise to avoid loosen-
ing of magneto flywheel Allen screw.
WARNING
Prevent burning yourself on hot engine parts. 3. Set the piston to precisely ignition TDC.
Preparing the Leak Test

1. Disconnect battery.
vmr2016-118 5
ENGINE REQUIRED TOOL REQUIRED TOOL

TDC DIAL INDICATOR
All ENGINE LEAK DOWN TEST
(P/N 414 104 700)
KIT (P/N 529 035 661)
DIAL INDICATOR
850
ADAPTER (P/N 529
1000R 2. Connect to an adequate air supply.
036 159)
3. Set needle of measuring gauge to zero.
NOTE: All testers have specific instructions on
gauge operation and required pressure.
4. Supply combustion chamber with air pressure.
5. Note the amount or percentage of leakage (de-
pending on tester).
LEAKAGE ENGINE
PERCENTAGE CONDITION
0% to 15% Excellent condition
16% to 25% Good condition
Fair condition; reduced
tmr2011-013-007_a 26% to 40%
engine performance
1. TDC dial indicator
Poor condition, diagnose
NOTE: If a dial gauge is not available, use a screw- 41% and higher
and repair engine
driver or another similarly suitable tool.
NOTICE Do not scratch or damage pis- NOTE: To make sure there is no false reading due
to a valve not being perfectly seated, tap each
ton/cylinder surface.
valve adjustment screw (on the rocker arm) using
NOTE: At ignition TDC the marks on the camshaft a soft hammer.
timing gear have to be parallel to cylinder head
base as per following illustration. Diagnosis
Listen for air leaks.
– Air escaping in intake port/throttle body means
leaking intake valve(s).
– Air escaping in exhaust port means leaking ex-
haust valve(s).
– Air bubbles in the coolant (radiator) means leak-
ing cylinder head gasket.
– Air/coolant escaping from cylinder/head means
damaged gasket(s) and/or loosened screws.
– Air escaping into crankcase area means exces-
sively worn cylinder and/or broken piston rings.
– Air/oil escaping from crankcase means dam-
aged gasket and/or loosened screws (refer to
tmr2011-013-008_a BOTTOM END subsection).
1. Marks on camshaft timing gear
2. Cylinder head base NOTE: For all checkpoints mentioned above, see
appropriate engine section to diagnose and repair
Leak Test the engine.
1. Install the gauge adapter in the spark plug hole. Reassembly
Reverse the preparation procedure. Ensure to
respect torque values and use of appropriate
products/lubricants. Refer to exploded views in
other subsections of this manual as required.
6 vmr2016-118
PROCEDURES Installing the Valve Cover

VALVE COVER However, pay attention to the following.
Valve Cover Access Tighten valve cover retaining screws to specified
torque in a criss-cross sequence.
Front Cylinder
TIGHTENING TORQUE
ing. Valve cover retaining 7 N•m ± 0.8 N•m
screws (62 lbf•in ± 7 lbf•in)
– Seat
– Console
– RH side panel ROCKER ARM
– RH side panel extension Removing the Rocker Arm
– RH inner fender panel 1. Remove VALVE COVER. See procedure in this
Rear Cylinder subsection.
Refer to BODY and remove: 2. Refer to TIMING CHAIN subsection and re-
– Seat move following parts:
– Console – Timing chain tensioner
– RH side panel and extension(s) – Camshaft timing gear.
– LH side panel and extension(s). 3. Remove pan head screw and camshaft retain-
ing plate.
Refer to EXHAUST SYSTEM and remove exhaust
pipe.
Removing the Valve Cover

Remove:
– Valve cover screws
– Valve cover
– Gasket.
vmr2016-033-002_a
TYPICAL
1. Camshaft retaining plate
2. Pan head screw
4. Remove rocker arm shafts.

vmr2016-033-001_a
TYPICAL — FRONT CYLINDER SHOWN

1. Valve cover screws
2. Valve cover
3. Gasket
Inspecting the Valve Cover

Check the gasket on the valve cover if it is brittle,
cracked or hard. If so, replace the gasket.
vmr2016-118 7
1 2 1
R400motr67A 4
1. 2 thrust washers
2. Rocker arm (exhaust side)
3. Cylinder head (spark plug side)
4. Big taper to spark plug side
Inspecting the Rocker Arm

vmr2006-043-016_a
Inspect each rocker arm for cracks and scored fric-
1. Rocker arm shaft
tion surfaces. If so, replace rocker arm assembly.
2. Rocker arm (exhaust side) Check the rocker arm rollers for free movement,
3. Rocker arm (intake side)
4. Adjustment screw wear and excessive radial play. Replace rocker
5. Lock nut arm assembly if necessary.
5. Remove rocker arm assembly (exhaust side
and intake side) with adjustment screws and 2 1
lock nuts.
6. Remove thrust washers.
A
R400motr68A
1. Rocker arm (exhaust side)

2. Roller
A. Bore for rocker arm shaft
Measure rocker arm bore diameter. If diameter

is out of specification, change the rocker arm as-
sembly.
ROCKER ARM BORE DIAMETER
tmr2011-013-010_a 12.036 mm to 12.050 mm
NEW
1. Rocker arm (exhaust side) (.4739 in to .4744 in)
2. Rocker arm (intake side)
3. Thrust washers SERVICE LIMIT 12.060 mm (.4748 in)
NOTICE Pay attention not to lose thrust
Check adjustment screws for free movement,
washers or drop them into the timing chain cracks and/or excessive play.
compartment.
8 vmr2016-118
R400motr69A
1. Free movement of adjustment screw top
Rocker Arm Shaft Inspection

Check for scored friction surfaces; if so, replace
parts.
Measure rocker arm shaft diameter.
vmr2006-043-016_b
1. Rocker arm shaft

2. Thrust washer (timing chain side)
3. Thrust washer (spark plug side)
5. Place the other thrust washer and push rocker

arm shaft to end position.
6. Install the camshaft retaining plate.
R400motr70A A
7. Adjust valve clearance, refer to PERIODIC
A. Measure rocker arm shaft diameter here
ROCKER ARM SHAFT DIAMETER
12.000 mm to 12.018 mm
CAMSHAFT
NEW
(.4724 in to .4731 in) NOTE: The engine is equipped with two different
SERVICE LIMIT 11.990 mm (.472 in) camshafts.
Any area worn excessively will require parts re-

placement.
Installing the Rocker Arm

NOTE: Use the same procedure for exhaust and
intake rocker arm.
1. Apply engine oil on rocker arm shaft.
2. Insert a rocker arm shaft with the chamfered
edge first through rocker arm pin bore.
3. Install a thrust washer at timing chain side, then
the proper rocker arm (exhaust side or intake
side).
4. Push in rocker arm shaft until its chamfer vmr2015-032-001_a
reaches the end of rocker arm bore. 1. Intake cam
2. Exhaust cam
3. Camshaft of cylinder 1
4. Camshaft of cylinder 2
5. Flat spot
Removing the Camshaft

The removal procedure is the same for both
camshafts.
vmr2016-118 9
NOTICE Each camshaft is different in design.

Thus, it is important not to mix up any parts of
the camshaft assembly with that of the other
cylinder. Keep parts as a group.
1. Remove valve cover (see VALVE COVER in this
subsection).
2. Refer to the TIMING CHAIN subsection to re-
move the following parts:
– Chain tensioner
– Camshaft timing gear.
3. Remove the camshaft retaining plate.
tmr2011-013-014_a

2. Area for camshaft lobes
3. Camshaft
Inspecting the Camshaft

Inspecting the Camshaft Lobe
Check each lobe for scoring, scuffing, cracks or
other signs of wear.
Measure camshaft lobe height using a microme-
ter.
vmr2016-033-002_a

2. Pan head screw
3. Cylinder head
4. Remove rocker arms (see ROCKER ARM in

this subsection).
5. Remove the camshaft.
NOTE: For removal rotate camshaft so that
intake/exhaust lobe shows to upper side of cylin- vmr2015-032-002_a
der head. A. Camshaft lobe (exhaust valves)
B. Camshaft lobe (intake valves)
C. Camshaft journal (timing chain side)
D. Camshaft journal (spark plug side)
CAMSHAFT LOBE (INTAKE)

31.830 mm to 32.030 mm
NEW
(1.2531 in to 1.261 in)
570
SERVICE
31.810 mm (1.2524 in)
LIMIT
32.110 mm to 32.310 mm
NEW
(1.2642 in to 1.272 in)
650
SERVICE
32.090 mm (1.2634 in)
LIMIT
10 vmr2016-118
CAMSHAFT LOBE (INTAKE)

32.890 mm to 33.090 mm
NEW
(1.2949 in to 1.3028 in)
850
SERVICE
32.870 mm (1.2941 in)
LIMIT
32.960 mm to 33.160 mm
NEW
1000 (1.2976 in to 1.3055 in)
1000R SERVICE
32.940 mm (1.2969 in)
LIMIT
CAMSHAFT LOBE (EXHAUST)

31.730 mm to 31.930 mm
NEW
(1.2492 in to 1.2571 in) vmr2015-032-002_a
570 A. Camshaft lobe (exhaust valves)
SERVICE B. Camshaft lobe (intake valves)
31.710 mm (1.2484 in)
LIMIT C. Camshaft journal (timing chain side)
D. Camshaft journal (spark plug side)
31.940 mm to 32.140 mm
NEW CAMSHAFT JOURNAL
(1.2575 in to 1.2654 in)
650 (TIMING CHAIN SIDE)
SERVICE
31.920 mm (1.2567 in) 34.959 mm to 34.975 mm
LIMIT NEW
(1.3763 in to 1.377 in)
32.950 mm to 33.150 mm
NEW SERVICE LIMIT 34.950 mm (1.376 in)
(1.2972 in to 1.3051 in)
850
SERVICE CAMSHAFT JOURNAL
32.930 mm (1.2965 in)
LIMIT (SPARK PLUG SIDE)
32.860 mm to 33.060 mm 21.959 mm to 21.980 mm
NEW NEW
1000 (1.2937 in to 1.3016 in) (.8645 in to .8654 in)
1000R SERVICE
32.840 mm (1.2929 in) SERVICE LIMIT 21.950 mm (.8642 in)
LIMIT
Measure camshaft bearing in cylinder head. Refer Installing the Camshaft

to CYLINDER HEAD INSPECTION in this subsec- Reverse the removal procedure. Pay attention to
tion. the following details.
Inspecting the Camshaft Journal NOTICE The camshafts are not identical in
Check each journal for scoring, scuffing, cracks or design. Do not invert the camshafts during
other signs of wear. assembly. Any mix-up of the components will
Measure camshaft journal using a micrometer. lead to engine damage.
Place the camshaft retaining plate in the slot of the
camshaft.
vmr2016-118 11
10. First remove the M6 cylinder head screws,

then the cylinder head screws M10.
tmr2011-013-014_b
1. Direction of movement
2. Camshaft retaining plate tmr2011-013-011_a
3. Slot retaining camshaft
1. Cylinder head screws M10
2. Cylinder head screws M6
For other parts, refer to proper installation proce-
dure. 11. Pull up cylinder head.
12. Remove timing chain guide (fixed).
CYLINDER HEAD 13. Remove and discard the cylinder head gasket.
Cylinder Head Access
Refer to VALVE COVER in this subsection.
Removing the Cylinder Head

1. The removal procedure is the same for both 4
cylinder heads. 2
2. Drain coolant (refer to PERIODIC MAINTE-
NANCE PROCEDURES subsection).
3. Disconnect the coolant hose from the thermo-
stat housing.
NOTE: Before removing cylinder head, blow out
remaining coolant by air pressure. During cylin-
1
der head removal, the remaining coolant in cylin-
der head could overflow into the engine and a little
quantity of coolant could drop into the engine. In R400motr72A 3
this case, the engine oil will be contaminated. 1. Cylinder head
4. Refer to EXHAUST SYSTEM subsection and 2. Timing chain
3. Chain guide (fixed)
disconnect exhaust system head pipe from 4. Cylinder head gasket
cylinder head.
5. Disconnect spark plug wire. Inspecting the Cylinder Head
6. Disconnect temperature sensor connector, lo- Inspect timing chain guide (fixed) for wear, cracks
cated at rear cylinder head. or other damages. Replace if necessary.
7. Remove the intake manifold. Refer to INTAKE Check for cracks between valve seats, if so, re-
MANIFOLD subsection. place cylinder head.
8. Remove the valve cover and its gasket (see Check mating surface between cylinder and cylin-
VALVE COVER in this subsection). der head for contamination. If so, clean both sur-
faces.
9. Refer to the TIMING CHAIN subsection to re-
move the following parts: Clean oil support through the cylinder head from
contamination.
– Chain tensioner
– Camshaft timing gear.
12 vmr2016-118
Reverse the removal procedure. Pay attention to

the following details.
1 Ensure dowel pins are in place.
NOTICE Timing chain guide (fixed) has to be
fixed between cylinder and cylinder head.
2 3
R400motr73A
1. Oil port to lubricate camshaft lobes intake/exhaust

2. Oil supply to camshaft bearing journal (timing chain side)
3. Oil supply to camshaft bearing journal (spark plug side)
Inspecting the Cylinder Head Camshaft

Bearing
Measure camshaft bearing in cylinder head.
vmr2016-033-002_b
1. Timing chain guide (tensioner side) mounted in crankcase

B 2. Timing chain guide (fixed) between cylinder and cylinder head
Install a NEW cylinder head gasket.

Install cylinder head screws in correct position.
A NOTICE Cylinder head screws have different
sizes and lengths.
R400motr77A
A. Camshaft bearing (timing chain side)

B. Camshaft bearing (spark plug side)
CAMSHAFT BEARING
(TIMING CHAIN SIDE)
35.000 mm to 35.025 mm
NEW
(1.378 in to 1.3789 in)
SERVICE LIMIT 35.040 mm (1.3795 in)
CAMSHAFT BEARING
(SPARK PLUG SIDE)
22.000 mm to 22.021 mm
NEW
(.8661 in to .867 in)
Installing the Cylinder Head

NOTE: Front and rear cylinder heads are not iden-
tical. Never interchange cylinder heads.
vmr2016-118 13
TIGHTENING TORQUE
20 N•m ± 1 N•m
M10 cylinder STEP A
head screws
STEP B 180° +/- 5°
Tighten M6 cylinder head screws as per following

specification.
vmr2015-032-003_a tmr2011-013-011_d
1. Location no. 1 1. M6 Screws

2. Location no. 2
TIGHTENING TORQUE
CYLINDER HEAD SCREW IDENTIFICATION
M6 cylinder head 10 N•m ± 1 N•m
570 Location no. 1 M10 x 140 screws (89 lbf•in ± 9 lbf•in)
650
850 Location no. 2 M6 x 85
Check timing chain guide (tensioner side) for
1000 Location no. 1 M10 x 159 movement.
1000R Location no. 2 M6 x 105 Refer to applicable subsection for installation de-
tails of remaining removed parts.
Tighten M10 cylinder head screws FIRST as per
following specifications. VALVE SPRINGS
NOTE: Always perform one step on all M10 cylin-
der head screws before going to the next step.
Removing the Valve Spring
1. Refer to following procedures in this subsection
to remove:
– CAMSHAFT
– CYLINDER HEAD.
2. Remove valve spring.
ENGINE REQUIRED TOOL
VALVE SPRING
All COMPRESSOR
(P/N 529 035 724)
570 VALVE SPRING
650 COMPRESSOR CUP
tmr2011-013-011_c
1000 (P/N 529 035 764)
TIGHTENING SEQUENCE - M10 CYLINDER HEAD SCREWS VALVE SPRING
850
COMPRESSOR CUP
1000R
(P/N 529 036 270)
14 vmr2016-118
WARNING
Always wear safety glasses when disassem-
bling valve springs. Be careful when unlock-
ing valves. Components could fly away be-
cause of the strong spring preload.
tmr2011-013-015_a
1. Valve spring retainer

2. Valve spring
Inspecting the Valve Spring

Check valve spring for visible damage. If so, re-
place valve spring.
Check valve spring for free length and straight-
R400motr79A ness.
LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF
THE VALVE
3. Remove valve cotters.
1 3 2
R400motr80A A
A. Valve spring length
VALVE SPRING FREE LENGTH

570
650 40.81 mm (1.607 in)
1000 NOMINAL NEW
R400motr78A
850
40.41 mm (1.591 in)
1. Valve spring compressor clamp 1000R
2. Valve spring compressor cup
3. Valve cotter All Service limit 39.00 mm (1.535 in)
4. Remove tools and withdraw valve spring re- Replace valve springs if not within specifications.
tainer and valve spring.
Installing the Valve Spring
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.
vmr2016-118 15
NOTE: Valve cotter must be properly engaged in REQUIRED TOOL

valve stem grooves.
SNAP-ON PLIERS (P/N YA 8230)
R400motr81A
1. Position of the valve spring

2. Valve cotter
After spring is installed, ensure it is properly

locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
times. vmr2006-043-023
NOTICE An improperly locked valve spring Inspecting the Valve

will cause engine damage. Whenever valves are removed always inspect
valve guides. Refer to VALVE GUIDES in this
VALVES subsection.
Removing the Valve Valve Stem Seal
1. Remove valve spring, see VALVE SPRING in Always install NEW seals whenever valves are re-
this subsection. moved.
2. Push valve stem, then pull valves (intake and Inspecting the Valve
exhaust) out of valve guide.
Inspect valve surface, check for abnormal stem
wear and bending. If out of specification, replace
by a new one.
mmr2009-115-072_a
vmr2006-043-021_a
VALVE OUT OF ROUND
1. Intake valves 31 mm (INTAKE AND EXHAUST VALVES)
2. Exhaust valves 27 mm
NEW 0.005 mm (.0002 in)
3. Remove valve stem seal and discard it.
16 vmr2016-118
Inspecting the Valve Stem Inspecting the Valve Face and Seat
Measure valve stem in three places using a mi-
crometer.
Replace valve if valve stem is out of specification
or has other damages such as wear or friction sur-
face.
2
3
R400motr84A
A 1. Valve seat
2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seat)
Check valve face and seat for burning or pitting

R400motr83A and replace valve or cylinder head if there are
A. Valve stem diameter
signs of damage.
Ensure to seat valves properly. Apply some lap-
VALVE STEM DIAMETER ping compound to valve face and work valve on
EXHAUST VALVE its seat with a lapping tool (see VALVE GUIDES in
this subsection).
570 4.956 mm to 4.970 mm
NEW Measure valve face contact width.
650 (.1951 in to .1957 in)
1000 SERVICE LIMIT 4.930 mm (.1941 in) NOTE: The location of contact area should be in
center of valve seat.
5.461 mm to 5.476 mm
850 NEW Measure valve seat width using a caliper.
(.215 in to .2156 in)
1000R VALVE SEAT CONTACT WIDTH
INTAKE VALVE EXHAUST VALVE
4.966 mm to 4.980 mm 1.25 mm to 1.55 mm

570 NEW NEW
(.1955 in to .1961 in) (.049 in to .061 in)
650
1000 SERVICE LIMIT 4.930 mm (.1941 in) SERVICE LIMIT 2.00 mm (.079 in)
5.472 mm to 5.486 mm INTAKE VALVE

850 NEW
(.2154 in to .216 in) 1.05 mm to 1.35 mm
1000R NEW
SERVICE LIMIT 5.450 mm (.2146 in) (.041 in to .053 in)
If valve seat contact width is too wide or has dark

spots, replace the cylinder head.
vmr2016-118 17
VALVE GUIDES
Inspecting the Valve Guide
Always replace valve stem seals whenever valve
guides are removed.
Measure valve guide in three places using a small
bore gauge.
NOTE: Clean valve guide to remove carbon de-
posits before measuring.
Replace valve guide if it is out of specification or
has other damages such as wear or friction sur-
face.
vmr2016-033-003_a VALVE GUIDE DIAMETER (INTAKE AND
A. Valve seat contact width EXHAUST VALVES)
570 4.998 mm to 5.018 mm

Installing the Valve New
650 (.1968 in to .1976 in)
Reverse the removal procedure. Pay attention to 1000 Service limit 5.050 mm (.1988 in)
5.506 mm to 5.518 mm
Install a NEW valve stem seal. Make sure thrust 850 New
(.2168 in to .2172 in)
washer is installed before installing seal. 1000R
Service limit 5.568 mm (.2192 in)
Apply engine oil on valve stem and install it.
NOTICE Be careful when valve stem is Removing the Valve Guide
passed through sealing lips of valve stem
1. Remove cylinder head (see CYLINDER
seal.
HEAD in this subsection).
1 2 2. Remove valves (see VALVES in this subsec-
tion).
NOTE: Clean valve guide area from contamination
before removal.
3. Drive valve guide out of cylinder head using
specified tool.
570 VALVE GUIDE
R400motr85A 650 REMOVER 5 MM
1. Thrust washer
1000 (P/N 529 035 924)
2. Sealing lips of valve stem seal
VALVE GUIDE
850
To ease installation of cotters, apply oil or grease REMOVER (6 MM)
1000R
on them so that they remain in place while relea- (P/N 529 036 074)
sing the spring. All Hammer
After spring is installed, ensure it is properly
locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
times.
NOTICE An improperly locked valve spring
will cause engine damage.
18 vmr2016-118
2 All Engines
1
1
R400motr86A
2
1. Valve guide remover R400motr87A
2. Valve guide
1. Valve guide installer
2. Valve guide
Installing the Valve Guide
For installation, reverse the removal procedure. NOTE: Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
Pay attention to the following details. (P/N 293 800 070) on valve guide prior to install it
into the cylinder head.
Clean the valve guide bore before reinstalling the
valve guide into cylinder head. NOTICE Push valve guide in the cold cylinder
Install valve guide. head as per following illustration.

570 VALVE GUIDE
650 INSTALLER
1000 (P/N 529 036 140)
VALVE GUIDE
850
INSTALLER
1000R
(P/N 529 036 269)
A 2
NOTICE Valve guide installer is used for in- 1
take and exhaust valve guides. Choose proper R400motr87B
side for installation.
1. Thrust surface of cylinder head
2. Valve guide
A. Measurement from thrust surface to valve guide top
VALVE GUIDE (MEASUREMENT A)

570
Intake and 14.00 mm to 14.40 mm
650
Exhaust (.5512 in to .5669 in)
1000
13.1 mm to 13.5 mm
Intake
850 (.5157 in to .5315 in)
1000R 14.3 mm to 14.7 mm
Exhaust
(.563 in to .579 in)
tmr2013-068-026_a
1. Valve guide installer Apply some lapping compound to valve face and
2. Mark "EX" - exhaust valve guide installer
3. Mark "IN" - intake valve guide installer work valve on its seat with a lapping tool.
A. 14.5 mm (.571 in)
B. 13.3 mm (.524 in)
vmr2016-118 19
Inspecting the Cylinder

3 A
Check cylinder for cracks, scoring and wear ridges
2
on the top and bottom of the cylinder. If so, re-
1 place cylinder.
Cylinder Taper
Measure cylinder bore at recommended posi-
tions.
R400motr89A
1. Valve seat
2. Valve face (contact surface to valve seat)
3. Turn valve while pushing against cylinder head
A. Valve seat angle 45°
NOTE: Ensure to seat valves properly. Apply

marking paste to ease checking contact pattern.
Repeat procedure until valve seat/valve face fits
together.
vmr2016-118-001_a
CYLINDER A. First measurement
B. Second measurement
Removing the Cylinder C. Third measurement
1. Refer to the TIMING CHAIN subsection to re- CYLINDER TAPER MEASUREMENTS

– Chain tensioner ENGINE MEASUREMENTSPECIFICATION
– Camshaft timing gear. A 5 mm (.197 in)
570
2. Remove the cylinder head (see CYLINDER 650 B 58 mm (2.28 in)
HEAD in this subsection). 850
C 37 mm (1.46 in)
3. Pull cylinder.
A 5 mm (.197 in)
4. Discard cylinder base gaskets. 1000
B 53 mm (2.09 in)
1000R
4 C 57 mm (2.24 in)
CYLINDER TAPER SPECIFICATION

NEW (MAXIMUM) 0.038 mm (.0015 in)
1 SERVICE LIMIT 0.090 mm (.0035 in)
Distance between measurements should not ex-

ceed the service limit. Otherwise, replace cylin-
2 der and piston rings.
3
Cylinder Out of Round
Measure cylinder diameter:
R400motr90A
– in piston axis
1. Cylinder – perpendicular to piston axis.
2. Piston assembly
3. Cylinder base gasket NOTE: Use the same measuring points as de-
4. Camshaft timing chain
scribed in CYLINDER TAPER.
20 vmr2016-118
B
A
R400motr92A
A. Perpendicular to crankshaft axis

B. Parallel to crankshaft axis
vmr2016-033-004_a
CYLINDER OUT OF ROUND 1. Piston ring compressor
2. Cylinder
NEW (MAXIMUM) 0.015 mm (.0006 in)
SERVICE LIMIT 0.020 mm (.0008 in) NOTICE Chain guide has to be fixed between
cylinder and cylinder head.
Installing the Cylinder NOTE: After both cylinders are installed, turn
Reverse the removal procedure. Pay attention to crankshaft until piston of cylinder 2 is at TDC and
the following details. lock crankshaft. Refer to CRANKSHAFT in the
BOTTOM END subsection.
NOTICE Always replace cylinder base gasket
Install cylinder head and the other parts in accor-
before installing the cylinder.
dance with the proper installation procedures.
NOTE: Make sure piston rings are properly
spaced, refer to PISTON RINGS in this sub- PISTON
section.
Removing the Piston
Apply engine oil:
– In the bottom area of the cylinder bore 1. Refer to following procedures in this subsection
and remove following parts:
– On the piston rings
– Cylinder head
– On the piston ring compressor.
– Cylinder.
Compress piston rings.
2. Place a rag under piston and in the area of tim-
REQUIRED TOOL ing chain compartment.
Piston ring compressor with band width of
15 mm to 20 mm (.59 in to .79 in) WARNING
Piston circlips are spring loaded.
First mount cylinder 2.
NOTE: The cylinder can not be pushed fully over 3. Remove one piston circlip and discard it.
the piston unless the piston is located at TDC.
Then remove the CRANKSHAFT LOCKING BOLT
(P/N 529 035 617).
Crank the engine further and position piston 1 at
TDC.
Mount cylinder 1.
Put timing chain through the chain passage, then
slide cylinder over piston.
vmr2016-118 21
A
R400motr96A
1. Measuring perpendicularly (90°) to piston pin

A. 8 mm (.315 in)
The measured dimension should be as described

vmr2016-033-005_a
in the following tables. If not, replace piston.
1. Piston circlip
PISTON MEASUREMENT
NOTE: The removal of both piston circlips is not
83.950 mm to 83.966 mm
necessary to remove piston pin. New
570 (3.3051 in to 3.3057 in)
4. Push piston pin out of piston.
Service limit 83.850 mm (3.3012 in)
81.950 mm to 81.966 mm
New
650 (3.2264 in to 3.227 in)
1
93.950 mm to 93.966 mm
New
850 (3.6988 in to 3.6994 in)
2 Service limit 93.900 mm (3.6969 in)
90.950 mm to 90.966 mm
1000 New
(3.5807 in to 3.5813 in)
1000R
R400motr95A
1. Piston Piston/Cylinder Clearance

2. Piston pin
Adjust and lock a micrometer to the piston dimen-
5. Detach piston from connecting rod. sion.
Inspecting the Piston 1
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) perpendicularly (90°) to piston pin.
F00B08A
1. Micrometer set to the piston dimension
With the micrometer set to the dimension, adjust

a cylinder bore gauge to the micrometer dimen-
sion and set the indicator to 0 (zero).
22 vmr2016-118
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
2 1 Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other
damages.
Measure piston pin. See the following illustration
for the proper measurement positions.
F00B09A
1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge
R400motr30A A
A. Piston pin diameter
PISTON/CYLINDER CLEARANCE
570 19.996 mm to 20.000 mm

New
650 (.7872 in to .7874 in)
850 Service limit 19.980 mm (.7866 in)
1 New
21.996 mm to 22.000 mm
1000 (.866 in to .866 in)
1000R
F00B0AA Service limit 21.980 mm (.8654 in)
TYPICAL Replace piston pin if diameter is out of specifica-
1. Indicator set to 0 (zero)
tions.
Position the dial bore gauge 20 mm (.787 in) above Measure inside diameter of connecting rod small
cylinder base, measuring perpendicularly (90°) to end bushing.
piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.
PISTON/CYLINDER CLEARANCE
0.057 mm to 0.087 mm
570 New
(.0022 in to .0034 in)
650
2 1
850 0.027 mm to 0.057 mm
New
1000 (.0011 in to .0022 in)
1000R Service limit 0.100 mm (.0039 in)
R1004motr11A
NOTE: Make sure used piston is not worn. 1. Bore gauge

2. Connecting rod
If clearance exceeds specified tolerance, replace
piston by a new one and measure piston/cylinder
clearance again.
vmr2016-118 23
CONNECTING ROD SMALL END DIAMETER
570 20.010 mm to 20.020 mm

New
650 (.7878 in to .7882 in)
850 Service limit 20.060 mm (.7898 in)
22.010 mm to 22.020 mm
1000 New
(.8665 in to .8669 in)
1000R
Replace connecting rod if diameter of connecting

rod small end is out of specifications. Refer to
BOTTOM END subsection for removal proce-
dure.
Compare measurements to obtain the connecting
rod/piston pin clearance.
CONNECTING ROD/
PISTON PIN CLEARANCE
vmr2016-118-002_a
570 , 850, 1000 AND 1000R ENGINES

Installing the Piston 1. Piston of cylinder 1 (front)
2. Mark on piston must show to intake side of cylinder 1
Reverse the removal procedure. Pay attention to 3. Piston of cylinder 2 (rear)
the following details. 4. Mark on piston must show to exhaust side of cylinder 2
Apply engine oil on the piston pin. 650 Engines

Insert piston pin into piston and connecting rod. For each cylinder, install the piston with the arrow
570, 850, 1000 and 1000R Engines on the piston dome pointing towards the exhaust
side of the engine.
For each cylinder, install piston with the punched
arrow on piston dome pointing towards the rear Front cylinder: Mark on top of piston must show
side of the engine. to exhaust side.
Front cylinder: Mark on top of piston must show Rear cylinder: Mark on top of piston must show
to intake side. to exhaust side.
Rear cylinder: Mark on top of piston must show
to exhaust side.
24 vmr2016-118
1
2
R400motr100A
1. Circlip
2. Sleeve
3. Assembly jig from piston clip installer
Push taper side of assembly jig until circlip

vmr2007-036-007_a reaches middle of sleeve.
650 ENGINE
1. Piston of cylinder 1 (front) Align sleeve with piston pin axis and push assem-
2. Mark on piston must show to exhaust side of cylinder 1 bly jig until circlip engages in piston.
3. Piston of cylinder 2 (rear)
4. Mark on piston must show to exhaust side of cylinder 2
All Engines
Use the piston appropriate circlip installer to as-
semble the NEW piston circlip as per following
procedure:
REQUIRED TOOL
PISTON CIRCLIP
570
INSTALLER
650
(P/N 529 035 921)
PISTON CIRCLIP
850 INSTALLER
(P/N 529 036 083) vmr2007-036-008_a
PISTON CIRCLIP 1. Hold piston while pushing circlip in place

1000 2. Sleeve
INSTALLER 3. Assembly jig
1000R
(P/N 529 036 153) 4. Direction to push circlip
NOTICE Always replace disassembled piston NOTE: Take care that the hook of the piston circlip
circlip(s) by NEW ones. Place a rag on cylinder is positioned properly.
base to avoid dropping the circlip inside the en-
gine.
Place circlip in sleeve as per following illustration.
vmr2016-118 25
1
2
R400motr103A
1. Piston
2. Feeler gauge
Ring End Gap

RING END GAP
vmr2016-033-006 UPPER COMPRESSION RING
CORRECT POSITION OF THE PISTON CIRCLIP
0.10 mm to 0.30 mm
NEW
570 (.004 in to .012 in)
PISTON RINGS
Removing the Piston Rings
0.20 mm to 0.35 mm
Remove the piston (see PISTON in this subsec- NEW
850 (.008 in to .014 in)
tion).
Inspecting the Piston Rings 650 0.20 mm to 0.40 mm
NEW
1000 (.008 in to .016 in)
Ring/Piston Groove Clearance
1000R SERVICE LIMIT 0.60 mm (.024 in)
Using a feeler gauge measure each ring/piston
groove clearance. If the clearance is too large, the LOWER COMPRESSION RING
piston and the piston rings should be replaced.
0.35 mm to 0.55 mm
570 NEW
RING/PISTON GROOVE CLEARANCE (.014 in to .022 in)
850
UPPER COMPRESSION RING SERVICE LIMIT 0.85 mm (.033 in)
0.025 mm to 0.070 mm 650 0.20 mm to 0.40 mm
NEW NEW
570 (.001 in to .0028 in) 1000 (.008 in to .016 in)
SERVICE LIMIT 0.100 mm (.0039 in) 1000R SERVICE LIMIT 0.70 mm (.028 in)
650 0.030 mm to 0.070 mm OIL SCRAPER RING
NEW
850 (.0012 in to .0028 in)
0.20 mm to 0.70 mm
1000 NEW
SERVICE LIMIT 0.150 mm (.0059 in) All (.008 in to .028 in)
1000R
LOWER COMPRESSION RING
0.020 mm to 0.060 mm To measure the ring end gap place the ring
NEW
All (.0008 in to .0024 in) in the cylinder in the area of 8 mm to 16 mm
SERVICE LIMIT 0.150 mm (.0059 in) (5/16 in to 5/8 in) from top of cylinder.
NOTE: In order to correctly position the ring in the
OIL SCRAPER RING
cylinder, use piston as a pusher.
0.010 mm to 0.180 mm Using a feeler gauge, check ring end gap. Replace
NEW
All (.0004 in to .0071 in)
ring if gap exceeds specified tolerance.
Installing the Piston Rings
26 vmr2016-118
NOTE: First install spring and then rings of oil

scraper ring.
NOTE: Use a ring expander to prevent breakage
during installation. The oil ring must be installed
by hand.
Install the oil scraper ring first, then the lower
compression ring with the word “N and TOP “
facing up, then the upper compression ring with
the word “N and TOP“ facing up.
3
vmr2007-036-009_a
1. Upper compression ring

2. Lower compression ring
3. Oil scraper ring
NOTICE Ensure that top and second rings are

not interchanged.
Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120° apart and do
not align the gaps with the piston pin bore or the
thrust side axis.
A
A A
A31C2OA
1. DO NOT align ring gap with piston thrust side axis

2. DO NOT align ring gap with piston pin bore axis
A. 120°
vmr2016-118 27
Subsection 09 (TIMING CHAIN)
TIMING CHAIN
SERVICE TOOLS
CAMSHAFT TIMING TOOL........................................................... 529 036 268 ............................................. 6
CRANKSHAFT TDC POSITION TOOL ........................................... 529 036 201 ......................................... 6, 9
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ....................................... 7, 12
4,5 ± 0,5 N•m

(40 ± 4 lbf•in)
0,1 N•m
(0.89 lbf•in)
Engine oil
6 ± 0,7 N•m
10 ± 1 N•m (53 ± 6 lbf•in)
(89 ± 9 lbf•in) Loctite 243
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
6 ± 0,7 N•m
(53 ± 6 lbf•in)
Loctite 243
0,1 N•m
(0.89 lbf•in)
Engine oil
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243 4,5 ± 0,5 N•m
(40 ± 4 lbf•in)
vmr2015-033-010_a
vmr2016-119 1
TROUBLESHOOTING
UNUSUAL ENGINE NOISE OR VIBRATION
1. IMPROPER VALVE CLEARANCE ADJUSTMENT
AND/OR WORN OUT ROCKER ARM(S)
- Readjust valve clearance and/or replace defective
part(s), refer to TOP END subsection.
2. DEFECTIVE CHAIN TENSIONER
- Replace 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. tmr2011-045-005_a
570 AND 650 ENGINES (FRONT CYLINDER SHOWN)

5. LOOSE TIMING GEAR RETAINING SCREWS 1. Timing chain tensioner
- Retighten screws to recommended torque. 850, 1000 and 1000R Engines
6. INCORRECT CAMSHAFT TIMING The timing chain tensioner is located in the cylin-
- Replace damaged components and readjust der.
camshaft timing.
ENGINE LACKS ACCELERATION OR

POWER
1. INCORRECT CAMSHAFT TIMING
- Replace damaged components and readjust
camshaft timing.
PROCEDURES
TIMING CHAIN TENSIONERS
Timing Chain Tensioner Location
570 and 650 Engines
The timing chain tensioner is located on the back tmr2011-045-002_a
of each cylinder head. 850, 1000 AND 1000R ENGINES (FRONT CYLINDER SHOWN)
1. Timing chain tensioner
Timing Chain Tensioner Access

For the front cylinder chain tensioner, refer to
BODY subsection and remove the following:
– Seat
For the rear cylinder chain tensioner, refer to
BODY subsection and remove the following:
– Seat
– LH side panel and extension.
For the rear cylinder chain tensioner, also remove
the outer exhaust system heat shield. Refer to
EXHAUST SYSTEM subsection.
2 vmr2016-119
vmr2015-033-100_a
1. Heat shield to remove vmr2006-043-005_a
1. Screws
Removing the Timing Chain Tensioner 2. Chain tensioner housing
3. O-ring
1. Make sure the applicable piston is set to TDC ig-
nition. Refer to CAMSHAFT TIMING GEARS in Inspecting the Timing Chain Tensioner
this subsection.
Check chain tensioner housing and screw plug for
2. Carefully remove chain tensioner screw plug cracks or other damages. Replace if necessary.
and release spring tension.
Check chain tensioner plunger for freedom of
movement and/or scoring.
CAUTION Tensioner is spring loaded.
Ensure O-rings are not brittle, cracked or hard. Re-
3. Remove: place if necessary.
– O-ring
Check spring condition. Replace if bent, broken or
– Spring worn.
– Chain tensioner plunger.
Installing the Timing Chain Tensioner
NOTE: Before installing the chain tensioner, make
sure the camshaft timing gear can be moved back
and forth.
vmr2006-043-004_a
1. Chain tensioner screw plug

2. O-ring
3. Spring
4. Chain tensioner plunger
4. Remove:
– Chain tensioner housing retaining screws
– Chain tensioner housing
– O-ring.
vmr2016-119 3
tmr2013-069-006_a
1. Plug
tmr2011-045-003_a 2. Slot
3. Spring
MOVE GEAR BACK AND FORTH 4. Spring end
5. O-Ring
1. Apply engine oil on the chain tensioner plunger
before installation. 7. Fit the spring on the other side into the plunger.
2. Slightly turn the camshaft timing gear in order NOTE: Turn spring only clockwise in order to fit
to move the timing chain excess play to the ten- the spring end into the notch of the plunger to
sioner side. avoid loosening the plunger during spring installa-
3. Slightly screw in the plunger until the timing tion. Do not preload the spring.
chain does not allow back and forth movement
of the camshaft timing gear.
4. Screw the plunger in an additional 1/8 turn to
obtain the required specified torque.
TIMING CHAIN TENSIONER ADJUSTMENT
(TIGHTENING TORQUE)
0.1 N•m (.9 lbf•in)
NOTICE Improper adjustment of the timing

chain will lead to severe engine damage.
5. Place the O-ring on chain tensioner screw plug.
6. Fit the spring on one side into the slot of the tmr2013-069-007_a
chain tensioner screw plug. FOR CLARITY PARTS ARE REMOVED FROM CYLINDER
1. Plunger
2. Notch
3. Spring
4. Spring end
5. Plug with O-ring
8. Then compress the spring and screw the plug

in.
NOTE: To avoid overstressed timing chain, the
plug must engage into threads within the first full
turn.
4 vmr2016-119
tmr2013-069-008_a
Step 1: Compress spring

Step 2: Screw in plug
9. Remove locking tool and install all other re- tmr2011-045-003_b
moved parts. TYPICAL

1. Camshaft timing gear retaining screws
10. Tighten the chain tensioner screw plug to 2. Camshaft timing gear
specification. 5. Remove the camshaft timing gear.
TIGHTENING TORQUE NOTE: Secure timing chain with a piece of wire.
4.5 N•m ± 0.5 N•m
Chain tensioner plug Inspecting the Camshaft Timing Gear
Check camshaft timing gear for wear or deteriora-
tion.
CAMSHAFT TIMING GEARS
If timing gear is worn or damaged, replace it as a
Removing the Camshaft Timing Gear set with the timing chain.
1. Remove valve cover, refer to TOP END subsec- For crankshaft gear inspection, refer to CRANK-
tion. SHAFT in the BOTTOM END subsection.
2. Set applicable piston to TDC ignition and lock
magneto flywheel. Refer to CAMSHAFT TIM- Installing the Camshaft Timing Gear
ING in this subsection. For installation, reverse the removal procedure.
3. Remove timing chain tensioner. Refer to TIM- Pay attention to the following details.
ING CHAIN TENSIONERS in this subsection. 1. Clean camshaft mating surface and threads
4. Remove camshaft timing gear retaining prior to installing camshaft timing gear.
screws.
tmr2011-045-004_a
1. Camshaft mating surface

2. Camshaft screw threads
vmr2016-119 5
2. Set applicable piston to TDC ignition position

and install the crankshaft position tool, refer to
CAMSHAFT TIMING in this subsection.
REQUIRED TOOL
CRANKSHAFT TDC
POSITION TOOL
(P/N 529 036 201)
3. Install camshaft timing tool on the cylinder

head.
REQUIRED TOOL
vmr2015-033-002_a
CAMSHAFT TIMING TOOL PRESS TOOL LEVER DOWN
(P/N 529 036 268) 1. Lever
2. Flat portion
3. Camshaft
NOTE: Properly align tube of camshaft timing tool
with machined radius on cylinder head. NOTICE Crankshaft and camshaft must
be locked at TDC ignition position to place
camshaft timing gear and timing chain in the
proper position.
5. Place camshaft timing gear and timing chain on
the camshaft.
NOTE: The printed marks on the camshaft timing
gear must be parallel to the cylinder head base.
vmr2015-033-001_a
CAMSHAFT TIMING TOOL INSTALLED

1. Tube (camshaft timing tool)
2. Machined radius (camshaft timing tool)
3. Cylinder head
4. Set camshaft to TDC ignition position by align-

ing the flat portion on the camshaft flange with
the tool lever.
NOTE: In addition, to ensure proper camshaft tim- vmr2015-033-003_a
ing, press camshaft timing tool lever downwards. 1. Timing chain

2. Camshaft timing gear
3. Printed marks on camshaft timing gear
6. Install and adjust timing chain tensioner, refer to

TIMING CHAIN TENSIONER in this subsection.
7. Install and tighten camshaft timing gear retain-
ing screws to specified torque.
6 vmr2016-119
vmr2015-033-004_a
1. Camshaft timing gear vmr2015-033-005_a

2. Timing gear retaining screws
1. Screw plug
2. O-ring
TIGHTENING TORQUE
4. Remove the crankshaft position sensor (CPS).
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Camshaft timing gear 10 N•m ± 1 N•m
retaining screws (89 lbf•in ± 9 lbf•in)
8. Remove the camshaft timing tool.
Camshaft Timing
NOTE: If a piston (cylinder 1 or 2) is set to TDC
ignition, the camshaft timing gear of the opposite
cylinder must be in the following position.
vmr2015-033-006_a
1. CPS
2. Screw
5. Set rear piston no. 2 to TDC ignition by turning

the crankshaft clockwise.
REQUIRED TOOL
Allen key 14 mm
tmr2011-045-011_a
TYPICAL
1. Cylinder head base
2. Marks on timing gear of the opposite cylinder
Camshaft Timing Piston No. 2 (rear)

1. Remove spark plugs of both cylinders.
2. Remove valve covers of both cylinders.
3. Remove the screw plug and O-ring from mag-
neto cover.
vmr2016-119 7
vmr2015-033-007_a
TURN CRANKSHAFT CLOCKWISE TO PISTON NO. 2 TDC

1. Allen key 14 mm
tmr2011-045-003_c
5.1 The rear piston is at TDC when it's index TYPICAL - PISTON AT TDC IGNITION
mark on the magneto flywheel is aligned 2. Cylinder head base
with the notch in the magneto cover.
6. Install the crankshaft TDC position tool to lock
crankshaft in position. Refer to CRANKSHAFT
TDC POSITION TOOL in this subsection.
Camshaft Timing Piston No. 1 (front)
1. Set rear piston no. 2 to TDC ignition, see
CAMSHAFT TIMING PISTON NO. 2 (REAR) in
this subsection.
2. Remove crankshaft TDC position tool.
3. To set front piston no. 1 to TDC ignition turn
crankshaft 280° counterclockwise.
REQUIRED TOOL
Allen key 14 mm
vmr2007-037-008_b
PISTON NO. 2 AT TDC

1. Piston no. 2 identifier
2. Index mark on magneto flywheel
3. Notch on magneto cover
4. CPS bore in magneto cover
5.2 Confirm printed marks on the camshaft

timing gear are parallel with cylinder head
base, in the lowest position. In this posi-
tion the piston is set to TDC ignition.
NOTE: If marks on camshaft timing gear are
not as specified, turn crankshaft 360°.
vmr2015-033-007_b
TURN COUNTERCLOCKWISE 280° TO NUMBER 1 PISTON TDC

1. Allen key 14 mm
3.1 The front piston is at TDC when it's index

mark on the magneto flywheel is aligned
with the notch in the magneto cover.
8 vmr2016-119
Install tool in magneto cover CPS bore.

REQUIRED TOOL
CRANKSHAFT TDC
POSITION TOOL
(P/N 529 036 201)
NOTE: Make sure to match the teeth on the

crankshaft TDC position tool with the magneto
rotor.
vmr2007-036-006_b
CYLINDER 1 AT TDC
1. Number 1 piston identifier
2. Index mark “1” on magneto flywheel
4. Crankshaft position sensor bore
3.2 Confirm printed marks on the camshaft tmr2011-045-020_a
timing gear are parallel with cylinder head 1. Crankshaft TDC position tool teeth (end view)
base, in the lowest position. In this posi-
tion the piston is set to TDC ignition.
vmr2015-033-008_a
MAGNETO COVER
1. Crankshaft TDC position tool installed in CPS bore
NOTICE Tool must be fully inserted.

tmr2011-045-003_c
TYPICAL - PISTON AT TDC IGNITION

2. Cylinder head base
4. Insert the crankshaft TDC position tool to lock

crankshaft in position. Refer to CRANKSHAFT
TDC POSITION TOOL INSTALLATION in this
subsection.
Crankshaft TDC Position Tool Installation
NOTICE Never use crankshaft TDC position
tool to remove or tighten drive CVT screw or
rotor retaining screw. Damage to the teeth of
the trigger wheel on the rotor will occur.
vmr2016-119 9
vmr2015-033-009_a
1. Magneto cover Vmr2012-016-005_a

2. TDC position tool 1. Timing chain
2. Lower timing chain guide
3. Timing chain guide (tensioner side)
TIMING CHAIN
NOTE: Mark the operating direction of the timing
Timing Chain Location chain and check for excessive radial play before
The engine is equipped with two timing chains. removal. Refer to TIMING CHAIN INSPECTION.
– MAG side timing chain is located behind the 5. Carefully pull the timing chain downwards and
magneto cover. sideways, then out of the crankcase.
– PTO side timing chain is located behind the PTO
cover. Removing the Timing Chain (PTO
Side)
Removing the Timing Chain (MAG 1. Refer to BOTTOM END subsection and remove
Side) following parts:
1. Refer to MAGNETO AND STARTER subsection – PTO cover
and remove following parts: – Breather gear
– Magneto cover – Intermediate gear.
– Rotor
2. Refer to TOP END subsection and remove fol-
– Sprag clutch gear. lowing part:
2. Refer to TOP END subsection and remove the – Valve cover.
following part:
3. Refer to applicable procedures in this subsec-
– Valve cover. tion and remove following parts:
3. Refer to following procedures in this subsection – Chain tensioner
and remove following parts: – Camshaft timing gear.
– Chain tensioner
4. Remove timing chain guide (tensioner side) and
– Camshaft timing gear. lower timing chain guide.
4. Remove timing chain guide (tensioner side) and
lower timing chain guide.
10 vmr2016-119
vmr2006-044-018_a
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-
formation. Replace as required.
tmr2011-045-015_a NOTE: Check also the timing chain guide (ten-
1. Timing chain sioner side).
2. Lower timing chain guide
3. Timing chain guide (tensioner side)
Installing the Timing Chain
NOTE: Mark the operating direction of the timing The installation is essentially the reverse of the re-
chain and check for excessive radial play before moval procedure however, pay attention to the fol-
removal. Refer to TIMING CHAIN INSPECTION. lowing details.
5. Carefully pull the timing chain sideward and NOTE: Installation is the same for both timing
down from the crankcase. chains.
Inspecting the Timing Chain Install timing chain with camshaft timing gear.
Inspection is the same for both timing chains. NOTE: Ensure to carry out proper valve timing, re-
fer to CAMSHAFT TIMING GEARS in this subsec-
Check timing chain on camshaft timing gear for tion.
excessive radial play.
NOTICE Improper valve timing will damage
engine components.
TIMING CHAIN GUIDE

(TENSIONER SIDE)
tmr2011-045-003_d
CHECKING TIMING CHAIN RADIAL PLAY
Check chain condition for wear and teeth condi- tmr2011-045-019_a
tion. 1. Timing chain guide (tensioner side)

2. Bearing screw
Removing the Timing Chain Guide

(Tensioner Side)
Refer to TIMING CHAIN in this subsection.
vmr2016-119 11
Inspecting the Timing Chain Guide

(Tensioner Side)
Check timing chain guide for wear, cracks or de-
formation. Replace if necessary.
Installing the Timing Chain Guide

(Tensioner Side)
cedure.
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Timing chain guide 10 N•m ± 1 N•m
bearing screw (89 lbf•in ± 9 lbf•in)
12 vmr2016-119
Subsection 10 (BOTTOM END)
BOTTOM END
SERVICE TOOLS
CRANKCASE SUPPORT MAG/PTO .............................................. 529 036 031 ........................................... 14
CRANKSHAFT LOCKING BOLT..................................................... 529 035 617 ........................................... 18
DRIVE SHAFT OIL SEAL INSTALLER ........................................... 529 036 028 ......................................... 6–7
DRIVE SHAFT OIL SEAL PROTECTOR......................................... 529 036 029 ............................................. 5
PLAIN BEARING REMOVER/INSTALLER ..................................... 529 035 917 ..................................... 14–15
PLAIN BEARING REMOVER/INSTALLER ..................................... 529 036 032 ............................................. 9
PTO COVER OIL SEAL INSTALLER .............................................. 529 036 033 ............................................. 8
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 6
LOCTITE 5910 ............................................................................... 293 800 081 ............................................. 5
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ............................................. 5
ENGINE DRIVE SHAFT
Engine oil
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 767
(antiseize lubricant)
Petamo
grease
Loctite
5910
Engine oil
Loctite
10 ± 1 N•m 5910
(89 ± 9 lbf•in)
Loctite
243 Engine oil
Petamo
grease
tmr2011-014-001_b
vmr2016-120 1
CRANKCASE AND PTO COVER
Engine oil
NEW
See tightening sequence

Loctite 243 25 ± 3 N•m
(18 ± 2 lbf•ft)
6 ± 0,7 N•m 10 ± 1 N•m

(53 ± 6 lbf•in) (89 ± 9 lbf•in)
NEW
Engine oil
25 ± 3 N•m
(18 ± 2 lbf•ft)
Engine oil
See
tightening 10 ± 1 N•m
sequence (89 ± 9 lbf•in)
12 ± 1 N•m
(106 ± 9 lbf•in) Loctite 243
Engine oil
Petamo Grease
NEW
10 ± 1 N•m
(89 ± 9 lbf•in)
vmr2015-034-001_b
2 vmr2016-120
CRANKSHAFT
NEW
SeeSee torquing
tightening
NEW procedure
procedureinside
Engine
oil
See torquing
See tightening
procedure
procedure
inside
Engine oil
vmr2013-018-001_b
vmr2016-120 3
PROCEDURES
IMPORTANT: Note position of parts on disas-
sembly. This may help to find the root cause of
a problem. A component that is not replaced
should be reinstalled in the same position as
originally mounted.
ENGINE DRIVE SHAFT

NOTE: The engine drive shaft transmits the
power from the gearbox to the front differential
tmr2011-014-007_a
and is located inside the crankcase.
1. Bearing cover front drive side
2. Circlip
Removing the Engine Drive Shaft 3. Drive shaft
Remove the engine. Refer to ENGINE REMOVAL Removing the Engine Drive Shaft
AND INSTALLATION subsection.
Split crankcase, refer to CRANKCASE in this sub-
Removing the Rear Bearing Cover section.
Detach gearbox from engine, refer to GEARBOX Remove engine drive shaft from the crankcase.
AND 4X4 COUPLING UNIT subsection.
At rear of engine, remove the bearing cover and
its O-ring.
tmr2011-014-008_a
1. Crankcase MAG side

2. Engine drive shaft
tmr2011-014-006_a
Inspecting the Engine Drive Shaft
1. Bearing cover screws Replace oil seals and/or O-ring (bearing cover
2. O-ring gearbox side) if they are brittle, hard or damaged.
3. Bearing cover gearbox side
Check drive shaft bearings for contamination
Removing the Front Bearing Cover and/or metal shavings. Check if bearings turn
Remove the bearing cover at the front of the en- freely and smoothly. Replace if necessary.
gine.
NOTICE Check ends of the circlip for sharp
edges or burrs before removing the drive shaft,
to avoid damaging the oil seal.
4 vmr2016-120
tmr2011-014-009_a
1. Bearing cover
2. Drive shaft bearing
Check drive shaft for cracks, bend, pitting or other F12R17A
visible damages.
Check drive shaft splines for wear or damages. Do not apply in excess as it will spread out inside
Check oil seal running surface of the drive shaft crankcase.
for scratches. Replace if necessary. NOTE: It is recommended to apply this specific
sealant as described here to get a uniform appli-
Installing the Engine Drive Shaft cation without lumps. If you do not use the roller
The installation is the reverse of removal proce- method, you may use your finger to uniformly dis-
dure however, pay attention to the following de- tribute the sealant (using a finger will not affect
tails. the adhesion).
Clean all metal components in solvent. Installing the Rear Bearing Cover
Clean crankcase surfaces and bearing covers us- For bearing cover installation on gearbox side, pro-
ing a combination of LOCTITE CHISEL (GASKET RE- tect the oil seal to avoid damaging the sealing lip.
MOVER) (P/N 413 708 500) and a brass brush. First
REQUIRED TOOL
brush in one direction then make the final brush-
ing perpendicularly (90°) to the first pass.
DRIVE SHAFT OIL SEAL
NOTICE Do not wipe with rags. Use a new PROTECTOR (P/N 529 036 029)
clean hand towel only.
Use a suitable installer for installing bearings.
Use LOCTITE 5910 (P/N 293 800 081) on mating sur-
faces.
IMPORTANT: When beginning the application of
the bearing cover sealant, the assembly and the
first torquing should be done within 10 minutes.
It is suggested to have all you need on hand to
save time.
Use a plexiglass plate and apply some sealant
on it. Use a soft rubber roller 50 mm - 75 mm
(2 in - 3 in), available in arts products suppliers for
printing, and roll the sealant to get a thin uniform tmr2011-014-010_a
coat on the plate (spread as necessary). When 1. Drive shaft
ready, apply the sealant on bearing cover sur- 2. Bearing cover gearbox side
faces. 3. O-ring
4. Protection sleeve
TIGHTENING TORQUE
Rear bearing cover 10 N•m ± 1 N•m
vmr2016-120 5
Installing the Front Bearing Cover
tmr2013-018-005_a
1. Bearing cover
2. Oil seal
vmr2016-120-001_a 5. Install drive shaft oil seal using the following

FRONT OF ENGINE tool.
1. Bearing cover front side
2. Drive shaft REQUIRED TOOL
3. Water pump cover
TIGHTENING TORQUE DRIVE SHAFT OIL SEAL

INSTALLER (P/N 529 036 028)
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Front bearing cover 10 N•m ± 1 N•m
Installing the Engine Drive Shaft

Finally check for axial play of the drive shaft.
FRONT OIL SEAL

(ENGINE DRIVE SHAFT)
Replacing the Front Oil Seal
(Engine Drive Shaft)
NOTE: The front oil seal can be replaced with the
engine installed.
vmr2013-018-002_a
1. Remove front propeller shaft.
1. Bearing cover
2. Remove adapter sleeve between propeller 2. Oil seal
3. Oil seal installer
shaft and front engine drive shaft.
3. Remove the front bearing cover, refer to EN- 6. Reinstall remaining parts in the reverse order of
GINE DRIVE SHAFT REMOVAL/INSTALLATION removal.
in this subsection.
4. Remove drive shaft seal from bearing cover. REAR OIL SEAL
(ENGINE DRIVE SHAFT)
Replacing the Rear Oil Seal
(Engine Drive Shaft)
1. Remove gearbox from the engine, refer to
GEARBOX AND 4X4 COUPLING UNIT subsec-
tion.
6 vmr2016-120
2. Remove rear bearing cover, refer to ENGINE

DRIVE SHAFT REMOVAL/INSTALLATION in
this subsection.
3. Remove O-ring from bearing cover.
vmr2013-018-002_a
1. Bearing cover
2. Oil seal
6. Install O-ring in rear bearing cover.

vmr2013-018-003_a
1. Bearing cover
2. O-ring
4. Remove drive shaft seal from bearing cover.
vmr2013-018-004_a
1. O-ring
2. Bearing cover
tmr2013-018-005_a
1. Bearing cover
7. Reinstall remaining parts in the reverse order of
2. Oil seal removal.
5. Install drive shaft oil seal using the following
tool. PTO COVER OIL SEAL
REQUIRED TOOL NOTE: To replace oil seal it is not necessary to
remove engine from vehicle.
INSTALLER (P/N 529 036 028) Removing the PTO Oil Seal
1. Refer to CONTINUOUSLY VARIABLE TRANS-
MISSION (CVT) subsection and remove the fol-
lowing parts:
– CVT cover
– Drive pulley
– Driven pulley
– CVT air guide.
2. Remove oil seal using a small flat screwdriver.
vmr2016-120 7
NOTICE Avoid scoring surfaces with tool. PTO COVER

Removing the PTO Cover
MISSION (CVT) subsection to remove the fol-
lowing parts:
– CVT cover
– Drive pulley
– Driven pulley
– CVT air guide.
2. Disconnect vent hose.
3. Remove PTO cover screws and pull on PTO
cover to remove it.
vmr2015-034-003_a
1. PTO cover
2. Oil seal
Inspecting the PTO Oil Seal

Check oil seal running surface of crankshaft PTO
side for grooves. Replace if necessary.
Installing the PTO Oil Seal

cedure however, pay attention to the following de-
tails.
NOTICE Oil seal must be installed with seal-
ing lip toward the engine.
Push oil seal in place using the following tool.
REQUIRED TOOL
PTO COVER OIL SEAL

vmr2006-044-003_a
1. PTO cover
2. PTO cover screws
3. Vent hose nipple
Inspecting the PTO Cover

1. Check the PTO cover for cracks or other dam-
age.
2. Replace PTO cover if damaged.
3. Clean oil breather bore in PTO cover from con-
taminations with a parts cleaner then use pres-
vmr2015-034-004_a surized air to dry it.
1. PTO cover
3. Oil seal
8 vmr2016-120
WARNING Replacing the Plain Bearing

Always wear skin and eye protection. Chem-
(PTO Cover)
icals can cause skin rash, skin burns and se- Removing the Plain Bearing
vere eye injury.
NOTICE Unless otherwise instructed, never
4. Check surface of sealing sleeve for wear or use a hammer to install plain bearings. Always
other damages. Replace PTO cover if dam- use a press.
aged. 1. Carefully remove the PTO oil seal with a screw-
driver, without damaging the PTO cover.
2. Press out the plain bearings from the outside
towards the inside.
REQUIRED TOOL
PLAIN BEARING
REMOVER/INSTALLER
(P/N 529 036 032)
NOTE: The PTO cover has to be supported from

below on a suitable support with straight surface
tmr2011-014-013_a
in order to prevent damage of the sealing surface.
1. Oil breather bore
2. Surface of sealing sleeve
5. Check plain bearings for scoring or other dam-

ages.
NOTE: Measure plain bearing inside diameter
(PTO cover) and compare to crankshaft bearing
journal diameter (PTO cover bearing). Refer to
CRANKSHAFT in this subsection. Replace if the
measurement is out of specification.
vmr2006-044-007_a
1. PTO cover
2. Plain bearing remover/installer
Installing the Plain Bearing

NOTE: Do not lubricate plain bearings or PTO
tmr2011-014-013_b cover for installation.
1. Plain bearing
2. Oil bore Install plain bearings in a cold PTO cover.
A. Measure plain bearing inside diameter
REQUIRED TOOL
PLAIN BEARING INSIDE DIAMETER PLAIN BEARING
(PTO COVER) REMOVER/INSTALLER
SERVICE LIMIT 34.120 mm (1.3433 in) (P/N 529 036 032)
1. Mark position of oil bore on PTO cover and on

plain bearing remover/installer.
2. Align mark on plain bearing remover/installer
with mark on PTO cover.
vmr2016-120 9
Tighten PTO cover screws following the sequence

illustrated.
vmr2006-044-008_a
1. Mark position of oil bore on PTO cover

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

PTO cover oil bores will prevent proper oil
supply to plain bearings.
3. Carefully press in the plain bearings in the same
direction as during disassembly, from the out-
side towards the inside.
NOTE: Support PTO cover using a suitable sup- vmr2006-044-003_b
port with a straight surface to prevent damage of TIGHTENING SEQUENCE
the sealing surface. TIGHTENING TORQUE

NOTICE The joining surfaces of the plain 10 N•m ± 1 N•m
bearings must be positioned near the oil bore PTO cover screws
in a counterclockwise direction.
DRIVE GEARS
Drive Gears Location
The engine is equipped with a breather gear which
prevents engine oil from seeping out through the
breathing system into the air intake system.
The drive gears are located on the engine PTO
side behind the PTO cover.
tmr2011-014-013_c
1. Plain bearing joint

2. PTO cover (inside surface)
3. Oil bore
Installing the PTO Cover

For installation, reverse the removal procedure
however, pay attention to the following details.
NOTE: At installation, replace PTO cover gasket
and oil seal.
10 vmr2016-120
tmr2011-014-014_a tmr2011-014-016_a
1. Breather gear 1. Thrust washer

2. Intermediate gear 2. Water pump drive gear
3. Water pump drive gear 3. Needle pin
4. Oil pump drive gear
Inspecting the Drive Gears

Removing the Drive Gears
1. Remove PTO cover, refer to PTO COVER in this Intermediate Gear/Oil Pump Drive Gear/Water
subsection. Pump Drive Gear
2. Withdraw intermediate gear and breather gear. Inspect gears for wear or other damage. Replace
if damaged.
3. Remove oil pump drive gear, refer to OIL PUMP
in the LUBRICATION SYSTEM subsection. Breather Gear
4. To remove water pump drive gear, pull the shaft Check if oil seal is brittle, hard or damaged. Re-
assembly slightly out and turn it about one tooth place if necessary.
until it stays out.
5. Then push water pump drive gear in.
tmr2011-014-017_a
1. Breather gear
2. Oil seal
Inspect gear for wear or other damage.

tmr2011-014-015_a
Step 1: Push gear in

Check ball bearing for excessive play and smooth
1. Water pump drive gear
operation. Replace breather gear assembly if nec-
2. Intermediate shaft essary.
6. Remove needle pin and pull water pump drive Installing the Drive Gears
gear out.
The installation is essentially the reverse of the re-
7. Remove thrust washer from intermediate moval procedure however, pay attention to the fol-
shaft. lowing.
Adequately oil the ball bearing of the breather
gear.
vmr2016-120 11
CRANKCASE – Oil cooler (if applicable)

– Oil pump drive gear.
Disassembling the Crankcase
NOTE: Oil pump removal from crankcase is not
1. Refer to PERIODIC MAINTENANCE PROCE- necessary, but recommended to see condition of
DURES subsection and carry out the following: oil pump. Refer to LUBRICATION SYSTEM sub-
1.1 Drain cooling system. section.
1.2 Drain engine oil. 12. Remove electric starter.
1.3 Drain gearbox oil.
2. Lock crankshaft. Refer to CRANKSHAFT
LOCKING PROCEDURE in the this subsec-
tion.
MISSION (CVT) subsection and remove the fol-
lowing parts:
– CVT cover
– Drive pulley
– Driven pulley
– CVT air guide.
4. Remove engine from vehicle. Refer to ENGINE vmr2016-035-001_a
REMOVAL AND INSTALLATION subsection. 1. Electric starter
2. Screw
5. Remove gearbox from engine.
6. Refer to MAGNETO AND STARTER subsection NOTE: Before splitting the crankcase, measure
and remove the following parts: crankshaft axial play. Refer to CRANKSHAFT in
– Magneto cover this subsection.
– Rotor with sprag clutch gear 13. Remove crankcase retaining screws.
– Starter drive gears. Models Without Oil Cooler
7. Refer to applicable procedures in this subsec-
tion and remove the following parts:
– PTO cover
– Drive gears
– Bearing covers of engine drive shaft.
8. Refer to TIMING CHAIN subsection and re-
– Chain tensioners
– Camshaft timing gears
– Timing chains
– Timing chain guides.
9. Refer to TOP END subsection and remove the
following parts:
– Front cylinder head vmr2016-035-002_a
– Rear cylinder head 1. Four screws M8 x 65

2. 12 screws M6 x 75
– Cylinders. 3. One screw M6 x 25
10. Refer to COOLING SYSTEM subsection and
remove the following parts:
– Water pump housing.
11. Refer to LUBRICATION SYSTEM subsection
and remove the following parts:
– Oil filter
12 vmr2016-120
Models With Oil Cooler
vmr2006-044-023_b
tmr2011-014-021_a
17. Remove engine oil strainer.
1. Four screws M8 x 65
2. 13 screws M6 x 75 NOTE: Oil strainer removal for inspection and
3. Two screw M6 x 25 cleaning is recommended. Refer to LUBRICA-
All Models TION SYSTEM subsection.
14. Carefully split crankcase halves using a screw-
driver and a soft hammer.
vmr2006-042-017_a
vmr2016-035-003
1. Engine oil strainer
2. Retaining plate
NOTE: During disassembly, do not damage the 3. Screws
sealing surfaces of the crankcase halves.
15. Pull crankshaft out of crankcase.
Cleaning the Crankcase
16. Remove the water pump intermediate shaft. WARNING
Use safety goggles to avoid eye injuries.
Clean crankcase using a part cleaner.

Dry crankcase using compressed air.
Blow low pressure filtered air through the oil sup-
ply lines.
vmr2016-120 13
Inspecting the Crankcase Replacing the Plain Bearing (Main)

Check crankcase halves for cracks or other dam- Removing the Plain Bearing
age. Replace if damaged.
NOTICE Always properly support crankcase
Check MAG and PTO plain bearings for scoring or
other damages. halves when removing plain bearings. Dam-
age to crankcase halves may occur if this pro-
cedure is not performed correctly.
NOTE: Always use a press for removal of plain
bearings.
Carefully press the plain bearings out from the
crankcase half from the inside towards the out-
side.
NOTE: Place an appropriate support under
crankcase halves before removing plain bear-
ings.
REQUIRED TOOLS
tmr2011-014-024_a
1. Plain bearing CRANKCASE SUPPORT MAG/PTO

(P/N 529 036 031)
Measure plain bearing inside diameter and com-
pare to PTO/MAG main journal diameters of crank-
shaft, refer to CRANKSHAFT in this subsection. PLAIN BEARING
Replace if the measurements are out of specifi- REMOVER/INSTALLER
cation. (P/N 529 035 917)
NOTE: During disassembly, make sure not to

damage the sealing surfaces of the crankcase
halves.
vmr2006-044-025_a
1. Plain bearing
2. Oil bore
A. Measure plain bearing inside diameter
tmr2011-014-025_a
MAIN BEARING INSIDE DIAMETER (PTO/MAG) PRESS PLAIN BEARINGS OUTSIDE
1. Crankcase half
SERVICE LIMIT 42.100 mm (1.6575 in) 2. Plain bearing remover/installer
3. Crankcase support sleeve (P/N 529 036 031)
Installing the Plain Bearing

NOTICE Unless otherwise instructed, never
use a hammer to install plain bearings. Aways
use a press.
14 vmr2016-120
During reassembly, make sure not to damage the

sealing surfaces of the crankcase halves.
NOTE: Place the proper crankcase support sleeve
under crankcase halves before installing the plain
bearings, refer to PLAIN BEARING REMOVAL
PROCEDURE in this subsection.
Install plain bearings in a cold crankcase.
NOTE: Do not lubricate plain bearings and/or
crankcase for installation.
REQUIRED TOOL
PLAIN BEARING
tmr2011-014-027_a
REMOVER/INSTALLER
1. Crankcase half MAG (inside surface)
(P/N 529 035 917) 2. Partition
3. Oil bore
NOTE: Use an O-ring (Ø 42 x 1 mm to 1.5 mm NOTICE The joint of the plain bearings in the
(.04 in to .06 in) thickness) to hold plain bear- crankcase half PTO side must be positioned
ings in place during installation. The O-ring will near the oil bore in the counterclockwise di-
disappear in the groove of the plain bearing re- rection.
mover/installer.
1. Mark position of plain bearing oil bore on plain
bearing remover/installer.
2. Mark position of oil bore on crankcase half.
3. Align mark on plain bearing remover/installer
with mark on crankcase half.
tmr2011-014-028_a
1. Plain bearing joint

2. Oil bore
3. Crankcase half PTO (inside surface)
Assembling the Crankcase

The assembly of crankcase is essentially the re-
verse of removal procedure. However, pay atten-
tion to the following details.
tmr2011-014-026_a Clean oil passages and make sure they are not
1. Oil bore position marked on plain bearing remover/installer clogged.
2. Plain bearing oil bore
3. Oil bore position marked on crankcase Clean all metal components in a solvent.
NOTICE Misalignment of the plain bearing Install a NEW crankcase gasket.
and crankcase oil bores will prevent proper oil Oil the plain bearings before mounting the crank-
supply to plain bearings. shaft.
4. Carefully press in the plain bearings from inside Reinstall crankshaft, see procedure in this subsec-
the crankcase towards the outside. tion
NOTICE The joint of the plain bearings in Properly reinstall engine oil strainer and screws.
Refer to LUBRICATION SYSTEM subsection.
crankcase half MAG side must be positioned
near the oil bore in a clockwise direction.
vmr2016-120 15
Reinstall water pump intermediate shaft and Models With Oil Cooler
gears, refer to WATER PUMP GEARS in the
COOLING SYSTEM subsection.
Tighten crankcase retaining screws as per follow-
ing sequence.
All Models
tmr2011-014-021_c
M6 SCREWS TIGHTENING SEQUENCE
All Models
TIGHTENING TORQUE
vmr2016-035-002_b
10 N•m ± 1 N•m
M8 SCREWS TIGHTENING SEQUENCE M6 crankcase screws
TIGHTENING TORQUE
25 N•m ± 3 N•m CRANKSHAFT
M8 crankcase screws
Models Without Oil Cooler
vmr2016-035-002_c
M6 SCREWS TIGHTENING SEQUENCE
vmr2006-044-035_b
1. Crankcase MAG
2. Crankshaft
16 vmr2016-120
Crankshaft Locking Procedure

NOTE: When the crankshaft is locked, the rear
piston no. 2 is at TDC (top dead center). The
crankshaft cannot be locked with front piston no.
1 at TDC.
NOTICE To see if the rear piston no. 2 is
at TDC ignition, refer to CAMSHAFT TIMING
GEAR in the TIMING CHAIN subsection.
1. Remove spark plug cables and spark plugs from
both cylinders.
2. Remove screw plug and O-ring from magneto
vmr2015-034-005_a
cover. 1. Sealing ring
2. Plug screw
3. Crankcase PTO side, front side
5. Use a 14 mm Allen key to turn crankshaft until

the rear piston no. 2 is at TDC.
vmr2015-033-005_a
1. Plug screw
2. O-ring
3. Remove crankshaft position sensor.

vmr2015-033-007_a
1. Allen key 14 mm
NOTE: When the piston no. 2 is at TDC, the num-

ber 2 piston index mark on the magneto flywheel
and the notch on the magneto cover are aligned.
vmr2015-033-006_a
1. Crankshaft position sensor

2. Screw
4. Remove screw plug and discard sealing ring.
vmr2016-120 17
vmr2015-034-007_a
1. Crankshaft locking bolt

vmr2007-037-008_b
CYLINDER 2 AT TDC 8. Gradually insert the tool in the crankshaft

1. Number 2 piston identifier
2. Index mark on magneto flywheel groove. Make sure that the tool tip enters the
4. CPS bore in magneto cover
groove and does not jam on the crankshaft
balancer surface.
6. Use a screwdriver to check if the groove in the
crankshaft is aligned with the crankshaft locking Removing the Crankshaft
tool orifice. Refer to CRANKCASE.
Inspecting the Crankshaft

NOTE: Check each crankshaft bearing journal for
scoring, scuffing, cracks or other signs of wear.
NOTE: Replace crankshaft if the crankshaft tim-
ing gears are worn or otherwise damaged.
NOTICE Components out of specifications
must always be replaced. If this is not ob-
served, severe damage may be caused to the
engine.
vmr2015-034-006_a
1. Screwdriver
7. Lock crankshaft.
REQUIRED TOOL
CRANKSHAFT LOCKING
BOLT (P/N 529 035 617)
vmr2006-044-036_a
1. Crankshaft timing gears
Crankshaft Axial Play

NOTE: Axial play must be measured before split-
ting the crankcase.
18 vmr2016-120
Measure axial play on PTO end of crankshaft using Connecting Rod Big End Radial Play
a dial indicator. NOTE: Prior to removing connecting rod from the
CRANKSHAFT AXIAL PLAY crankshaft, mark big end halves together to en-
sure a correct reinstallation (cracked surface fits
0.200 mm to 0.500 mm in only one position).
NEW
(.008 in to .02 in)
1. Remove connecting rods from crankshaft.
NOTICE Connecting rod screws are not
If axial play is out of specification, replace reusable. Always discard screws and replace
crankcase and/or crankshaft. with NEW ones. It is recommended to install
new plain bearings when reinstalling connect-
Connecting Rod Big End Axial Play
ing rods.
Using a feeler gauge, measure between face of
connecting rods and crankshaft counterweight.
If the measurement exceeds specified tolerance,
replace the crankshaft.
vmr2007-037-003_a
1. Connecting rod screws
2. Measure crankpin. Compare to inside diameter

of connecting rod big end.
vmr2006-044-037_a
1. Crankshaft
2. Connecting rods
3. Feeler gauge
CONNECTING ROD BIG END AXIAL PLAY

570
0.200 mm to 0.500 mm
650 NEW
(.008 in to .02 in) vmr2006-044-038_a
850
1. Micrometer
1000 0.250 mm to 0.550 mm 2. Crankpin
NEW
1000R (.0098 in to .0217 in)
All SERVICE LIMIT 0.600 mm (.024 in)
Connecting Rod/Piston Pin Clearance

Refer to TOP END subsection.
vmr2016-120 19
CRANK PIN DIAMETER

40.001 mm to 40.025 mm
570 NEW
(1.5748 in to 1.5758 in)
650
850 SERVICE
39.990 mm (1.5744 in)
LIMIT
41.986 mm to 42.010 mm
NEW
1000 (1.653 in to 1.6539 in)
1000R SERVICE
41.967 mm (1.6522 in)
LIMIT
If the crank pin diameter is out of specification,

replace crankshaft.
NOTE: To measure the connecting rod big end di-
ameter, use the OLD connecting rod screws.
3. Install the OLD plain bearings as they were
mounted initially. vmr2006-044-040_a
1. Micrometer
4. Carry out the tightening procedure described in 2. Crankshaft MAG side main bearing journal
CRANKSHAFT ASSEMBLY in this subsection.
vmr2006-044-039_a
A. Connecting rod big end plain bearing
CONNECTING ROD BIG END DIAMETER

570
SERVICE
650 40.100 mm (1.5787 in)
LIMIT
850
1000 SERVICE vmr2006-044-041_a
42.100 mm (1.6575 in)
1000R LIMIT 1. Micrometer
2. Crankshaft PTO side main bearing journal
If connecting rod big end diameter is out of spec- CRANKSHAFT MAIN BEARING JOURNAL
ification, replace plain bearings and recheck. DIAMETER (MAG/PTO SIDE)
CONNECTING ROD BIG END RADIAL 42.016 mm to 42.040 mm
CLEARANCE NEW
(1.6542 in to 1.6551 in)
SERVICE LIMIT 0.09 MM (.0035 IN) SERVICE LIMIT 42.000 mm (1.6535 in)
If connecting rod big end radial clearance is out of CRANKSHAFT RADIAL PLAY (MAG/PTO SIDE)
specification, replace plain bearings and recheck.
Crankshaft Radial Play MAG/PTO Side
Measure crankshaft main bearing journals on
MAG and PTO sides. Compare to inside diam-
eter of MAG and PTO plain bearings, refer to
CRANKCASE in this subsection.
20 vmr2016-120
Crankshaft Radial Play

(PTO Cover Bearing)
Measure crankshaft journal diameter (PTO cover 1
bearing). Compare to plain bearing inside diame-
ter (PTO cover). Refer to PTO COVER in this sub-
section. 3
2
R1004motr20A
1. Half plain bearing of connecting rod big end

2. Mating surface of the connecting rod
3. Joining surface of plain bearing in line with connecting rod
groove
Oil the plain bearing surface of the connecting rod

and crankshaft pin before installation.
NOTICE Lower cap and rod must match to-
gether since there is a cracked surface.
vmr2006-044-042_a Oil NEW connecting rod screws.
1. Micrometer
2. Crankshaft journal (PTO support bearing) Thread screws in the connecting rods, then
tighten as per following procedure.
CRANKSHAFT JOURNAL DIAMETER
(PTO COVER BEARING) NOTICE Strictly adhere following instruc-
tions:
34.004 mm to 34.020 mm
NEW
(1.3387 in to 1.3394 in)
– Always use NEW connecting rod screws at fi-
nal assembly. They are not reusable.
SERVICE LIMIT 33.998 mm (1.3385 in) – Do not apply any thread locker.
– The running direction of the big end bearings
CRANKSHAFT RADIAL PLAY
(PTO COVER BEARING)
and of the piston pins must not change.
– Always perform each step on both connecting
SERVICE LIMIT 0.10 mm (.0039 in) rod screws before going to the next step.
If crankshaft journal diameter is out of specifica- – Failure to strictly follow procedure may cause
tion, replace crankshaft. connecting rod screws to loosen and lead to se-
vere engine damage.
If crankshaft radial play (PTO cover bearing) is
out of specification, replace plain bearings and REQUIRED TOOLS
recheck. Torque wrench
Assembling the Crankshaft Angle torque wrench

For assembly, reverse the disassembly procedure
however, pay attention to following details.
Clean the split surface on both sides (cracked
area) carefully with compressed air.
Insert plain bearings in the connecting rods as il-
lustrated.
vmr2016-120 21
tmr2011-014-036_a
1. Connecting rod small ends

2. Connecting rod offset
3. Connecting rod screws
TIGHTENING TORQUE
Tighten to 1/2 of
Step A
specified torque
vmr2006-044-043_a
1. Angle torque wrench Tighten to

Connecting rod Step B 30 N•m ± 2 N•m
570, 650 and 850 Engines screws (22 lbf•ft ± 1 lbf•ft)
NEW connecting rods can be installed either way. Torque an additional
Step C 90 ± 5° turn using an
TIGHTENING TORQUE
angle torque wrench
Tighten to 1/2 of
Step A
specified torque
Installing the Crankshaft
Tighten to For installation of crankshaft in crankcase reverse
Connecting rod Step B 20 N•m ± 2 N•m the removal procedure. However, pay attention to
Torque an additional Do not interchange the connecting rods of pistons
Step C 60 ± 5° turn using an
angle torque wrench
1 and 2 during installation.
NOTICE Observe the correct installation po-
1000 and 1000R Engines sition when fitting the crankshaft with the
NOTICE Connecting rods are asymmetrical. connecting rods. The connecting rod MAG
There must be no gap between the small ends side has to face cylinder no. 1.
when they face each other.
22 vmr2016-120
vmr2006-044-035_a
1. Crankcase half MAG side

2. Connecting rod cylinder 1
3. Connecting rod cylinder 2
vmr2016-120 23
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/650/850)
TRANSMISSION (CVT)
(570/650/850)
SERVICE TOOLS
CLUTCH HOLDER......................................................................... 529 036 238 ..................... 6, 14, 20, 22–23
CLUTCH PULLER .......................................................................... 529 035 746 ............................................. 7
PULLER/LOCKING TOOL.............................................................. 529 036 098 ................................. 5, 20, 23
SERVICE PRODUCTS
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ........................................... 12
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ................................. 9, 16, 19
vmr2016-123 1
Loctite 767
Isoflex
grease 10 ± 1 N•m
Topas NB 52 (89 ± 9 lbf•in)
Loctite 243
All Models except
PRO-Models
All
PRO-Models
570/650
NEW engine
Pulley flange cleaner

NEW
1000/850
engine
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
NEW
5 ± 0,6 N•m Isoflex grease
(44 ± 5 lbf•in) Topas NB 52
NEW All Models except NEW

PRO-Models
See tightening
procedure
120 ± 8 N•m
(89 ± 6 lbf•ft)
7 ± 0.8 N•m
vmr2013-019-001_d
2 vmr2016-123
PRO Models
NEW
NEW
5 ± 1 N•m
(44 ± 9 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4.5 lbf•ft)
5 ± 1 N•m
(44 ± 9 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4.5 lbf•ft)

vmr2016-036-101_a
vmr2016-123 3
GENERAL 2. Let water drain from CVT cover.

NOTE: For a better understanding, the following 3. Reinstall drain reservoir.
illustrations are taken with engine out of vehicle. NOTICE If an appreciable amount of water or
To perform the following instructions, it is not nec- any debris entered the CVT cover, CVT must be
essary to remove engine. cleaned and inspected.
WARNING Removing the CVT Cover
Never touch CVT while engine is running. Remove CVT cover screws.
Never drive vehicle when CVT cover is re-
moved. NOTE: Do not use and impact tool to remove CVT
cover screws. To support the CVT cover remove
the top center screw last.
WARNING
Any drive pulley repairs must be performed Remove the CVT cover and its gasket.
by an authorized Can-Am dealer. Subcompo-
nent installation and assembly tolerances re-
quire strict adherence to procedures detailed.
WARNING
The clutch assembly is a precisely balanced
unit. Never replace parts with used parts
from another clutch assembly.
PROCEDURES
CVT COVER
Vmr2012-018-004_a
CVT Cover Access 1. CVT cover screw
Refer to BODY subsection and remove the follow- 2. CVT cover
3. Gasket
ing:
– LH side and extension panels Installing the CVT Cover
– LH footboard panel. Install the top center screw of first.
Draining the CVT Cover NOTE: Do not use and impact tool to install CVT
cover screws.
If water is present in CVT cover, it can be drained
as follows: Tighten the CVT cover screws as per following se-
quence.
1. Remove drain reservoir from CVT cover.
Vmr2012-018-003_a
Vmr2012-018-003_b
CVT COVER TIGHTENING SEQUENCE
1. Drain reservoir
2. Spring clip
4 vmr2016-123
TIGHTENING TORQUE Inspecting the Drive Belt

7 N•m ± 0.8 N•m For drive belt inspection refer to DRIVE BELT
CVT cover screws INSPECTION in the PERIODIC MAINTENANCE
PROCEDURES subsection.
DRIVE BELT Installing the Drive Belt
Removing the Drive Belt For installation, reverse the removal procedure.
Pay attention to following details.
NOTICE In case of a drive belt failure, the The maximum drive belt life span is obtained
CVT, cover, drain reservoir and air outlet must when the drive belt has the proper rotation direc-
be cleaned and inspected for obstruction. tion. Install it so that the arrow printed on belt
1. Remove CVT COVER. is pointing towards front of the vehicle, viewed
from top.
2. Open driven pulley.
REQUIRED TOOL
PULLER/LOCKING TOOL
(P/N 529 036 098)
3. Screw tool in the threaded hole of driven pulley

and tighten to open the pulley.
vmr2007-051-006_a
1. Arrow printed on belt

2. Drive pulley (front)
3. Driven pulley (rear)
4. Rotation direction
DRIVE PULLEY
Removing the Drive Pulley
Vmr2012-018-005_a
1. Remove DRIVE BELT, see procedure in this
1. Puller/locking tool
2. Fixed sheave of driven pulley subsection.
2. Prior to removing the drive pulley, mark sliding
4. Slide the belt over the top edge of fixed sheave
sheave and governor cup to ensure correct in-
to remove it.
dexation at reinstallation.
Vmr2012-018-006_a
vmr2016-123 5
CAUTION Sliding sheave of drive pulley is

spring loaded.
vmr2006-021-011_a
1. Mark on drive pulley sliding sheave

2. Mark on governor cup
3. Lock the drive pulley. tmr2011-015-004_a
REQUIRED TOOL Step 1: Push

1. Thrust washer
2. Conical spring washer
CLUTCH HOLDER 3. Drive pulley screw
4. Sliding sheave with governor cup
(P/N 529 036 238)
8. Slowly release and remove sliding sheave.
Outlander 570/650/850 Models (Except
PRO Package)
9. Remove friction washer.
tmr2013-019-003_a
1. Clutch holder
2. Drive pulley sliding sheave
Vmr2012-018-008_a
4. Loosen the drive pulley screw. 1. Friction washer

2. One way clutch
NOTICE Never use any type of impact 3. Drive pulley fixed sheave
wrench for drive pulley removal. All Models
NOTE: Do not unscrew the drive pulley screw 10. Screw clutch puller in fixed sheave to remove
completely. If governor cup is stuck, hit it using fixed pulley.
a soft hammer.
NOTICE Use only recommended tool.
5. Remove service tool.
6. Apply axial pressure with your hand on the slid-
ing sheave and governor cup.
7. Remove drive pulley screw with its conical
spring washer and thrust washer.
6 vmr2016-123
REQUIRED TOOL
CLUTCH PULLER
(P/N 529 035 746)
R400motr171A 1
1. Slider shoe
3. Place the governor cup on a vice to push out the

Vmr2012-018-009_a roller sleeve in the direction illustrated (against
1. Drive pulley puller insertion arrow marked on governor cup arm).
2. Fixed sheave Use an appropriate punch (diameter of punch
must be smaller than the diameter of the sleeve
Disassembling the Drive Pulley bore in the governor cup arm).
Governor Cup NOTICE Do not clamp the governor cup in
1. Carefully lift governor cup until slider shoes the vice to push out roller sleeve. Governor
move to their highest position in the guides. cup will be damaged.
NOTE: Use protection plates to avoid marks
and/or damages to the governor cup.
NOTICE Always replace all rollers as a set.
Partly worn rollers may cause damage to the
CVT system.
tmr2011-015-005_a
1. Governor cup
2. Slider shoes
3. Sliding sheave
4. Guides
NOTE: The following steps are not necessary ex- vmr2006-021-015_a
cept if roller must be removed. Refer to INSPEC- 1. Punch

2. Vice
TION before proceeding.
2. Remove slider shoes from governor cup arm.
Use a flat screwdriver if necessary.
vmr2016-123 7
Fixed Sheave
WARNING
Always wear safety glasses to remove spring
sleeves.
Pull and rotate one-way clutch slowly until the

spring sleeves are visible.
vmr2006-021-016_a
1. Removal direction
2. Assembly direction
NOTE: Whenever removing a governor cup which

already has two marked boxes, replace it by a new
one.
vmr2006-021-020_a
1. One-way clutch
2. Fixed sheave
3. Spring sleeve area
vmr2006-021-018
Sliding Sheave Hold both spring sleeves with fingers and carefully
remove them when the one-way clutch is disen-
Unscrew lock nut and remove centrifugal lever gaged.
pivot bolt. This drive pulley is equipped with 4
levers.
Remove centrifugal lever and both thrust wash-
ers.
Vmr2012-018-024_a
vmr2006-021-021_a
1. Lock nut
2. Centrifugal lever pivot bolt 1. Springs
3. Centrifugal lever 2. Spring sleeves
4. Thrust washers
8 vmr2016-123
Cleaning the Drive Pulley

Clean pulley faces and shaft with fine steel wool
and a dry cloth.
Using a paper towel with the recommended
cleaning solvent, clean:
– Crankshaft tapered end
– Taper inside the fixed sheave of the drive pulley
– Crankshaft threads
– Drive pulley screw threads.
REQUIRED PRODUCT
PULLEY FLANGE CLEANER (P/N 413 711 809)
tmr2011-015-006_a
NOTICE Avoid contact between cleaner and 1. Sliding sheave
crankshaft seal as damage may occur. 2. Bushings
Remove all hardened oil deposits that have baked Inspecting the Drive Pulley
on the crankshaft and pulley tapered surfaces us-
ing coarse or medium steel wool, and/or sand pa- Bushings
per no. 600. For bushing inspection, refer to SLIDING SHEAVE
in this subsection.
NOTICE Do not use any other type of abra-
sive. Governor Cup
Reclean mounting surfaces with paper towel and Check governor cup for cracks or other visible
PULLEY FLANGE CLEANER (P/N 413 711 809). damage. Replace if necessary.
Wipe off the mounting surfaces with a clean, dry Roller and Slider Shoe
paper towel. Check each roller for roundness of external diam-
NOTICE Mounting surfaces must be free of eter.
any oil, cleaner or towel residue. Check if rollers move freely.
NOTICE Whenever replacing rollers and
slider shoes, always replace all rollers and
slider shoes as a set.
Check slider shoes for visible wear. If chamfer is
not present anymore, replace ALL slider shoes.
NOTE: If necessary, use a screwdriver to remove
slider shoes.
vmr2015-121-002_a
1. Taper of fixed sheave
Only use petrol base cleaner when cleaning slid-

ing sheave bushings.
NOTICE Do not use acetone to clean bush-
ing.
vmr2016-123 9
tmr2011-015-007_a
1. Centrifugal lever
2. Bushing
A. Bushing inner diameter
CENTRIFUGAL LEVER BORE DIAMETER

6.035 mm to 6.078 mm
NEW
vmr2016-036-002_a (.238 in to .239 in)
1. Roller SERVICE LIMIT 6.200 mm (.244 in)
2. Slider shoe
3. Chamfer
A. Roller outer diameter Inspect and replace as necessary the following
items if their contact surfaces are heavy worn:
ROLLER OUTER DIAMETER
– Centrifugal lever
13.80 mm to 14.00 mm – Thrust washers
NEW
(.543 in to .551 in)
– Centrifugal lever pivot bolts
SERVICE LIMIT 13.20 mm (.519 in) – Lock nuts.
ROLLER INNER DIAMETER
8.025 mm to 8.175 mm
NEW
(.316 in to .322 in)
Centrifugal Lever Pivot Bolt

Measure diameter of centrifugal lever pivot bolt;
replace if out of specification.
Vmr2012-018-024_b
1. Lock nut
2. Centrifugal lever pivot bolt
R610tran12A A 1 3. Centrifugal lever
4. Thrust washers
1. Centrifugal lever pivot bolt 5. Contact surface to the roller
A. Measure diameter here
WARNING
CENTRIFUGAL LEVER PIVOT BOLT DIAMETER Whenever replacing centrifugal levers, al-
6.078 mm to 6.100 mm ways replace all levers as a set. Otherwise,
NEW drive pulley unbalance will occur.
(.239 in to .24 in)
Sliding Sheave
Centrifugal Lever Check sliding sheave for cracks and sliding con-
Check bushing diameter in the centrifugal lever for tact surface for excessive wear. Replace sliding
wear. Replace centrifugal lever if necessary. sheave if necessary.
Measure centrifugal lever pivot bolt bores. Re-
place sliding sheave if bores are out of specifica-
tion or otherwise damaged.
10 vmr2016-123
SLIDING SHEAVE LARGE BUSHING

55.000 mm to 55.040 mm
NEW
(2.165 in to 2.167 in)
vmr2006-021-024_a
A. Centrifugal lever pivot bolt bore diameter
CENTRIFUGAL LEVER PIVOT BOLT BORE

DIAMETER
6.113 mm to 6.171 mm
NEW
(.241 in to .243 in)
SERVICE LIMIT 6.300 mm (.248 in) R610tran11A 1
Measure bushing diameters of sliding sheave. 1. Bushing on governor cup side
A. Bore diameter of bushing
REQUIRED TOOL
SLIDING SHEAVE SMALL BUSHING
Dial bore gauge
32.000 mm to 32.040 mm
NEW
MEASURING POINT (1.26 in to 1.261 in)
At least 5 mm (1/4 in) from bushing edge SERVICE LIMIT 32.200 mm (1.268 in)
Replace sliding sheave if one of the bushings is

A
out of specification. Visually inspect coatings for
wear.
Fixed Sheave
Check fixed sheave contact surface to the gover-
nor cup for scratches or other damages. If dam-
aged, replace fixed sheave.
R610tran14A 1
1. Bushing on fixed sheave side
Vmr2012-018-010_a
1. Visually check here
vmr2016-123 11
Check for any marks on fixed sheave plate. Re- One-Way Clutch
place if necessary. Clean parts.
Spring Lubricate springs, spring sleeves and between
Measure spring free length and squareness. If one way clutch bearings using recommended
spring is out of specification, replace by a new product.
one. REQUIRED PRODUCT
CLUTCH SPRING FREE LENGTH ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021)
570
85 mm 1000 Engine
650 Service Limit
(3.346 in)
1000 NOTE: Ball bearings have a seal on one side only.
850 Service Limit 95 mm (3.74 in) Install bearings with the seal towards the outside
of the one-way clutch.
CLUTCH SPRING SQUARENESS
NOTE: Apply ISOFLEX GREASE TOPAS NB 52
AlL Service Limit 4 mm (.157 in) (P/N 293 550 021) inside ball bearings to ensure
adequate lubrication.
One-Way Clutch
Check bearings for excessive play and smooth op-
eration. Replace bearings if necessary.
NOTICE Be careful not to damage the inside
of one-way clutch during bearing removal.
tmr2011-015-020_a
1. One-way clutch
2. Bearing
3. Retaining ring
4. Seal
vmr2015-035-002_a
1. One-way clutch Friction Washer

2. Bearings
Outlander 570/650/850 Models (Except
Measure length of spring sleeves and check if PRO Package)
edges on top of the spring sleeve are excessively
worn. If out of specification, replace both spring NOTE: Apply recommended grease on both sides
sleeves at the same time. of friction washer.
SPRING SLEEVE LENGTH REQUIRED PRODUCT
9.2 mm to 9.4 mm ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021)

NEW
(.362 in to .37 in)
NOTE: Friction washer must be assembled with
SERVICE LIMIT 9.0 mm (.354 in) collar towards one way clutch.
Assembling the Drive Pulley

For assembly, reverse the disassembly proce-
dure. Pay attention to following details.
12 vmr2016-123
vmr2007-051-003_a vmr2006-021-017
1. Friction washer
2. Collar NOTICE Rollers must move easily after in-
3. One way clutch stallation.
Sliding Sheave Carefully press slider shoes in the governor cup
Install centrifugal levers with their thrust washers. arm so they bottom out evenly in the machined
portion of the governor cup arm.
NOTICE Centrifugal levers must move easily
after installation. NOTICE Slider shoes must be pressed in
evenly to ensure they are centered in the arm
Governor Cup and slide properly in the guides.
Rebuild governor cup with new roller sleeves,
rollers and slider shoes. Installing the Drive Pulley
NOTICE Final position of roller sleeves must For installation, reverse the removal procedure.
be flush with the sleeve bore in the governor Pay attention to the following details.
cup arm (no protrusion).
WARNING
Do not apply antiseize or any lubricant on
crankshaft and drive pulley tapers.
NOTICE Never use any type of impact

wrench for drive pulley removal and instal-
lation.
Clean mounting surfaces as described in DRIVE
PULLEY CLEANING.
Install drive pulley on crankshaft extension.
NOTICE Do not forget to install thrust washer
and conical spring washer as per illustration
that follows.
NOTE: Install conical spring washer with its con-
vmr2006-021-029_a cave side towards drive pulley.
1. Top edge of roller sleeve
2. Mating surface of slider shoes
3. Vice
Whenever replacing the roller sleeves, make a

mark in the box on the governor arm using a
punch.
NOTICE Do not tap too hard. Severe damage
to the governor cup may appear.
vmr2016-123 13
DRIVEN PULLEY
Removing the Driven Pulley
1. Remove drive belt, refer to DRIVE BELT RE-
MOVAL in this subsection.
2. Hold the driven pulley and loosen the driven pul-
ley screw.
NOTE: Do not completely remove the driven pul-
ley screw.
REQUIRED TOOL
CLUTCH HOLDER
(P/N 529 036 238)
vmr2006-021-051_a
1. Drive pulley screw

2. Conical spring washer
3. Thrust washer
WARNING
Never substitute conical spring washer
and/or screw with aftermarket parts. Al-
ways use genuine BRP parts.
Lock the drive pulley as per removal procedure.

Tighten drive pulley screw to specification.
wrench for drive pulley installation.
TIGHTENING TORQUE
tmr2013-019-007_a
120 N•m ± 8 N•m 1. Driven pulley screw
Drive pulley screw
(89 lbf•ft ± 6 lbf•ft) 2. Clutch holder (P/N 529 036 238)
3. Remove service tool.

4. Apply axial pressure with your hand on driven
pulley and maintain during screw removal.
5. Remove driven pulley screw and washer. Dis-
card driven pulley screw.
CAUTION Driven pulley is spring loaded.

Hold driven pulley tight and slowly remove the
driven pulley screw to release spring tension.
tmr2013-019-006_a
1. Clutch holder (P/N 529 036 238)

2. Drive pulley
14 vmr2016-123
Vmr2012-018-011_a
1. Driven pulley screw

2. Thrust washer
6. Remove the driven pulley with the spring and vmr2006-021-035_a
1. Retaining ring
the cam. 2. Torque gear
3. Fixed sheave of driven pulley
NOTE: The following procedure is not necessary

except if ball bearing or shaft must be removed.
Refer to INSPECTION before proceeding.
2. Heat ball bearing area up to 100°C (212°F) be-
fore removing ball bearing.
vmr2015-035-003_a

2. Sliding sheave of driven pulley
3. Spring
4. Cam
Disassembling the Driven Pulley

Fixed Sheave
tmr2011-015-009_a
1. Remove retaining ring and lift torque gear. 1. Ball bearing
2. Shaft
3. Use a soft hammer to push shaft and bearing

out of fixed sheave.
vmr2016-123 15
Using a paper towel with PULLEY FLANGE

CLEANER (P/N 413 711 809), clean countershaft
1 end and shaft bore.
NOTICE To avoid damage, make sure cleaner
does not contact the countershaft oil seal.
2
R610tran18A
1. Soft hammer
2. Shaft
4. Remove shaft from ball bearing. vmr2006-021-037_a
5. Remove distance sleeve and O-ring from coun- 1. Countershaft support

2. Countershaft oil seal
tershaft.
6. Replace O-ring if brittle, hard or damaged. Inspecting the Driven Pulley
Sliding Sheave
Check sliding sheave for cracks and sliding con-
tact surface for excessive wear. Replace sliding
sheave if necessary.
Check bushings for cracks, scratches and for
freedom of movement when assembled to slid-
ing sheave.
Measure bushing inner diameter.
NOTE: Bushings cannot be replaced. Replace
sliding sheave if bushings are out of specification.
Visually inspect coatings.
vmr2006-021-044_b
1. O-ring
2. Distance sleeve
Cleaning the Driven Pulley

When a dust deposit has to be removed from the
cam or the shaft, use a dry cloth.
Clean pulley faces and shaft using fine steel wool
and a dry cloth.
Clean driven pulley using the recommended prod-
uct.
RECOMMENDED PRODUCT
PULLEY FLANGE CLEANER (P/N 413 711 809) vmr2006-021-038_a
1. Bushings
Clean the CVT air guide area from contamination. 2. Backside of sliding sheave of driven pulley
16 vmr2016-123
REQUIRED TOOL BUSHING INNER DIAMETER

Dial bore gauge 30.060 mm to 30.100 mm
New
(1.183 in to 1.185 in)
MEASURING POINT
Service Limit 30.200 mm (1.189 in)
At least 5 mm (1/4 in) from bushing edge
Check torque gear for visible damage and cracks.
BUSHING INNER DIAMETER Measure for wear limit using a caliper.
30.060 mm to 30.100 mm
New
(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, measure bushing inner di-
ameter. tmr2011-015-011_a
A. Measurement inside
NOTE: This bushing cannot be replaced. Replace B. Measurement outside
fixed sheave if bushing is out of specification. Vi-
sually inspect coatings. WEAR ON TEETH (BOTH SIDES)
Service Limit 7.500 mm (.295 in)
Cam
Check cam for visible damage and measure for
wear using a caliper.
tmr2011-015-010_a
1. Bushing
REQUIRED TOOL tmr2011-015-012_a
570, 850 AND 1000 ENGINE

Dial bore gauge 1. Caliper
2. Contact surface
MEASURING POINT
vmr2016-123 17
Spring
570 and 650 Engines
Tmr2013-071-037_a
vmr2015-121-003_a CVT DRIVEN SPRING

650 ENGINE A. Spring free length
1. Caliper
2. Contact surface 850 and 1000 Engines
A. Width to be measured due to wear on contact surface
WIDTH ON TOP SURFACE

570 16.0 mm
850 (.63 in)
4.5 mm
650 Service Limit
(.177 in)
9.0 mm
1000
(.354 in)
Vmr2012-018-013_a
CVT DRIVEN SPRING (850 AND 1000 ENGINES)

A. Spring free length
All Engines
Measure spring free length and squareness. If
spring is out of specification, replace by a new.
SPRING FREE LENGTH
ALL Service limit 125 mm (4.921 in)

ALL Service limit 3.8 mm (.15 in)
Assembling the Driven Pulley

vmr2006-021-041_a
1. Caliper
2. Sliding sheave Pay attention to following details.
3. Contact surface
A. Wear to be measured Heat ball bearing area up to 100°C (212°F) before
ball bearing installation.
WEAR ON CONTACT SURFACE NOTE: Place new ball bearing in a freezer for 10
SERVICE LIMIT 1.00 mm (.039 in) minutes before installation.
Install ball bearing with the writing on top and
press it in using only the outer race.
18 vmr2016-123
Installing the Driven Pulley

Place O-ring on countershaft splines and move it
and the distance sleeve into position.
NOTICE Chamfer on inside diameter of the
distance sleeve must face to gearbox side.
vmr2006-021-042_a
1. Ball bearing
NOTICE Do not use a hammer, bearing must

be pressed in only.
vmr2006-021-044_a
1. O-ring
1 2. Distance sleeve
3. Chamfered area of distance sleeve
2 NOTICE Threads of gearbox countershaft

and driven pulley screw must be free of oil
and grease. Lubricants in threads will create
too high preload to tightened driven pulley
R610tran37A
screw.
1. Shaft Clean threads using PULLEY FLANGE CLEANER
2. Fixed sheave
3. Press machine (P/N 413 711 809).
Install torque gear then secure it with the retaining 570 and 650 Engines
ring. Install cam on countershaft.
NOTICE Cam splines must engage on coun-
tershaft splines.
REQUIRED PRODUCT
Countershaft splines LOCTITE 767
and countershaft (ANTISEIZE LUBRICANT)
end (P/N 293 800 070)
vmr2006-021-035_a
1. Retaining ring
2. Torque gear
vmr2016-123 19
Vmr2012-018-011_a

2. Thrust washer
Vmr2012-018-014_a
TYPICAL
Install drive belt. Refer to DRIVE BELT in this sub-
1. Countershaft splines section.
2. Cam splines
A. Loctite 767 here REQUIRED TOOL
Insert sliding sheave in fixed sheave. PULLER/LOCKING

TOOL
Place spring behind sliding sheave then align (P/N 529 036 098)
driven pulley with cam.
Vmr2012-018-022_a
Vmr2012-018-015_a
2. Sliding sheave
TYPICAL
1. Cam NOTE: If driven pulley sheaves cannot be opened
2. Spring when the service tool is screwed in, the cam is not
3. Sliding sheave
4. Fixed sheave correctly engaged in the sliding sheave.
Tighten driven pulley screw to specification.
With your hand, push the driven pulley onto the
shaft to compress the spring. REQUIRED TOOL
NOTICE A cam not correctly engaged will
CLUTCH HOLDER
cause damage to the driven pulley and cam.
(P/N 529 036 238)
As you hold the pulley compressed, install a NEW
driven pulley screw and thrust washer.
NOTICE This assembly uses a stretch screw.
Always install a NEW screw.
NOTE: Tighten the screw with your hand suffi-
ciently for the cam to remain engaged.
20 vmr2016-123
TIGHTENING TORQUE
20 N•m ± 1 N•m
Driven pulley Step A
screw
Step B 180° ± 5°
Check driven pulley end play.

SPECIFICATION
Driven pulley end play 0 mm (0 in)
850 and 1000 Engines

Insert the sliding sheave in the fixed sheave.
Place spring behind sliding sheave and engage
spring end in the sliding sheave spring bore. Vmr2012-018-017_a
850 AND 1000 ENGINES

1. Cam
2. Spring end
3. Spring bore
Install pre-assembled cam with spring and driven

pulley on countershaft end.
NOTICE Cam must engage on countershaft
splines.
Vmr2012-018-016_a

1. Sliding sheave
2. Spring end
3. Spring bore
Place cam on the opposite end of the spring and

engage the other spring end in the cam spring
bore.
Vmr2012-018-018_a

1. Countershaft splines
2. Cam
3. Spring
4. Sliding sheave
5. Fixed sheave
With your hand, push the driven pulley onto the

shaft to compress the spring.
As you hold the pulley in, install a NEW driven pul-
ley screw and thrust washer.
NOTICE This assembly uses a stretch screw.
Always install a NEW screw.
NOTE: Tighten the screw with your hand approx-
imately 3 to 4 turns.
vmr2016-123 21
Vmr2012-018-011_a

2. Thrust washer
tmr2013-019-008_a
Insert a screwdriver of approximately 5 mm
(.197 in) diameter in the cam. 1. Fixed sheave
2. Clutch holder
NOTE: For clarity of understanding, some parts 3. Screwdriver
not shown in the following illustration.
Turn the screwdriver approximately 20° counter-
clockwise until cam engages in the driven pulley
sliding sheave and hold it in this position (spring
preload).
Vmr2012-018-019_a

1. Cam
2. Screwdriver, diameter 5 mm (.197 in)
Hold the driven pulley in a fix position. tmr2013-019-009_a

REQUIRED TOOL 1. Clutch holder
2. Screwdriver
A. Turn counterclockwise
CLUTCH HOLDER
(P/N 529 036 238) Using a socket and extension, hand tighten the
driven pulley screw.
NOTE: Do not apply specified torque at this time.
Move the screwdriver back and forth to check
cam for free movement.
22 vmr2016-123
TIGHTENING SEQUENCE
(DRIVEN PULLEY SCREW)
20 N•m ± 1 N•m
Step 1
Step 2 180° ± 5°
tmr2013-019-009_b

1. Clutch holder
2. Screwdriver
A. Cam freedom of movement
Install drive belt. Refer to DRIVE BELT in this sub-

section.
REQUIRED TOOL tmr2013-019-007_a

PULLER/LOCKING 2. Clutch holder
TOOL (P/N 529 036 098)
SPECIFICATION
CVT AIR GUIDE

Removing the CVT Air Guide
1. Remove the DRIVE PULLEY and the DRIVEN
PULLEY.
2. Unscrew the clamps retaining the CVT air
hoses.
3. Remove CVT air guide.
Vmr2012-018-022_a 4. Remove and discard O-rings.
2. Sliding sheave Inspecting the CVT Air Guide
NOTE: If driven pulley sheaves can to be opened Clean CVT air guide from contamination.
when the service tool is screwed in, the cam is
not correctly engaged in the sliding sheave.
Tighten driven pulley screw as specified.
REQUIRED TOOL
CLUTCH HOLDER
(P/N 529 036 238)
vmr2016-123 23
570/650/850 Engines (Except PRO Package)
vmr2012-018-020_a
1. CVT air guide

2. O-rings
Outlander PRO 570/650/1000 Models
vmr2012-018-030_a
1. CVT air guide

2. O-rings
Installing the CVT Air Guide

For installation reverse the removal procedure.
Always install NEW O-rings before installing the
CVT air guide.
24 vmr2016-123
Subsection 12 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (1000R))
TRANSMISSION (CVT) (1000R)
SERVICE TOOLS
CLUTCH HOLDER......................................................................... 529 036 238 ................................. 6, 17, 26
CLUTCH PULLER .......................................................................... 529 035 746 ............................................. 7
COUNTERSHAFT RETAINER TOOL.............................................. 529 036 312 ..................................... 18, 24
DRIVEN PULLEY STUD TOOL ...................................................... 529 036 360 ..................................... 18, 24
PULLER/LOCKING TOOL.............................................................. 529 036 098 ....................................... 5, 26
SERVICE PRODUCTS
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ........................................... 14
LOCTITE 272 ................................................................................. 420 899 526 ........................................... 17
XPS BRAKES AND PARTS CLEANER (USA) ................................. 219 701 705 ....................................... 9, 20
XPS BRAKES AND PARTS CLEANER ........................................... 219 701 776 ....................................... 9, 20
vmr2016-122 1
Loctite 767
(antiseize lubricant)
Isoflex Topas NB52
NEW
Pulley flange
cleaner
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
Isoflex 45 ± 2 N•m
Topas NB52 (33 ± 1 lbf•ft)
NEW
8 ± 1 N•m
(70 ± 9 lbf•in) See tightening
procedure
50 ± 6 N•m
(37 ± 4 lbf•ft)
NEW
65 ± 2 N•m
(48 ± 1 lbf•ft)
7 ± 0,5 N•m
(62 ± 4 lbf•in)

vmr2016-122-001_a
2 vmr2016-122
5 ± 1 N•m 2.5 ± 0.5 N•m

(44 ± 9 lbf•in) (22 ± 4 lbf•in)
7 ± 1 N•m
(62 ± 9 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
vmr2016-122-500_a
vmr2016-122 3
GENERAL
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle.
To perform the following instructions, it is not nec-
essary to remove engine.
This CVT is lubrication free. Never lubricate any
components except drive pulley one-way clutch.
WARNING
Never touch CVT while engine is running.
Never drive vehicle when CVT cover is re-
moved. Vmr2012-018-003_b
1. Drain reservoir
WARNING 2. Spring clip
Any drive pulley repairs must be performed Let water drain from CVT cover.
by an authorized Can-Am dealer. Subcompo-
nent installation and assembly tolerances re- Reinstall drain reservoir.
quire strict adherence to procedures detailed. NOTICE If any debris entered the CVT cover,
CVT must be cleaned and inspected.
WARNING
The clutch assembly is a precisely balanced Removing the CVT Cover
unit. Never replace parts with used parts Loosen CVT inlet and outlet hose clamps.
from another clutch assembly. Remove CVT cover screws.
NOTE: Remove the center top screw last to sup-
PROCEDURES port the cover during removal.
NOTICE Do not use and impact tool to re-
CVT COVER move CVT cover screws.
CVT Cover Access
Remove the CVT cover and its gasket.
Refer to BODY and remove:
– LH side and extension panels
– LH footboard panel.
Draining the CVT Cover

If water is present in CVT cover, it can be drained
as follows:
Remove drain reservoir from CVT cover.
Vmr2012-018-004_a
1. CVT cover screws

2. CVT cover
3. Gasket
Installing the CVT Cover

Install the center top screw of first.
Tighten the CVT cover screws as per following se-
quence.
4 vmr2016-122
Vmr2012-018-003_a
CVT COVER TIGHTENING SEQUENCE vmr2016-122-009_a
TIGHTENING TORQUE 2. Fixed sheave of driven pulley
7 N•m ± 1 N•m To remove belt, slip the belt over the top edge of
CVT cover screws
(62 lbf•in ± 9 lbf•in) fixed sheave, as shown.
Reinstall CVT inlet and outlet hoses.

TIGHTENING TORQUE
2.5 N•m ± 0.5 N•m
CVT hose clamps
DRIVE BELT
Removing the Drive Belt
NOTICE In case of a drive belt failure, the
CVT, cover and air outlet must be cleaned.
Remove CVT COVER.
Open driven pulley. vmr2016-122-010_a
1. Belt
REQUIRED TOOL 2. Fixed sheave of driven pulley
PULLER/LOCKING TOOL
(P/N 529 036 098) Inspecting the Drive Belt
For drive belt inspection refer to DRIVE BELT
Screw tool in the threaded hole of driven pulley INSPECTION in the PERIODIC MAINTENANCE
and tighten to open the pulley. PROCEDURES subsection.
Installing the Drive Belt
The maximum drive belt life span is obtained
when the drive belt has the proper rotation direc-
tion. Install it so that the arrow printed on belt
is pointing towards front of the vehicle, viewed
from top.
vmr2016-122 5
vmr2007-051-006_a
1. Arrow printed on belt

vmr2016-122-012_a
2. Drive pulley (front)
3. Driven pulley (rear) 1. Clutch holder
4. Rotation direction 2. Drive pulley sliding sheave
3. Governor cup
DRIVE PULLEY Remove set screw.

Removing the Drive Pulley NOTE: Heat set screw to break the threadlocker
bond prior to removal.
Remove DRIVE BELT, see procedure in this sub-
section.
Prior to removing the drive pulley, mark sliding
sheave and governor cup to ensure correct index-
ation at reinstallation.
vmr2016-122-013_a
1. Set screw
2. Drive pulley nut
Loosen the drive pulley nut.

vmr2016-122-011_a NOTICE Never use any type of impact
1. Mark on drive pulley sliding sheave wrench for drive pulley removal.
Lock the drive pulley. NOTE: Do not unscrew the drive pulley nut com-
pletely. If governor cup is stuck, hit it using a soft
REQUIRED TOOL hammer.
Remove service tool.
CLUTCH HOLDER
(P/N 529 036 238) Apply axial pressure with your hand on the sliding
sheave and governor cup.
Remove:
– Drive pulley nut
– Small thrust washer (discard it)
– Large thrust washer (discard it)
6 vmr2016-122
CAUTION Sliding sheave of drive pulley is

spring loaded.
vmr2016-122-002_a
1. Counter nuts
2. Stud
vmr2016-122-014_a
Lock crankshaft, refer to CRANKSHAFT LOCKING
Step 1: Push governor cup
PROCEDURE in the BOTTOM END subsection.
1. Drive pulley nut Remove stud from PTO.
2. Small thrust washer (discard it)
3. Large thrust washer (discard it) Remove fixed pulley.
Slowly release and remove sliding sheave. NOTICE Use only recommended tool.
Remove friction washer. REQUIRED TOOL
CLUTCH PULLER
(P/N 529 035 746)
vmr2016-122-015_a
1. Friction washer
2. One way clutch
3. Drive pulley fixed sheave
tmr2015-022-005_a
Counter two M12 x 1.75 nuts for removing the
1. Drive pulley puller
stud. 2. Fixed sheave
NOTICE Do not use original installed nuts.
Disassembling the Drive Pulley
Governor Cup
Carefully lift governor cup until slider shoes come
at their highest position into guides.
vmr2016-122 7
Tmr2013-071-012_a
1. Punch
2. Vice
vmr2016-122-016_a
1. Governor cup
2. Slider shoes
3. Sliding sheave
NOTE: The following procedure is not neces-

sary except if slider shoe and/or roller must be
removed. Refer to INSPECTION before proceed-
ing.
Remove slider shoes.
Tmr2013-071-013_a
1. Removal direction
2. Assembly direction
NOTE: Whenever removing a governor cup with

already two marked boxes replace it by a new one.
vmr2016-122-017_a
1. Slider shoe
Put governor cup on a vice to push out bearing

sleeve of roller in the foreseen direction (against
arrow).
NOTICE Do not clamp the governor cup in Tmr2013-071-014_a
the vice to push out bearing sleeve. Governor 1. Marked boxes
cup will be damaged.
Sliding Sheave
NOTE: Use protection plates to avoid marks This drive pulley is equipped with 6 levers.
and/or damages to the governor cup.
NOTICE Always replace all rollers at the except if centrifugal lever must be removed. Re-
same time. Partly worn rollers may cause fer to INSPECTION before proceeding.
damage to the CVT system. To remove centrifugal levers remove:
– Lock nut
8 vmr2016-122
– Centrifugal lever pivot bolt

– Centrifugal lever
– Thrust washers.
vmr2006-021-021_a
1. Springs
2. Spring sleeves
vmr2016-122-021_a
1. Lock nut
2. Centrifugal lever pivot bolt Cleaning the Drive Pulley
3. Centrifugal lever
4. Thrust washers Using a small brush, paper towel and parts cleaner
, clean all the mounting surfaces and threads as
Fixed Sheave shown.
WARNING REQUIRED PRODUCT
Always wear safety glasses to remove spring XPS BRAKES AND PARTS
sleeves. CLEANER (P/N 219 701 776)
or XPS BRAKES AND PARTS CLEANER
Pull and rotate one-way clutch slowly until the (USA) (P/N 219 701 705)
sheave of spring sleeves are visible.
NOTICE Avoid contact between cleaner and
crankshaft seal because damage may occur.
Remove all deposits that have baked on pulley
tapered surfaces with medium steel wool and/or
sand paper no. 600.
NOTICE Do not use any other type of abra-
sive.
Reclean surfaces after steel wool and/or sand pa-
per use.
Blow compressed air on all cleaned parts and sur-
faces to remove any residue.
NOTICE Mounting surfaces and threads
must be free of any oil, cleaner or towel
residue.
vmr2006-021-020_a
1. One-way clutch
2. Fixed sheave
3. Spring sleeve area
Hold both spring sleeves with fingers and release

when one-way clutch is disengaged.
vmr2016-122 9
vmr2016-122-019_a
BACK OF GOVERNOR CUP

1. Tapered contact surface
tbg2013-004-002_a
Only use petrol base cleaner when cleaning bush- BACK OF FIXED SHEAVE
1. Tapered end of the Crankshaft side fixed sheave
ings of sliding sheave.
NOTICE Do not use acetone to clean bush-
ing.
vmr2016-122-020_a
1. Tapered end of fixed sheave shaft
tmr2011-015-006_a
1. Sliding sheave
2. Bushings
tbg2013-004-003_a
PTO
1. Tapered contact surface
2. PTO inner threads
10 vmr2016-122
Inspecting the Drive Pulley

Bushings
For bushing inspection, refer to SLIDING SHEAVE
in this subsection.
Governor Cup
Check governor cup for cracks or other visible
damage. Replace if necessary.
Roller and Slider Shoe
NOTICE Always replace all rollers and slider
shoes at the same time.
tbg2014-003-007
PTO END OF STUD Check if rollers move freely.

Check slider shoes for visible wear. If chamfer is
not present anymore, replace ALL slider shoes.
tbg2014-003-006
STUD END RECEIVING NUT
vmr2016-036-002_a
1. Roller
2. Slider shoe
3. Slider shoe chamfer
A. Roller outer diameter
tbg2014-003-005
Check roller outer and inner diameter, replace if it
M12 NUT is out of specification.
ROLLER OUTER DIAMETER
13.80 mm to 14.00 mm
NEW
(.543 in to .551 in)
ROLLER INNER DIAMETER
8.025 mm to 8.175 mm
NEW
(.316 in to .322 in)
Centrifugal Lever Pivot Bolt

tbg2014-003-009 Measure diameter of centrifugal lever pivot bolt,
M12 SET SCREW replace if it is out of specification.
vmr2016-122 11
R610tran12A A 1
A. Measure diameter here
CENTRIFUGAL LEVER PIVOT BOLT DIAMETER

6.063 mm to 6.091 mm
NEW
(.239 in to .24 in)
vmr2016-122-021_b
Centrifugal Lever 1. Lock nut

Check bushing diameter in the centrifugal lever for 3. Centrifugal lever
4. Thrust washers
wear. Replace centrifugal lever if necessary. 5. Contact surface to the roller
WARNING
Always replace ALL levers at the same time.
Otherwise, unbalanced drive pulley will occur
because of levers difference.
Sliding Sheave
Tmr2013-071-018_a
tact surface for excessive wear. Replace sliding
1. Centrifugal lever sheave if necessary.
2. Bushing
Measure centrifugal lever pivot bolt bores. Re-
A. Bushing inner diameter
place sliding sheave if bores are out of specifica-
CENTRIFUGAL LEVER BORE DIAMETER tion or otherwise damaged.
6.107 mm to 6.218 mm
NEW
(.24 in to .245 in)
Replace centrifugal lever, thrust washers, cen-

trifugal lever pivot bolts and lock nuts if the
contact surfaces show heavy visible wear.
vmr2016-122-022_a
A. Centrifugal lever pivot bolt bore diameter
CENTRIFUGAL LEVER PIVOT BOLT BORE

DIAMETER
6.113 mm to 6.171 mm
NEW
(.241 in to .243 in)
12 vmr2016-122
Measure bushing diameters of sliding sheave. Fixed Sheave

REQUIRED TOOL Check fixed sheave contact surface to the gover-
nor cup for scratches or other damages. If so, re-
Dial bore gauge place fixed sheave.
MEASURING POINT
vmr2016-122-020_a
1. Visually check here
Tmr2013-071-021_a Check for any marks on fixed sheave plate. Re-

1. Bushing on fixed sheave side place if necessary.
Spring
SLIDING SHEAVE LARGE BUSHING Measure spring free length and squareness. If
55.000 mm to 55.040 mm spring is out of specification, replace by a new
NEW one.
(2.165 in to 2.167 in)
SERVICE LIMIT 55.200 mm (2.173 in) CLUTCH SPRING FREE LENGTH
SERVICE LIMIT 95 mm (3.74 in)

SERVICE LIMIT 4 mm (.157 in)
One-Way Clutch
Check bearings for excessive play and smooth op-
eration. Replace one-way clutch bearings if nec-
essary.
NOTICE Be careful not to damage the inside
Tmr2013-071-022_a
of one-way clutch during bearing removal.
1. Bushing on governor cup side
SLIDING SHEAVE SMALL BUSHING

32.000 mm to 32.040 mm
NEW
(1.26 in to 1.261 in)
Replace sliding sheave if one of the bushings is

out of specification. Visually inspect coatings.
vmr2016-122 13
vmr2015-035-002_a
1. One-way clutch
2. Bearings
tmr2011-015-020_b
Measure length of spring sleeves and check if 1. One-way clutch

2. Bearing
edges on top of the spring sleeve are excessively 3. Retaining ring
worn. If they out of specifications, replace both
spring sleeves at the same time. Friction Washer
SPRING SLEEVE LENGTH NOTE: Apply recommended grease on both sides
of friction washer.
9.2 mm to 9.4 mm
NEW REQUIRED PRODUCT
(.362 in to .37 in)
SERVICE LIMIT 9.0 mm (.354 in) ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021)
NOTE: Friction washer must be assembled with

Assembling the Drive Pulley collar towards one way clutch.
For assembly, reverse the disassembly proce-
dure. Pay attention to following details.
One-Way Clutch
Clean parts.
Lubricate:
– Springs
– Spring sleeves
– Room between one-way clutch bearings.
ONE-WAY CLUTCH LUBRICATION
ISOFLEX GREASE
Service product TOPAS NB 52 (P/N 293 vmr2007-051-003_a
550 021) 1. Friction washer

2. Collar
3. One way clutch
Sliding Sheave
Install centrifugal levers with their thrust washers.
Install NEW lock nuts and tighten them to speci-
fication.
TIGHTENING TORQUE
8 N•m ± 1 N•m
Lock nuts
14 vmr2016-122
Tmr2013-071-026_a
1. Punch
vmr2016-122-021_c NOTICE Rollers must move easily after in-

1. Centrifugal lever stallation.
2. Thrust washers
3. Centrifugal lever pivot bolt Insert slider shoes into governor cup to properly
4. Lock nut
slide in guides.
NOTICE Centrifugal levers must move easily
after installation. Installing the Drive Pulley
Governor Cup For installation, reverse the removal procedure.
Rebuild governor cup with new bearing sleeves,
thrust washers, rollers and slider shoes. WARNING
NOTICE Final position has to be aligned with Do not apply antiseize or any lubricant on
the contact surface of the slider shoes (no pro- crankshaft and drive pulley tapers.
trusion).
wrench at drive pulley removal and instal-
lation.
Clean mounting surfaces and parts as described
in CLEANING THE DRIVE PULLEY in this subsec-
tion.
Hand tighten the threaded stud in the PTO.
Tmr2013-071-025_a
1. Punch
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.
vmr2016-122-024_a
1. Stud
vmr2016-122 15
Counter two M12 X 1.75 nuts for tightening the NOTICE The washers are shipped with spe-
threaded stud. cial coating. Do not clean washers using
degreaser, abrasive products, etc; this could
NOTICE Do not use original installed nuts. damage the special coating washers comes
with.
vmr2016-122-002_a
1. Counter nuts
2. Stud tbg2014-003-008_b
Lock crankshaft, refer to CRANKSHAFT LOCKING Install NEW larger washer first, then NEW smaller
PROCEDURE in the BOTTOM END subsection. washer and nut.
Tighten the threaded stud to specification.
TIGHTENING TORQUE
50 N•m ± 2 N•m
Threaded stud
Remove both M12 counter nuts from the stud.

Remove tool from magneto side. Install plug and
O-ring on magneto cover.
Install fixed sheave on PTO.
Install sliding sheave and governor cup.
NOTE: Make sure that sliding sheave and gover-
nor cup are properly aligned as marked before re-
moval. vmr2016-122-014_b
Step 1: Push
1. Large thrust washer (NEW)
2. Small thrust washer (NEW)
3. Drive pulley nut
Lock the drive pulley with clutch holder tool.

Tighten drive pulley nut to specification.
DRIVE PULLEY M12 FLANGE NUT
80 N•m ± 1 N•m
Tightening STEP 1
procedure
STEP 2 90° ± 5°
vmr2016-122-011_a
1. Mark on drive pulley sliding sheave

16 vmr2016-122
REQUIRED TOOL
CLUTCH HOLDER
(P/N 529 036 238)
vmr2016-122-026_a
1. Nut
2. Drive pulley
Install M12 X 10 set screw in M12 nut and tighten

the set screw to specification.
TIGHTENING TORQUE vmr2016-122-012_b
1. Clutch holder
LOCTITE 272 2. Driven pulley
Service product
(P/N 420 899 526)
Remove the counter nut and discard it.
65 N•m ± 2 N•m
M12 X 10 set screw
NOTE: It is important to use the specified thread-

locker: High temperatures are involved and this
product is specifically designed for these temper-
atures. No other product should be used.
tmr2015-022-007_a
1. Counter nut
2. Driven pulley nut
vmr2016-122-013_b
3. Clutch holder
1. Set screw
Loosen the driven pulley nut.
DRIVEN PULLEY NOTE: Do not unscrew the driven pulley nut com-
pletely.
Removing the Driven Pulley
Remove DRIVE BELT.
Lock the driven pulley.
vmr2016-122 17
tmr2015-022-008_a vmr2016-122-003_a
1. Driven pulley nut 1. Fixed sheave of driven pulley

2. Sliding sheave of driven pulley
3. Spring
Remove service tool. 4. Shaft
5. Cam
Apply axial pressure with your hand on driven pul-
ley and maintain during nut removal. Install the tightening tool on the stud.
Remove driven pulley nut (discard) and washer. REQUIRED TOOL
CAUTION Driven pulley is spring loaded. DRIVEN PULLEY STUD TOOL

Hold driven pulley tight and slowly remove the (P/N 529 036 360)
driven pulley nut to release spring tension.
tmr2015-022-100
tmr2015-022-009_a
Step 1: Push
Block countershaft.
1. Driven pulley nut (discard) REQUIRED TOOL
2. Thrust washer
COUNTERSHAFT RETAINER
Remove:
TOOL (P/N 529 036 312)
– Driven pulley
– Spring
– Shaft
– Cam.
18 vmr2016-122
tmr2011-015-009_a
tmr2015-022-102
1. Ball bearing
2. Shaft
Remove stud. 3. Fixed sheave of driven pulley
Disassembling the Driven Pulley Use a soft hammer to push shaft with bearing out
of fixed sheave.
Fixed Sheave
Remove retaining ring and lift torque gear.
1
Tmr2013-071-033_a
1. Retaining ring
2. Torque gear

except if ball bearing or shaft must be removed. R610tran18A
Refer to INSPECTION before proceeding. 1. Soft hammer

2. Shaft
Heat ball bearing area up to 100°C (212°F) before
removing ball bearing. Remove shaft from ball bearing.
Remove distance sleeve and O-ring from counter-
shaft.
Replace O-ring if brittle, hard or damaged.
vmr2016-122 19
vmr2006-021-044_b
1. O-ring
2. Distance sleeve
vmr2016-122-030_a
1. Countershaft end
Cleaning the Driven Pulley 2. Countershaft oil seal
3. Countershaft inner threads
Clean the CVT air guide area from contamination.
Using a small brush, paper towel and parts
cleaner, clean all the mounting surfaces and
threads as shown.
REQUIRED PRODUCT
XPS BRAKES AND PARTS
CLEANER (P/N 219 701 776)
or XPS BRAKES AND PARTS CLEANER
(USA) (P/N 219 701 705)
NOTICE Avoid contact between cleaner and

countershaft oil seal or damage may occur.
Remove all deposits that have baked on pulley
tapered surfaces with medium steel wool and/or
tbg2014-006-001_a
sand paper no. 600.
GEARBOX COUNTERSHAFT
NOTICE Do not use any other type of abra- 1. Countershaft outer surface
2. Countershaft inner threads
sive.
Reclean surfaces after steel wool use.
Blow compressed air on all cleaned parts and sur-
faces to remove any residue.
NOTICE Mounting surfaces and threads
must be free of any oil, cleaner or towel
residue.
tbg2014-003-007
COUNTERSHAFT END OF STUD
20 vmr2016-122
vmr2006-021-038_a
tbg2014-003-006
1. Bushings
STUD END RECEIVING COUNTER NUTS 2. Backside of sliding sheave of driven pulley
BUSHINGS BORE DIAMETER

30.060 mm to 30.100 mm
NEW
(1.183 in to 1.185 in)
tbg2014-006-014
Fixed Sheave
THREADS OF DRIVEN PULLEY NUT
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.
tbg2014-006-015
If the shaft is removed measure bushing diameter.
THREADS OF COUNTER NUT
REQUIRED TOOL
Inspecting the Driven Pulley Dial bore gauge
Sliding Sheave
MEASURING POINT
tact surface for excessive wear. Replace sliding At least 5 mm (1/4 in) from bushing edge
sheave if necessary.
This bushing can not be replaced. Replace fixed
Check bushings for cracks, scratch and for free sheave if bushing is out of specification. Visually
movement when assembled to sliding sheave. inspect coatings.
Measure bushing diameter.
REQUIRED TOOL
Dial bore gauge
MEASURING POINT
This bushing can not be replaced. Replace sliding

sheave if bushings are out of specification. Visu-
ally inspect coatings.
vmr2016-122 21
tmr2011-015-012_a
1. Caliper
2. Contact surface
tmr2011-015-010_a
A. Width to be measured due to wear on contact surface
1. Bushing
WIDTH ON TOP SURFACE
BUSHING BORE DIAMETER SERVICE LIMIT 16.0 mm (.63 in)
30.060 mm to 30.100 mm
NEW
(1.183 in to 1.185 in)
Check torque gear for visible damage and cracks.

Measure wear limit with a caliper.
vmr2006-021-041_a
1. Caliper
2. Sliding sheave
3. Contact surface
A. Wear to be measured
tmr2011-015-011_a
WEAR ON CONTACT SURFACE
A. Measurement inside
B. Measurement outside SERVICE LIMIT 1.00 mm (.039 in)
WEAR ON TEETH BOTH SIDES Spring

SERVICE LIMIT 7.500 mm (.295 in) Measure spring free length and squareness. If
spring is out of specification, replace by a new.
Cam
Check cam for visible damage and wear limit with
a caliper.
22 vmr2016-122
Vmr2012-018-013_a
CVT DRIVEN SPRING

A. Spring free length
Tmr2013-071-036_a
SPRING FREE LENGTH 1. Shaft

2. Fixed sheave
SERVICE LIMIT 125 mm (4.921 in) 3. Press machine
CLUTCH SPRING SQUARENESS Install torque gear then secure it with retaining
SERVICE LIMIT 3.8 mm (.15 in) ring.
Assembling the Driven Pulley

Heat ball bearing area up to 100°C (212°F) before
ball bearing installation.
NOTE: Place new ball bearing in a freezer for 10
minutes before installation.
Install ball bearing with the writing on top and
press in only on the outer ring.
Tmr2013-071-033_a
1. Retaining ring
2. Torque gear
Installing the Driven Pulley

wrench at drive pulley removal and instal-
lation.
Clean mounting surfaces and parts as described in
vmr2006-021-042_a
1. Ball bearing
CLEANING THE DRIVEN PULLEY in this subsec-
2. Fixed sheave of driven pulley tion.
NOTICE Do not use hammer, use press ma- Place O-ring on countershaft splines and move it
chine only. with distance sleeve in end position.
NOTICE Chamfer on inside diameter of the
distance sleeve must face to gearbox side.
vmr2016-122 23
vmr2006-021-044_a
1. O-ring
2. Distance sleeve tmr2015-022-101
3. Chamfered area of distance sleeve
Tighten the stud to specification.
Hand tighten the stud in the countershaft.
TIGHTENING TORQUE
Install the tightening tool on the stud.
45 N•m ± 2 N•m
REQUIRED TOOL Stud
DRIVEN PULLEY STUD TOOL Remove the tightening tool from the stud.
(P/N 529 036 360)
Remove countershaft retainer tool.
Lubricate:
– Countershaft splines
– Countershaft outer surface.
SERVICE PRODUCT
LOCTITE 767
Countershaft splines
(ANTISEIZE
and countershaft outer
LUBRICANT) (P/N 293
surface
800 070)
tmr2015-022-100
Block countershaft.
REQUIRED TOOL
COUNTERSHAFT RETAINER
TOOL (P/N 529 036 312)
tmr2015-022-014_a
2. Countershaft outer surface
Place spring behind sliding sheave and engage

spring end in the sliding sheave spring bore.
24 vmr2016-122
vmr2016-122-004_a
Vmr2012-018-016_a
850 AND 1000 ENGINES 2. Cam
1. Sliding sheave 3. Spring
2. Spring end 4. Sliding sheave
3. Spring bore 5. Fixed sheave
Place cam on the opposite end of the spring and With your hand, push the driven pulley onto the
engage the other spring end in the cam spring shaft to compress the spring.
bore.
As you hold the pulley in, install thrust washer and
a NEW driven pulley nut.
NOTE: Finger tighten the driven pulley nut suffi-
ciently so that the cam remains engaged.
Vmr2012-018-017_a
1. Cam
2. Spring end
3. Spring bore
Install pre-assembled cam with spring and driven

pulley on countershaft end.
tmr2015-022-009_b
NOTICE Cam must engage on countershaft Step 1: Push
splines. 1. Thrust washer
2. Driven pulley nut (NEW)
Insert a screwdriver of approximately 5 mm

(.197 in) diameter in the cam.
vmr2016-122 25
vmr2016-122-005_a vmr2016-122-007_a
FOR CLARITY OF UNDERSTANDING, SOME PARTS ARE NOT 1. Clutch holder

SHOWN 2. Screwdriver
1. Cam A. Turn counterclockwise
2. Screwdriver, diameter 5 mm (.197 in)
Hold the driven pulley in a fix position. Tighten driven pulley nut as specified.
Using a socket and extension, hand tighten the
REQUIRED TOOL driven pulley nut.
CLUTCH HOLDER NOTE: Do not apply specified torque at this time.
(P/N 529 036 238) Move the screwdriver back and forth to check
cam for free movement.
vmr2016-122-006_a
1. Fixed sheave
2. Clutch holder
3. Screwdriver
vmr2016-122-007_b
Turn the screwdriver approximately 20° counter- 1. Clutch holder

clockwise until cam engages in the driven pulley 2. Screwdriver
sliding sheave and hold it in this position (spring A. Cam freedom of movement
preload). Install drive belt. Refer to DRIVE BELT in this sub-
section.
REQUIRED TOOL
PULLER/LOCKING
TOOL (P/N 529 036 098)
26 vmr2016-122
vmr2016-122-008_a
2. Sliding sheave vmr2016-122-018_a

NOTE: If driven pulley sheaves can to be opened 2. Spanner
3. Counter nut
when the service tool is screwed in, the cam is
not correctly engaged in the sliding sheave. In order to confirm the cam is in the right position,
TIGHTENING TORQUE measure the length of the stud out of the counter
nut.
20 N•m ± 1 N•m – If the distance between counter nut and the
Driven STEP 1
pulley nut end of the stud is within specification, the pul-
STEP 2 180° ± 5° ley and cam are properly installed.
– Otherwise the cam might not correctly en-
gaged. Remove the clutch except stud, and
reinstall.
– If distance is still out of specification, please
consult the TST # 81274 on Knowledge Center
for instructions.
tmr2015-022-008_a
Remove service tool.

Hold driven pulley nut using a spanner and tighten
the NEW counter nut to specification. tbg2014-006-300
TIGHTENING TORQUE MEASUREMENT ACTION

35 N•m ± 1 N•m Less than flush with Refer to TST # 81274 on
Counter nut
(26 lbf•ft ± 1 lbf•ft) the counter nut Knowledge Center
Installation is good.
0 to 3.6 mm Install the drive belt to
complete the procedure
Refer to TST # 81274 on
3.7 mm and more
Knowledge Center
vmr2016-122 27
SPECIFICATION
CVT AIR GUIDE

Removing the CVT Air Guide
Remove the DRIVE PULLEY and the DRIVEN
PULLEY.
Unscrew the clamps retaining the CVT air hoses.
Remove CVT air guide.
Remove and discard O-rings.
vmr2012-018-020_a
1. CVT air guide

2. O-rings
Inspecting the CVT Air Guide

Clean CVT air guide from contamination
Installing the CVT Air Guide

Always install new O-rings before installing the
CVT air guide.
28 vmr2016-122
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES))
GEARBOX AND 4X4 COUPLING UNIT

(WITH EXTERNAL SWITCHES)
SERVICE TOOLS
BACKLASH MEASUREMENT TOOL............................................. 529 036 030 ........................................... 14
BEARING INSTALLER (GEARBOX) ............................................... 529 035 763 ........................................... 30
BEARING INSTALLER (GEARBOX) ............................................... 529 035 762 ........................................... 30
COUNTERSHAFT OIL SEAL PUSHER .......................................... 529 036 222 ........................................... 12
DRIVE SHAFT OIL SEAL INSTALLER ........................................... 529 036 028 ........................................... 13
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 5, 9
HANDLE ........................................................................................ 420 877 650 ..................................... 12, 30
OIL SEAL INSTALLER (GEARBOX) ............................................... 529 035 758 ........................................... 12

FLUKE RIGID BACK-PROBE ......................................................... TP88 ............................................. 6
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 35
LOCTITE 5910 ............................................................................... 293 800 081 ....................... 8–9, 17–18, 34
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ............................... 17, 26, 34
PETAMO GREASE GHY 133N ...................................................... 420 899 271 ........................................... 11
SUPER LUBE GREASE.................................................................. 293 550 030 ................................. 7, 10, 18
vmr2016-123 1
GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM
Super Lube
grease
Engine
oil 10 ± 1 Nm
Engine (89 ± 9 lbfin)
oil
Loctite 243
25 ± 3 Nm
(18 ± 2 lbfft)
Engine oil
Loctite
Super Lube 243
grease NEW
Engine
oil Engine oil
Engine
oil
NEW
Engine
oil Super Lube
grease

vmr2012-019-001_a
2 vmr2016-123
GEARBOX HOUSING AND 4X4 ACTUATOR UNIT
2.5 ± 0.3 N•m

(22 ± 3 lbf•in)
Petamo grease
Petamo
grease
Petamo
grease

vmr2015-036-001_a
vmr2016-123 3
GENERAL OVERVIEW
GEARBOX IDENTIFICATION
Gearbox with GBPS
This gearbox is equipped with 1 gearbox position
sensor.
vmr2012-019-003_a
1. Right housing
2. Center housing
3. Left housing
4. Output shaft
5. Bearing cover
6. Countershaft
7. Shift shaft
8. Actuator
vmr2016-124-001_a
GEARBOX, RIGHT HAND SIDE TROUBLESHOOTING

1. Gearbox position sensor
2. Output shaft
UNUSUAL GEARBOX NOISE AND/OR
Gearbox with External Switches VIBRATIONS
This gearbox is equipped with 3 gearbox position 1. Low oil level in gearbox.
indicator switches. - Oil leakage from gearbox. Replace damaged gas-
ket(s) and/or oil seal(s).
2. Defective bearings.
- Bearing(s) do(es) not turn smoothly. Replace
bearing(s).
3. Damaged or worn gears.
- Inspect gears for damages or missing teeth. Re-
place respective gears.
GEAR INDICATION FAILS

1. Check contact screws on gear housing center.
- Contact(s) is (are) corroded and/or connectors to
wiring harness got loose.
- Damaged wires. Repair as required.
vmr2016-123-001_a - Shifting indicator switch(es) pin(s) is (are) worn
GEARBOX, RIGHT HAND SIDE and/or damaged. Replace shifting indicator
1. Gearbox position indicator switches switch(es).
2. Output shaft
GEAR(S) IS (ARE) HARD TO SHIFT
1. Incorrect shift rod adjustment.
- Adjust shift rod (refer to SHIFT ROD in SHIFTER
subsection).
4 vmr2016-123
4 WHEEL DRIVE INDICATION FAILS

1. 4WD indicator switch failure.
- Test 4WD indicator switch. Replace as required.
- Bad contact. Check for corrosion or loose con-
nector.
- Damaged wires. Repair as required.
4 WHEEL DRIVE DOES NOT ENGAGE OR

DISENGAGE
1. Defective 4WD switch.
- Check 4WD switch operation.
2. Defective actuator.
- Test actuator.
vmr2016-123-002_a
3. Damaged or worn shifting fork or sleeve. 1. VSS connector

2. OPS (Oil Pressure Switch)
- Remove actuator and inspect shifting fork and
sleeve.
VSS Access
PROCEDURES To reach the VSS, refer to BODY subsection and
remove the RH footrest panel.
VEHICLE SPEED SENSOR (VSS) VSS Connector Access
VSS Location Refer to BODY subsection and remove the RH
The vehicle speed sensor is located on the right side panel extension.
housing of the gearbox behind the actuator.
VSS Wire Identification
COLOR -
COLOR -
WIRING
FUNCTION PIN SENSOR
HARNESS
CONNECTOR
CONNECTOR
12-volt
input from A RED VIOLET/BLUE
fuse F5
Speed
signal
B WHITE PINK
(to cluster
pin 9)
Ground GREEN/
C BLACK
(to ECM C3) BROWN
vmr2016-123-004_a VSS Circuit Protection

1. VSS (Vehicle Speed Sensor)
2. Right housing of gearbox CONDITION CIRCUIT PROTECTION
3. Actuator
Supplied with main
The VSS connector is located between the cylin- Fuse 5
relay activated
ders, behind the OPS cover.
Testing the VSS Input Voltage
1. Remove VSS connector cover.
2. Set multimeter to Vdc.
REQUIRED TOOL
FLUKE 115 MULTIMETER (P/N 529 035 868)
vmr2016-123 5
3. Turn ignition switch ON. VEHICLE SPEED SENSOR SIGNAL TEST

4. Set emergency engine stop switch to RUN. RESULT
5. Back-probe the VSS connector. TEST PROBES (WHILE ROTATING
WHEELS)
REQUIRED TOOL
Alternate reading
FLUKE RIGID BACK-PROBE (P/N TP88) PIN B PIN C
between battery
WHITE wire BLACK wire
voltage and 0 Vdc
NOTE: Since we measure pulsating voltage, the

numeric display will continuously change. The
analog display may be easier to follow.
vmr2016-123-002_b
smr2005-056-010_a
1. VSS connector 1. Analog display
6. Measure voltage as per following table.

Removing the VSS
VEHICLE SPEED SENSOR INPUT VOLTAGE TEST Pull out the VSS after removing the retaining
RESULT screws.
TEST PROBES
(KEY ON)
PIN A PIN C
VIOLET/BLUE GREEN/BROWN Battery voltage
wire wire
If voltage is not as specified, test positive and

ground circuits separately.
Testing the VSS Signal

1. Lift rear of vehicle so that rear wheels are off
the ground.
2. Set transmission to 2WD and to NEUTRAL.
3. Back-probe the VSS connector.
REQUIRED TOOL
vmr2016-123-003_a
FLUKE RIGID BACK-PROBE (P/N TP88)
1. Screw
2. VSS
4. Turn ignition switch ON.
5. Set emergency engine stop switch to RUN. Installing the VSS
6. Set multimeter to Vdc. For installation, reverse the removal procedure.
7. Measure voltage while slowly rotating rear Pay attention to the following.
wheels by hand. Lubricate VSS O-ring.
6 vmr2016-123
VSS O-RING
SUPER LUBE GREASE
Service product
(P/N 293 550 030)
Tighten VSS retaining screw to specification.

TIGHTENING TORQUE
10 N•m ± 1 N•m
VSS retaining screw
GEARBOX POSITION INDICATOR

SWITCHES
Gearbox Position Indicator Switch
Access vmr2012-019-004_b
1. Gearbox position indicator switch - position 1

Refer to BODY subsection and remove the follow- 2. Gearbox position indicator switch - position 2
ing: 3. Gearbox position indicator switch - position 3
4. BROWN/GREY wire
– Seat 5. WHITE/RED wire
6. ORANGE/GREY wire
– Console
– RH side panel and extension(s) SHIFTER
CORRESPONDING SWITCH
– RH footrest panel. POSITION
BROWN/ WHITE/ ORANGE/
GREY RED GREY
Position 1 Position 2 Position 3
L X X
H X
N X X
R X
P X X
An “X” indicates switch is making ground contact,

thus there should be continuity (R is close to 0
Ohms).
A blank space indicates switch is not making con-
vmr2015-036-101
tact, there should be no continuity (R = infinite).
Testing the Gearbox Position Indicator If the indicator switch is good, check the vehicle
Switch Continuity harness and/or indicator lights.
1. Remove parts required for access, refer to Removing the Gearbox Position
GEARBOX POSITION INDICATOR SWITCH Indicator Switch
ACCESS in this subsection.
NOTE: Clean area of dirt before removing gear-
NOTE: Take note of corresponding switch posi- box indicator position switch(es). Take note of cor-
tion and wire color. responding switch position and wire color.
2. Disconnect wires from switches. Disconnect indicator switch from engine wiring
NOTE: Remove insulating paint to obtain correct harness.
readings.
3. Using a multimeter, measure the resistance
from the indicator switch to engine ground
while selecting the gearbox to each position.
Compare results with the logic table below.
vmr2016-123 7
vmr2012-019-004_a vmr2012-019-004_a
1. Gearbox position indicator switches 1. Indicator switches

2. BROWN/GREY wire 2. BROWN/GREY wire
3. WHITE/RED wire 3. WHITE/RED wire
4. ORANGE/GREY wire 4. ORANGE/GREY wire
Unscrew switch.
4WD INDICATOR SWITCH
Installing the Gearbox Position 4WD Indicator Switch Access
Indicator Switch
Reverse the removal procedure. However, pay ating:
tention to the following. – Seat
Take care to avoid damaging threads in switch – Console
bores during installation. – RH side panel and extension(s)
Carefully apply some sealant on threads of shift – RH footrest panel.
indicator switches.
NOTICE Do not apply sealant on switch
plunger as it will lead to switch malfunction.
TIGHTENING TORQUE
LOCTITE 5910 (P/N 293
Service product
800 081)
2.5 N•m ± 0.3 N•m
Indicator switches
If all switches are removed, make sure to put the

wires back in the correct location as noted prior to
removal.
vmr2015-036-102
4WD INDICATOR SWITCH LOCATIONS
Removing the 4WD Indicator Switch

Disconnect 4WD indicator switch connector from
engine wiring harness.
8 vmr2016-123
– Console
– RH side panel and extension(s)
Testing the 4WD Actuator

REQUIRED TOOL

(P/N 529 035 868)
1. Unplug 4WD actuator connector.

2. Turn ignition key ON.
3. Set emergency engine stop switch to RUN.
vmr2012-019-005_a
4. Measure voltage as follows.
1. 4WD indicator switch
2. BLACK/BEIGE wire for contact to 4WD SWITCH
3. Actuator SWITCH WIRE VOLTAGE
POSITION
Testing the 4WD Indicator Switch 2WD WHITE/BLUE Battery
WHITE
Measure switch resistance as follows. 4WD WHITE/BLACK voltage
SWITCH
POSITION
SWITCH WIRE RESISTANCE If the selector is out of specifications, check
wires, connectors and replace the selector if nec-
2WD BLACK/ Engine Close to 0 essary.
4WD BEIGE ground Infinite (OL) If the selector is good, check the vehicle harness.
If the vehicle harness is good, replace the actua-
If the resistance is out of specification, replace the tor.
4WD indicator switch.
Removing the 4WD Actuator
Installing the 4WD Indicator Switch
NOTE: Before beginning any servicing on the ac-
Reverse the removal procedure. However, pay at- tuator, make sure the vehicle is in 4WD position.
tention to the following. No need to remove engine from vehicle.
Take care to avoid damaging threads in switch 1. Detach brake master cylinder from frame.
bore during installation.
Carefully apply some sealant on threads of indica-
tor switch.
NOTICE Do not apply sealant on switch
plunger, as it will lead to switch malfunction.
TIGHTENING TORQUE
Service product
800 081)
2.5 N•m ± 0.3 N•m
4WD indicator switch
4WD ACTUATOR
4WD Actuator Access vmr2012-037-006_a
1. Remove retaining screws from master cylinder support

To access the actuator, refer to BODY subsection
and remove the following parts:
– Seat
vmr2016-123 9
Vmr2015-123-003_a
vmr2012-037-007_a 1. Actuator O-ring

1. Master cylinder moved apart
2. Verify if coupling fork is in 4WD position. The
2. Unplug actuator connector. coupling fork should be positioned toward the
3. Place a drain pan under actuator. front of vehicle.
4. Unscrew actuator bolts.
vmr2006-022-131_a vmr2006-022-132_a
5. When all actuator bolts are removed, pull the 3. Align the actuator fork with the pin on coupling
actuator out of housing. fork then push the actuator in the housing. See
the following illustration to position the actuator
Installing the 4WD Actuator correctly.
1. Lubricate actuator O-ring.
ACTUATOR O-RING
SUPER LUBE GREASE
Service product
(P/N 293 550 030)
10 vmr2016-123
NOTICE Refill missing gearbox oil, refer to

PERIODIC MAINTENANCE PROCEDURES sub-
section.
13. Install all other removed parts.
GEARBOX OIL SEALS

Replacing the Gearbox Oil Seals
Replace oil seals if they are brittle, hard or dam-
aged.
A small flat screwdriver can be used to remove
most of these oil seals.
NOTICE Avoid scoring parts during oil seal
removal.
When replacing an oil seal, take this opportunity
to inspect the following:
– Check bearings behind each oil seal for contam-
ination and/or metal shavings.
– Check oil seal running surfaces for scratches.
Lubricating the Oil Seal
vmr2006-022-133_a
When installing or reinstalling oil seals, use
4. Rotate the actuator counterclockwise until it ori- PETAMO GREASE GHY 133N (P/N 420 899 271) to:
ents itself to mounting position. – Lubricate sealing lips all around.
NOTICE Do not cut or break the actuator – Fill up the room between sealing lips halfway
O-ring. around the perimeter.
5. Install all actuator bolts then torque them to

specification.
TIGHTENING TORQUE
25 N•m ± 3 N•m
Actuator screws
6. Connect actuator.
7. Lift the front of vehicle.
8. Turn front wheels. The front propeller shaft
should not turn (the PARK position must be
selected).
If the front propeller shaft turns, the actuator is not
installed correctly. Remove actuator and reinstall vmr2013-020-001_a
it. 1. Sealing lips

2. Room between sealing lips
9. Set ignition switch to ON.
Countershaft Oil Seal
The countershaft oil seal can be removed without
11. Select the 2WD position. removing gearbox from vehicle. Remove drive
12. Turn front wheel again. The front propeller and driven pulley and CVT air guide.
shaft. The shaft should turn easily.
If the front propeller shaft does not turn, the ac-
tuator is not installed correctly. Remove actuator
and reinstall it.
vmr2016-123 11
vmr2012-019-007_a

vmr2006-022-006_a 2. Oil seal pusher
2. Distance sleeve Shift Shaft Oil Seal
The shift shaft oil seal can be removed without
NOTE: When oil seal is removed also inspect removing the gearbox from the vehicle.
O-ring.
To replace the shift shaft oil seal, refer to BODY
subsection and remove:
– Seat
– Console
– RH side panel
– RH footrest panel
– Shift plate from shift shaft (refer to SHIFTER
subsection.
Using a suitable tube with the proper diameter to
install the shift shaft oil seal.
If gearbox housing is apart, the following tools can
be used for shift shaft oil seal installation.
REQUIRED TOOL
OIL SEAL INSTALLER
(GEARBOX) (P/N 529 035 758)
vmr2012-019-006_a HANDLE (P/N 420 877 650)

1. Distance sleeve
2. O-ring
For countershaft oil seal installation use the fol- ing lip toward gearbox.
lowing service tool.
Output Shaft Oil Seal
REQUIRED TOOL Remove propeller shaft. Refer to REAR DRIVE
subsection.
COUNTERSHAFT OIL SEAL
PUSHER (P/N 529 036 222) Punch a sharp screwdriver through oil seal for re-
moval.
NOTE: When oil seal is removed also inspect
O-ring.
12 vmr2016-123
vmr2006-022-008_a
1. Output shaft oil seal

vmr2012-019-008_a 2. Oil seal installer
1. Distance sleeve
2. O-ring
OUTPUT SHAFT AND COUPLING
MECHANISM
Remove gearbox. Refer to GEARBOX in this sub-
section.
Before removing the right housing and output
shaft measure the backlash on output shaft. This
measure will indicate if output shaft adjustment
is necessary.
Output Shaft Backlash Procedure

1. Engage PARK position on the gear shaft to
block gearbox.
2. Remove bearing cover with oil seal
vmr2006-022-007_a
1. Shift shaft oil seal

For output shaft oil seal installation use the follow-

ing service tool.
REQUIRED TOOL

vmr2006-022-010_a
1. Bearing cover
2. Oil seal
vmr2016-123 13
3. Remove:
– Distance sleeve
– O-ring.
vmr2006-022-012_a
vmr2006-022-011_a
1. Backlash measurement tool
2. Mark on tab
1. Distance sleeve A. 47 mm (1.85 in)
2. O-ring
4. Install the measurement tool at the end of out- 6. Position the head of the dial indicator, against
put shaft. the tab at a 90° angle and on the line. Then,
gently rotate the output shaft.
REQUIRED TOOL
This reading gives the backlash measurement.
Refer to the following table for backlash specifi-
BACKLASH MEASUREMENT cations.
TOOL (P/N 529 036 030)
OUTPUT SHAFT BACKLASH
0.10 mm to 0.20 mm
5. From center of tool bolt, measure 47 mm NEW
(.0039 in to .0079 in)
(1.85 in)and place a mark on the tab.
If backlash is not within the specification, remove

the output shaft and select the next thicker or thin-
ner shim to meet the specifications.
NOTE: Use next thicker shim to increase back-
lash and next thinner shim to reduce backlash.
Removing the Output Shaft and

Coupling Mechanism
1. Remove actuator.
2. Remove the bearing cover with oil seal.
3. Unscrew all bolts retaining the right housing to
the center housing.
4. To remove right housing, use 2 big screw-
drivers.
14 vmr2016-123
vmr2012-019-009_a
vmr2006-022-021
1. Output shaft
POSITION FOR BIG FLAT SCREWDRIVER 2. Coupling sleeve
3. Soft hammer
6. Remove:
– Coupling sleeve
– O-ring
– Ball bearing
– Thrust washer.
vmr2006-022-022
POSITION FOR BIG FLAT SCREWDRIVER
5. Remove output shaft. vmr2006-022-024_a
REQUIRED TOOL 1. Coupling sleeve

2. O-ring
3. Ball bearing
Soft hammer 4. Thrust washer
7. Remove:
– Ball bearing
– Thrust washer.
vmr2016-123 15
Replace oil seal if brittle, hard or damaged.

Replace O-rings if brittle, hard or damaged.
Check splines of coupling sleeve for wear or other
damages.
vmr2012-019-010_a
vmr2006-022-030_a
1. Ball bearing
2. Thrust washer 1. Inspect splines
3. Distance ring
Measure the coupling sleeve groove width.
8. Remove:
– Screw
– Pin
– Coupling fork.
vmr2006-022-031_a
A. Groove width
COUPLING SLEEVE GROOVE WIDTH

5.25 mm to 5.35 mm
NEW
(.207 in to .211 in)
vmr2015-036-002_a
Check coupling fork claw thickness.
1. Screw
2. Pin
3. Coupling fork
Inspecting the Output Shaft and

Coupling Mechanism
Check output shaft and its gear for cracks, bend,
pitting or other visible damages.
Check output shaft splines for wear or other dam-
ages.
NOTICE Always replace output shaft and
bevel gear shaft at the same time. Adjust
these components upon replacement.
vmr2006-022-032_a
Check if the output shaft ball bearings turn freely 1. Coupling fork
2. Micrometer
and smoothly. Replace if necessary, refer to
GEARBOX ADJUSTMENT in this subsection.
16 vmr2016-123
COUPLING FORK CLAW THICKNESS If backlash is within specifications, remove dial

indicator, backlash measuring tool, bearing cover
4.95 mm to 5.05 mm and right housing.
NEW
(.195 in to .199 in)
NOTE: Install coupling fork, pin and screw in right
SERVICE LIMIT 4.80 mm (.189 in) housing before applying sealant to the mating sur-
face.
Clean housing split surface and especially the
bearing areas from metal particles or other con-
tamination.
Installing the Output Shaft and

Coupling Mechanism
Install thrust washer, bearing, O-ring and coupling
sleeve onto the output shaft.
Install distance ring, thrust washer and ball bear-
ing.
NOTE: O-ring and distance sleeve are not in-
stalled at this time.
vmr2015-036-003_a
Place the output shaft into the center housing. 1. Coupling fork
2. Pin
Use soft hammer to put bearing exactly in place 3. Screw
against center housing.
Clean all metal components in a solvent.
Housing mating surfaces are best cleaned us-
ing a combination of LOCTITE CHISEL (GASKET
REMOVER) (P/N 413 708 500) and a brass brush.
Brush a first pass in one direction then make the
final brushing perpendicularly (90°) to the first
pass cross (hatch).
NOTICE Do not wipe with rags. Use a new
IMPORTANT: When beginning the application
of sealant, the assembly and the first torquing
should be done within 10 minutes. It is suggested
to have all you need on hand to save time.
vmr2012-019-011_a
faces.
1. Soft hammer Use a plexiglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in)),
Clean the bearing cover location then attach bear- available in arts products suppliers for printing,
ing cover with oil seal to the housing. and roll the sealant to get a thin uniform coat
Temporarily install the right housing with the four on the plate (spread as necessary). When ready,
(4) M8 TORX screws beside bearing seats. apply the sealant on housing mating surfaces.
NOTE: Prior to tightening the TORX screws, tap
on the gear end of output shaft with a soft ham-
mer to take up all gear free play.
Verify output shaft backlash. Refer to OUTPUT
SHAFT BACKLASH PROCEDURE in this subsec-
tion. Adjust as required.
vmr2016-123 17
TIGHTENING TORQUE
Step A Hand tightened
Right housing
M8 screws 25 N•m ± 3 N•m
Step B
F12R17A
Do not apply in excess as it will spread out inside

housings.
NOTE: It is recommended to apply this specific
cation without lumps. If you do not use the roller
method, you may use your finger to uniformly dis- vmr2006-022-036_a
tribute the sealant (using a finger will not affect

the adhesion). Tighten all M6 Torx screws to specification
Install all other screws on right housing then the TIGHTENING TORQUE
O-ring and the distance sleeve on end of output
Right housing M6 10 N•m ± 1 N•m
shaft. Chamfered bore of distance sleeve has to screws (89 lbf•in ± 9 lbf•in)
face the engine.
Before installing bearing cover, apply LOCTITE
5910 (P/N 293 800 081) on the housing and SUPER
LUBE GREASE (P/N 293 550 030) on oil seal.
Install the actuator, refer to ACTUATOR in this
subsection.
Once this is done, complete final assembly.
GEARBOX
Removing the Gearbox
1. Remove engine from vehicle and place it on
footrest support. Refer to ENGINE REMOVAL
AND INSTALLATION subsection for the proce-
dure.
2. Drain gearbox. Refer to GEARBOX OIL DRAIN-
vmr2006-022-037_a
ING PROCEDURE in PERIODIC MAINTE-
1. O-ring NANCE PROCEDURES subsection.
2. Distance sleeve
3. Remove drive and driven pulley and CVT air
NOTE: To install the right housing align the cou- guide, refer to CONTINUOUSLY VARIABLE
pling fork with the groove in the coupling sleeve. TRANSMISSION (CVT) subsection.
Torque the four (4) M8 Torx screws in a crisscross 4. Unscrew the three (3) nuts that attach the gear-
sequence to following specification. box to the engine.
5. Pull gearbox to separate it from engine.
18 vmr2016-123
Disassembling the Gearbox BEVEL GEAR AXIAL CLEARANCE

NOTE: During gearbox disassembly, inspect the 0.02 mm to 0.15 mm
condition of each part closely. NEW
(.0008 in to .0059 in)
1. Remove the output shaft. Refer to OUTPUT SERVICE LIMIT 0.19 mm (.0075 in)
SHAFT AND COUPLING MECHANISM in this
subsection. 3. Unscrew the left housing screws.
2. Push bevel gear with a pin slightly down and 4. Place the left housing on a wood stand, center
measure the axial clearance of bevel gear with housing pointing upwards.
a feeler gauge.
5. Using 2 big flat screwdrivers, lift the center
NOTE: Bevel gear axial clearance must be mea- housing.
sured before center and left housings separation.
vmr2006-022-045
vmr2006-022-040_a
1. Bevel gear
vmr2006-022-041
vmr2006-022-046
MEASURE AXIAL CLEARANCE OF BEVEL GEAR
6. Remove center housing completely.

7. Remove shift shaft assembly.
vmr2016-123 19
vmr2006-022-055_a
1. Shift shaft assembly
8. Remove shift fork shaft.

9. Disengage shift forks from shift drum and re- vmr2006-022-058_a
1. Bevel gear
move shift fork. 2. Low range gear
3. Shim
11. Remove sliding gear with shift fork.
vmr2006-022-056_a
1. Shift fork shaft

2. Shift fork
3. Shift drum
10. Remove bevel gear shaft with low range gear

assembly and shim.
vmr2006-022-059_a
1. Sliding gear
2. Shift fork
12. Remove thrust washer, needle bearing and re-

verse gear.
20 vmr2016-123
vmr2006-022-060_a
1. Thrust washer vmr2006-022-062_a

2. Needle bearing 1. Countershaft
3. Reverse gear 2. Low range gear
3. High range gear
13. Remove shim on CVT side.
15. Insert a flat screwdriver in the slot of index
lever. Turn screwdriver clockwise and remove
shift drum.
vmr2006-022-061_a
1. Shim on CVT side

vmr2006-022-065_a
14. Remove countershaft with low range gear and 1. Index lever
high range gear assembly. 2. Shift drum
16. Remove parking lock lever.
vmr2016-123 21
vmr2006-022-066_a
1. Parking lock lever

vmr2006-022-068_a
17. Remove index lever with washer, step ring PRESS SHAFT IN THE DIRECTION AS SHOWN BY THE ARROW
1. Intermediate gear shaft
and spring. 2. Left housing
Removing the Bearings

If necessary heat housing up to 100°C (212°F) be-
fore removing ball bearings or needle bearings.
WARNING
Clean oil, outside and inside, from housing
before heating.
NOTICE Always support gearbox housings

properly when ball bearings or needle bear-
ings are removed. Housing damages may
occur if this procedure is not performed cor-
rectly.
To remove bevel gear needle bearing use a punch.
vmr2006-022-067_a
1. Index lever
2. Washer
3. Step ring
4. Index spring
18. Remove support flange.

NOTE: To remove intermediate gear and needle
bearing, use a press bench to push out the inter-
mediate gear shaft.
22 vmr2016-123
– Worn or scoured shift fork

– Worn or scoured shift fork shaft
– Rounded engagement dogs and slots
– Bent shift forks
– Bent shift fork shaft
– Worn shift fork engagement pins
– Worn tracks on shift drum
– Worn shift fork engagement groove
– Worn splines on shafts and gears.
Bearings
Check if ball bearings and needle bearings turn
freely and smoothly.
Check all bearings, bearing points, tooth flanks,
taper grooves and annular grooves. Annular
vmr2006-022-049_a grooves must have sharp edges.
1. Bevel gear needle bearing
2. Punch Shift Forks
3. Center housing
Check both shift forks for visible damage, wear or
To remove ball bearings of bevel gear and needle bent shift fork claws.
bearing of countershaft, use a blind hole bearing Measure the shift fork claw thickness.
puller.
For countershaft ball bearing, remove screw and
intermediate gear shaft, then push with a suitable
puller from outside in.
vmr2006-022-075_a
1. Micrometer
A. Shift fork claw thickness
SHIFT FORK CLAW THICKNESS

(HIGH GEAR SHIFTING)
4.80 mm to 4.90 mm
NEW
(.189 in to .193 in)
4.70 mm (.185
SERVICE LIMIT
vmr2006-022-052_a in)4.70 mm (.185 in)
1. Screw
3. Ball bearing countershaft
4. Bevel gear ball bearing
Inspecting the Gearbox

Always verify for the following when inspecting
gearbox components:
– Gear teeth damage
– Worn or scoured bearing surfaces
vmr2016-123 23
SHIFT FORK CLAW THICKNESS Gears

(LOW/REVERSE GEAR SHIFTING) NOTE: Replace gears only together with the
5.10 mm to 5.20 mm corresponding meshing gears. Always replace
NEW circlips and use special pliers to install them.
(.201 in to .205 in)
SERVICE LIMIT 5.00 mm (.197 in) Measure the width of shift fork engagement
groove.
Measure shift fork pins.
vmr2006-022-077_a
vmr2006-022-076_a
1. Micrometer 1. Main gear

2. Caliper
A. Shift fork pin diameter
A. Width for engagement of shift fork
SHIFT FORK PIN DIAMETER WIDTH OF SHIFT FORK ENGAGEMENT

6.920 mm to 6.970 mm GROOVE (HIGH GEAR SHIFTING)
NEW
(.272 in to .274 in) 5.00 mm to 5.10 mm
NEW
Shift Drum
Check shift drum tracks for scouring or heavy WIDTH OF SHIFT FORK ENGAGEMENT GROOVE
wear, like rounded engagement slots. (LOW/REVERSE GEAR SHIFTING)
Replace isolating washer if there are signs of wear 5.30 mm to 5.40 mm
NEW
or visible damages. (.209 in to .213 in)
Check free pinions for wear.
vmr2006-022-078_a
1. Track for the low/reverse gear shift fork

2. Track for the high gear shift fork
3. Isolating washer on the shift drum
Levers
Check parking lever for cracks or other damages.
Index lever with roller must move freely.
24 vmr2016-123
vmr2006-022-123_a
1. MAG side
2. Free pinion bearing
3. CVT side
COUNTERSHAFT
SERVICE LIMIT
vmr2006-022-080_a MAG SIDE 17.990 mm (.7083 in)
TYPICAL
1. Micrometer FREE PINION BEARING 24.970 mm (.9831 in)
2. Free pinion
CVT SIDE 24.970 mm (.9831 in)
DIAMETER FREE PINION
Check bevel gear shaft.
29.000 mm to 29.013 mm
NEW
(1.1417 in to 1.1422 in)
Shafts
Check shift shaft for worn splines and gears.
Check intermediate shaft for wear.
vmr2006-022-124_a
1. Free pinion bearings
BEVEL GEAR SHAFT

SERVICE LIMIT
FREE PINION BEARING 24.984 mm (.9836 in)
Shims
Always replace shim by a new one with the same
thickness, when reassembling the gearbox with
existing output shaft and bevel gear shaft.
vmr2012-019-012_a
1. Intermediate gear bearing
INTERMEDIATE GEAR SHAFT

24.979 mm to 25.000 mm
NEW
(.9834 in to .9843 in)
Check countershaft for wear. vmr2006-022-125_a
1. Shim for adjusting the bevel gear on center housing side

2. Area where wear signs appear
3. Thickness of the shim
vmr2016-123 25
Adjusting the Gearbox

Bevel Gear
NOTE: Only necessary if the backlash and axial
clearance of the bevel gear is out of specification
or if parts are changed (output shaft, bevel gear
shaft or housing).
There are 2 adjustments to perform on the bevel
gear.
– Bevel gear backlash on center housing
– Bevel gear axial clearance on left housing.
The bevel gear backlash is adjusted by finding the
proper shim thickness E as per following illustra-
tion.
The bevel gear axial clearance is adjusted by find-
ing the proper shim thickness J as per following
illustration.
Clean mating surface of housing before taking
measurements using a combination of LOCTITE
CHISEL (GASKET REMOVER) (P/N 413 708 500) and
a brass brush. Brush a first pass in one direction
then make the final brushing perpendicularly (90°)
to the first pass cross (hatch).
26 vmr2016-123
B H
D(E)
A I(J)
1 G F
vmr2006-022-079_a
1. Mating surface — output shaft

2. Mating surface — left housing
Bevel Gear Backlash Procedure

Use the following course of calculation to determine the theoretical shim thickness D:
D=B-C-A
B = The distance between the thrust surface of the bevel gear and the theoretical center of its taper.
This is defined by manufacturer and is written on the bevel gear shaft.
vmr2016-123 27
This bevel gear reference number could be be- When the measurements are taken, calculate the
tween - 10 and + 10. theoretical shim thickness (D) using the formula:
(D = B - C - A).
Take the obtained theoretical shim thickness (D)
and choose the corresponding shim number (E)
according to the following table.
THEORETICAL
SHIM NUMBER
SHIM THICKNESS
-E-
-D-
1.20 mm to 1.29 mm
120
(.0472 in to .0508 in)
1.30 mm to 1.39 mm
130
(.0512 in to .0547 in)
1.40 mm to 1.49 mm
140
(.0551 in to .0587 in)
vmr2006-022-085_a
1. Bevel gear 1.50 mm to 1.59 mm

2. Bevel gear reference number
150
(.0591 in to .0626 in)
Use following formula to find out value B. 1.60 mm to 1.69 mm
160
(.063 in to .0665 in)
Bevel gear reference number 1.70 mm to 1.79 mm

B=( ) + 37.8 170
(.0669 in to .0705 in)
100
1.80 mm to 1.89 mm
180
For example: bevel gear reference number = - 3. (.0709 in to .0744 in)
B = (- 3/100) + 37.8 = 37.77 NOTE: For example, if the theoretical shim thick-
C = Distance between the shim thrust surface in ness (D) is 1.53 mm (.0602 in), choose the corre-
the center housing and the mating surface to sponding shim number 150 (E). The shim number
right housing. 150 represents a nominal value equal to 1.50 mm
(.0591 in).
NOTE: For a better understanding following illus-
tration is made as a cutaway. Bevel Gear Axial Clearance Procedure
Use the following course of calculation to deter-
mine the theoretical shim thickness (I):
I= F+G-H-A-E
F = Distance between mating surface of left
housing to ball bearing inner race.
vmr2012-019-013_a
1. Deep gauge — measurement C

2. Shim surface in center housing
3. Mating surface to right housing
A = 2 mm (.0787 in) nominal thickness of axial

needle bearing.
28 vmr2016-123
A = 2 mm (.0787 in) nominal thickness of axial

needle bearing.
E = The shim number nominal value as found in
the BEVEL GEAR BACKLASH PROCEDURE.
For example, shim number 150 represents a
value of 1.50 mm (.0591 in).
When the measurements are taken, calculate the
theoretical shim thickness (I) using the formula:
(I = F + G - H - A - E).
Take the obtained theoretical shim thickness (I)
and choose the corresponding shim number (J)
according to the following table.
THEORETICAL
SHIM NUMBER
SHIM THICKNESS
-J-
-I-
vmr2006-022-082_a 1.22 mm to 1.31 mm
120
1. Ball bearing inner race (.048 in to .0516 in)
2. Mating surface of left housing
3. Depth gauge 1.32 mm to 1.41 mm
130
(.052 in to .0555 in)
G = Distance between mating surface of center
housing and shim surface. 1.42 mm to 1.51 mm
140
(.0559 in to .0594 in)
1.52 mm to 1.61 mm
150
(.0598 in to .0634 in)
1.62 mm to 1.71 mm
160
(.0638 in to .0673 in)
1.72 mm to 1.81 mm
170
(.0677 in to .0713 in)
1.82 mm to 1.91 mm
180
(.0717 in to .0752 in)
For example, if the theoretical shim thickness (I)

is 1.53 mm (.0602 in), choose the corresponding
shim number 150 (J).
Bevel gear axial clearance of 0.02 mm to 0.11 mm
(.0008 in to .0043 in) is included in the above table.
vmr2006-022-083_a
1. Mating surface of center gear housing

2. Shim surface
Assembling the Gearbox
Reverse the disassembly procedure. However,
H = Distance between thrust surfaces of bevel pay attention to the following details.
gear shaft.
Installing the Bearings
Unless otherwise instructed, never use hammer
to install ball bearings or needle bearings. Use
press machine only.
If necessary heat housings up to 100°C (212°F)
before installing ball bearings or needle bearings.
WARNING
before heating.
vmr2006-022-084
vmr2016-123 29
Place new bearing in freezer for 10 minutes be-

fore installation.
Use a suitable installer for installing ball bearings
of countershaft and bevel gear.
NOTE: Place gearbox housings on a wood stand
before installing ball bearings.
Install countershaft needle bearing in right hous-
ing.
REQUIRED TOOL
BEARING INSTALLER
(GEARBOX)
(P/N 529 035 762)
HANDLE (P/N 420 877 650) vmr2006-022-051_a
1. Bevel gear needle bearing

2. Center housing
3. Needle bearing installer
4. Installer handle
Install new oil seals with the proper installer (refer

to GEARBOX OIL SEALS in this subsection).
Other Gearbox Components
Fit intermediate gear with needle bearing on inter-
mediate gear shaft.
NOTE: Fit gear with collar facing to housing side
on the intermediate shaft.
vmr2006-022-050_a
1. Countershaft needle bearing

2. Right housing
3. Needle bearing installer
4. Installer handle
Install bevel gear needle bearing.

REQUIRED TOOL
BEARING INSTALLER
(GEARBOX) (P/N 529 035 763)
HANDLE (P/N 420 877 650)
vmr2006-022-089_a
2. Collar facing housing
3. Needle bearing
Press intermediate gear shaft in the left housing.
30 vmr2016-123
vmr2006-022-066_a
1. Parking lock lever

vmr2006-022-052_b

Place shim of CVT side on bearing.
Fit support flange in the left housing and install

index lever.
NOTE: Fit step ring into index lever.
vmr2006-022-090_a
vmr2006-022-092_a
1. Washer
2. Index lever 1. Shim CVT side
3. Step ring
4. Index spring Place reverse gear with needle bearing and thrust
Install parking lock lever, teeth showing to coun- washer.
tershaft. NOTE: Check if the screw to secure countershaft
bearing is installed.
vmr2016-123 31
vmr2006-022-095_a
1. Bevel gear
2. Sliding gear
vmr2006-022-093_a 3. Shift fork
1. Reverse gear
2. Needle bearing Install a new needle bearing and shim.
3. Thrust washer
4. Countershaft bearing screw
Install countershaft with low gear and high gear

assembly.
vmr2006-022-096_a
1. Needle bearing
2. Shim
Insert a flat screwdriver in the slot of the index

lever, turn screwdriver clockwise and install shift
vmr2006-022-094_a
drum on neutral position as per following illustra-
1. Countershaft
2. Low gear tion.
3. High gear
Install a new shim onto bevel gear shaft, fork side.

Install bevel gear with sliding gear assembly to-
gether with shift fork.
NOTE: If a new bevel gear and output shaft are
used, it is necessary to verify the shim adjustment
prior to finalize assembly. Refer to ADJUSTMENT
in this subsection. If the existing bevel gear is
used, it is mandatory to use a new shim with the
same thickness, a new needle bearing and shim.
32 vmr2016-123
vmr2006-022-097_a vmr2006-022-098_a
1. Index lever 1. Shift shaft assembly

2. Shift drum 2. Isolating washer
3. Neutral position 3. Marks
Install shift fork then engage both shift fork pins

in their corresponding groove on the shift drum.
NOTE: Move sliding gears to facilitate engage-
ment of pins inside grooves.
vmr2006-022-101_a
1. Parking stop location

2. Reverse stop location
3. Neutral stop location
4. High gear stop location
5. Low gear stop location
Install shift shaft assembly.

NOTE: Marks on shift drum/isolating washer and
shift shaft must align.
vmr2006-022-099_a
1. Shift fork pins

2. Sliding gear
Install shift fork shaft.

NOTE: Run all gears as a final function check be-
fore installing center housing.
Now, close the housings by doing the following:
Clean all metal components in a solvent.
vmr2016-123 33
Gearbox housing mating surfaces are best TIGHTENING TORQUE

cleaned using a combination of LOCTITE CHISEL
(GASKET REMOVER) (P/N 413 708 500) and a brass Step A Hand tightened
Gear housing
brush. Brush a first pass in one direction then screws 10 N•m ± 1 N•m
Step B
make the final brushing perpendicularly (90°) to (89 lbf•in ± 9 lbf•in)
the first pass cross (hatch).
Install O-ring including distance sleeve on counter-
NOTICE Do not wipe with rags. Use a new shaft CVT side.
NOTICE Place O-ring including distance
IMPORTANT: When beginning the application of sleeve right away. Chamfered bore of distance
the gear housing sealant, the assembly and the sleeve has to face the gearbox.
save time.
faces.
Use a plexiglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in)),
available in arts products suppliers for printing,
and roll the sealant to get a thin uniform coat on
the plate (spread as necessary). When ready, ap-
ply the sealant on gear housing mating surfaces.
vmr2006-022-100_a
COUNTERSHAFT END CVT SIDE

1. O-ring
2. Distance sleeve
3. Countershaft end CVT side
Refer to OUTPUT SHAFT AND COUPLING

MECHANISM to install these components. Mea-
sure the output shaft backlash.
Installing the Gearbox

F12R17A
cedure.
Do not apply in excess as it will spread out inside
gear housing. Before gearbox installation check O-ring in bearing
cover if brittle, hard or damaged. Replace if nec-
NOTE: It is recommended to apply this specific
essary.
method, you may use your finger to uniformly dis-
tribute the sealant (using a finger will not affect
the adhesion).
Tighten gear housing screws in a crisscross se-
quence.
34 vmr2016-123
vmr2016-037-001_a
1. O-ring
2. Bearing cover
Tighten the three (3) nuts that attaching the gear-

box to the engine.
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
25 N•m ± 3 N•m
Gearbox retaining nuts
After installation refill gearbox oil, refer to PERI-

ODIC MAINTENANCE PROCEDURES.
vmr2016-123 35
Subsection 14 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS))
GEARBOX AND 4X4 COUPLING UNIT

(WITH GBPS)
SERVICE TOOLS
COUNTERSHAFT OIL SEAL PUSHER .......................................... 529 036 222 ........................................... 12
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 8
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 5, 9
HANDLE ........................................................................................ 420 877 650 ........................................... 12
OIL SEAL INSTALLER (GEARBOX) ............................................... 529 035 758 ........................................... 12
OIL SEAL INSTALLER ................................................................... 529 036 204 ........................................... 13

FLUKE RIGID BACK-PROBE ......................................................... TP88 ......................................... 5–7
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 27
LOCTITE 5910 ............................................................................... 293 800 081 ....................................... 9, 25
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ........................................... 25
PETAMO GREASE GHY 133N ...................................................... 420 899 271 ........................................... 11
SUPER LUBE GREASE.................................................................. 293 550 030 ....................................... 7, 10
vmr2016-124 1
The shaded parts are not serviceable.

10 ± 1 N•m Loctite 5910 Gearbox replacement is requied.
(89 ± 9 lbf•in)
25 ± 3 N•m 25 ± 3 N•m
(18 ± 2 lbf•ft) (18 ± 2 lbf•ft) Engine oil
10 ± 1 N•m
(89 ± 9 lbf•in)
Petamo
Engine Grease
oil
NEW 10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
Loctite 243
3 ± 0,3 N•m
(27 ± 3 lbf•in)
Engine oil
Engine oil
Engine oil
Loctite 5910
Engine oil
Engine oil
Engine oil
Engine oil
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)

tmr2015-023-001_a
2 vmr2016-124
10 ± 1 N•m
(89 ± 9 lbf•in)
NEW
Super Lube
Grease Petamo Grease
25 ± 3 N•m
(18 ± 2 lbf•ft) 3 ± 0,3 N•m
(27 ± 3 lbf•in)
5 ± 0,6 N•m Loctite 5910

(44 ± 5 lbf•in)
28 ± 3 N•m
(21 ± 2 lbf•ft)
Loctite 243
NEW
Loctite 648
20 ± 2 N•m
(15 ± 1.5 lbf•ft)
10 ± 1 N•m
(89 ± 9 lbf•in)
Petamo Grease
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 648
NEW
Engine oil

tmr2015-023-002_a
vmr2016-124 3
GENERAL GEARBOX OVERVIEW

GEARBOX IDENTIFICATION
Gearbox with GBPS
sensor.
Tmr2011-016-003_a
1. Gearbox position sensor (GBPS)

2. Right cover
3. Vehicle speed sensor (VSS)
4. Actuator
5. 4WD indicator switch
vmr2016-124-001_a
GEARBOX, RIGHT HAND SIDE

1. Gearbox position sensor
2. Output shaft
Gearbox with External Switches

indicator switches.
Tmr2011-016-004_a
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.
vmr2016-123-001_a
- Oil leakage from gearbox. Replace damaged gas-
GEARBOX, RIGHT HAND SIDE ket(s) and/or oil seal(s).
1. Gearbox position indicator switches
2. Output shaft
2. Defective bearings.
- Bearing(s) do(es) not turn smoothly. Replace
bearing(s).
3. Damaged or worn gears.
- Inspect gears for damages or missing teeth. Re-
place respective gears.
4 vmr2016-124
GEAR INDICATION FAILS VSS Access

1. Defective gearbox position sensor (GBPS). To reach the VSS, refer to BODY subsection and
- Perform a gearbox position sensor test. remove the following parts:
- Damaged wires. Repair as required. – Seat
– Console
GEAR(S) IS (ARE) HARD TO SHIFT – RH side panel.
1. Incorrect shift rod adjustment.
VSS Wire Identification
- Adjust shift rod (refer to SHIFT ROD in SHIFTER
subsection. COLOR -
COLOR -
WIRING
FUNCTION PIN SENSOR
4 WHEEL DRIVE INDICATION FAILS CONNECTOR
HARNESS
CONNECTOR
1. 4WD indicator switch failure.
- Test 4WD indicator switch. Replace as required. 12-volt
input from A RED VIOLET/BLUE
- Bad contact. Check for corrosion or loose con- fuse F5
nector.
- Damaged wires. Repair as required. Speed
signal
B WHITE PINK
4 WHEEL DRIVE DOES NOT ENGAGE OR (to cluster
DISENGAGE pin 9)
1. Defective 4WD switch. Ground GREEN/

C BLACK
(to ECM C3) BROWN
- Check 4WD switch operation.
2. Defective actuator. VSS Circuit Protection
- Test actuator.
CONDITION CIRCUIT PROTECTION
3. Damaged or worn shifting fork or sleeve.
Supplied with main Fuse 5 of fuse block 1
- Remove actuator and inspect shifting fork and relay activated (from main relay R2)
sleeve.
PROCEDURES Testing the VSS Input Voltage

1. Remove VSS connector cover.
VEHICLE SPEED SENSOR (VSS) 2. Set multimeter to Vdc.
VSS Location REQUIRED TOOL
The vehicle speed sensor is located on the right FLUKE 115 MULTIMETER (P/N 529 035 868)
housing of the gearbox behind the actuator.
3. Turn ignition switch ON.
REQUIRED TOOL
Tmr2011-016-006_a
1. Right housing of gearbox

2. Actuator
3. VSS (Vehicle Speed Sensor)
vmr2016-124 5
NOTE: Since we measure pulsating voltage, the

numeric display will continuously change. The
analog display may be easier to follow.
vmr2012-020-020_a
smr2005-056-010_a
1. VSS connector 1. Analog display
6. Measure voltage as per following table.

Removing the VSS
VEHICLE SPEED SENSOR INPUT VOLTAGE TEST Remove screw retaining the VSS.
RESULT
TEST PROBES
(KEY ON)
PIN A PIN C
VIOLET/BLUE GREEN/BROWN Battery voltage
wire wire
If voltage is not as specified, test positive and

ground circuits separately.
Testing the VSS Signal

1. Lift rear of vehicle so that rear wheels are off
the ground.
2. Set transmission to 2WD and to NEUTRAL.
Tmr2011-016-088_a
REQUIRED TOOL 1. Screw

2. VSS
Turn sensor and weave it out of the gearbox right
4. Turn ignition switch ON. cover.
6. Set multimeter to Vdc.
7. Measure voltage while slowly rotating rear
wheels by hand.
VEHICLE SPEED SENSOR SIGNAL TEST
RESULT
TEST PROBES (WHILE ROTATING
WHEELS)
Alternate reading
PIN B PIN C
between battery
WHITE wire BLACK wire
voltage and 0 Vdc
tmr2011-016-089_a
6 vmr2016-124
Installing the VSS

Pay attention to the following.
Lubricate VSS O-ring.
VSS O-RING
SUPER LUBE GREASE
Service product
(P/N 293 550 030)
Tighten VSS retaining screw to specification.

TIGHTENING TORQUE
10 N•m ± 1 N•m tmr2011-016-090_a
VSS retaining screw TYPICAL
1. Read data button
2. Setting tab
3. ECM tab
GEARBOX POSITION SENSOR
3. Make sure that gearbox is set to NEUTRAL po-
(GBPS) sition.
GBPS Reset 4. In the Gear Position Sensor area, click on the
When replacing the gearbox position sensor Reset button.
(GBPS), it is required to reset (re-zero) 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. vmr2016-124-101_a
NOTE: Ignition key must stay ON and emergency GEAR POSITION SENSOR
1. Reset button
engine stop switch must remain to RUN during
the reset procedure. Otherwise, the procedure A message will be displayed if the operation is
must be carried out again. successful.
2. In B.U.D.S., select the following: 5. Close and disconnect B.U.D.S.
– Read Data button
– Setting tab GBPS Access
– ECM tab. To reach the GBPS sensor, refer to BODY and re-
– Seat
– Console
– RH side panel.
Testing the GBPS Input Voltage

NOTE: Prior to conduct testing, check fault codes
in B.U.D.S.
Back-probe the GBPS connector using FLUKE
RIGID BACK-PROBE (P/N TP88) or equivalent.
Test as follow:
vmr2016-124 7
MULTIMETER PROBE POSITIONS VOLTAGE If resistance is out of specification, check wires

and connectors. Repair and reset fault codes.
PIN 1 and PIN 3 of the GBPS connector
If resistance is good and the other tests suc-
ceeded, replace the GBPS and reset fault codes.
5 volts NOTE: The GBPS must be reset.
Removing the GBPS

Set shift lever in NEUTRAL position.
Unplug GBPS connector.
If voltage is adequate, check GBPS signal wire.
Remove screws and withdraw GBPS.
If there is no voltage, check each GBPS input as
follows.
MULTIMETER PROBE POSITIONS VOLTAGE
GBPS connector (pin 1)
and battery ground
5 volts

and battery + terminal
Tmr2011-016-010_a
Battery
voltage 1. Screws
2. Gearbox Position Sensor (GBPS)
Installing the GBPS

If there is no voltage, check wires and connector Pay attention to the following details.
pins. Replace or repair defective parts and reset Shift lever must be in the NEUTRAL position.
fault codes.
Align GBPS with the flat on the shift drum shaft.
Testing the GBPS Signal Wire IMPORTANT: Do not force to install GBPS if shaft
Continuity flat is not properly aligned. If alignment is incor-
Unplug ECM connector and connect it to the rect, check shift rod adjustment.
adapter tool.
REQUIRED TOOL
ECM ADAPTER TOOL (P/N 529 036 166)
MULTIMETER PROBE RESISTANCE

POSITIONS @ 20°C (68°F)
and ECM adapter tool (pin D2)
Below 1
Tmr2011-016-011_a
1. Flat on shift drum shaft
8 vmr2016-124
TIGHTENING TORQUE NOTICE Do not apply sealant on switch

plunger, as it will lead to switch malfunction.
10 N•m ± 1 N•m
GBPS retaining screws
(89 lbf•in ± 9 lbf•in) TIGHTENING TORQUE
Reset the GBPS. Refer to GBPS RESET in this LOCTITE 5910 (P/N 293
Service product
subsection. 800 081)
3 N•m ± 0.3 N•m
Indicator switch
4WD INDICATOR SWITCH (27 lbf•in ± 3 lbf•in)
4WD Indicator Switch Access

ACTUATOR
To reach the 4WD indicator switch, refer to BODY
and remove the following parts: Actuator Access
– Seat To access the actuator, refer to BODY and remove
– Console the following parts:
– RH side panel. – Seat
– Console
Removing the 4WD Indicator Switch – RH side panel
Disconnect 4WD indicator switch connector. – RH footrest panel
Testing the Actuator

Check if the 2WD/4WD selector works properly.
REQUIRED TOOL

(P/N 529 035 868)
Unplug actuator connector.

Turn ignition key ON.
Set emergency engine stop switch to RUN.
Tmr2011-016-012_a
1. 4 WD indicator switch Measure voltage as follows.

2. Actuator
SWITCH
SWITCH WIRE VOLTAGE
Testing the 4WD Indicator Switch POSITION
Measure switch resistance as follows. 2WD WHITE/BLUE Battery

WHITE
4WD WHITE/BLACK voltage
SWITCH
SWITCH WIRE RESISTANCE
POSITION
If the selector is out of specifications, check
2WD BLACK/ Engine Close to 0 wires, connectors and replace the selector if nec-
4WD BEIGE ground Infinite (OL) essary.
If the selector is good, check the vehicle harness.
If the resistance is out of specification, replace the
4WD indicator switch. If the vehicle harness is good, replace the actua-
tor.
Installing the 4WD Indicator Switch
Removing the Actuator
Pay attention to the following details. NOTE: Before beginning any servicing on the ac-
tuator, make sure the vehicle is in 4WD position.
Take care do not damage indicator switch threads No need to remove engine from vehicle.
during installation.
Place a drain pan under actuator.
Apply carefully some sealant on threads of indica-
tor switch. Detach brake master cylinder from frame (Out-
lander only).
vmr2016-124 9
Installing the Actuator

Lubricate actuator O-ring.
ACTUATOR O-RING
SUPER LUBE GREASE
Service product
(P/N 293 550 030)
vmr2012-037-006_a
OUTLANDER ONLY
1. Remove retaining screws from master cylinder support
Vmr2015-123-003_a
1. Actuator O-ring
Ensure coupling fork is in 4WD position (posi-

tioned toward the front of vehicle).
vmr2012-037-007_a
OUTLANDER ONLY
1. Master cylinder moved apart
Remove actuator screws.
Tmr2011-016-026_a
1. Coupling fork in 4WD position
Align the actuator fork with the pin on coupling

fork then push the actuator in the housing. See
the following illustration to position the actuator
correctly.
Tmr2011-016-025_a
1. Actuator
2. Washer
3. Screw
Pull the actuator out of housing.
10 vmr2016-124
GEARBOX OIL SEALS

Gearbox Oil Seal Replacement
Replace oil seals if they are brittle, hard or dam-
aged.
A small flat screwdriver can be used to remove
most of these oil seals.
NOTICE Avoid scoring parts during oil seal
removal.
When replacing an oil seal, take this opportunity
Tmr2011-016-027_a
to inspect the following:
1. Actuator – Check bearings behind each oil seal for contam-
2. Actuator fork ination and/or metal shavings.
3. Coupling fork
– Check oil seal running surfaces for scratches.
Rotate the actuator counterclockwise until it ori-
Oil Seal Lubrication
ents itself to mounting position.
When installing or reinstalling oil seals, use
NOTICE Do not cut or break the actuator PETAMO GREASE GHY 133N (P/N 420 899 271) to:
O-ring. – Lubricate sealing lips all around.
Install all actuator screws and tighten them. – Fill up the room between sealing lips halfway
around the perimeter.
TIGHTENING TORQUE
25 N•m ± 3 N•m
Actuator screws
Connect actuator.
Lift the front of vehicle.
Turn front wheels. The front propeller shaft
should not turn (the PARK position must be se-
lected).
If the front propeller shaft turns, the actuator is not
installed correctly. Remove actuator and reinstall
it.
Set ignition switch to ON.
Set emergency engine stop switch to RUN. vmr2013-020-001_a
1. Sealing lips
Select the 2WD position. 2. Room between sealing lips
Turn front wheel again. The front propeller shaft
should turn easily. Countershaft Oil Seal
If the front propeller shaft does not turn, the ac- To replace the countershaft oil seal, remove:
tuator is not installed correctly. Remove actuator – Drive and driven pulleys
and reinstall it. – CVT air guide.
NOTICE Refill gearbox, refer to GEARBOX NOTE: When oil seal is removed also inspect
OIL FILLING PROCEDURE in PERIODIC MAIN- O-ring behind distance sleeve.
Install all other removed parts.
vmr2016-124 11
Tmr2011-016-013_a

2. Distance sleeve
vmr2012-020-005_a

2. Oil seal pusher
Shift Shaft Oil Seal

The shift shaft oil seal can be removed without
removing the gearbox from the vehicle.
To replace the shift shaft oil seal, refer to BODY
and remove:
– Seat
– Console
– RH side panel
– Shift plate from shift shaft (refer to SHIFTER).
Use a suitable tube with the proper diameter to
install the oil seal.
If gearbox housing is apart, use following tools for
Tmr2011-016-014_a
shift shaft oil seal installation.
1. Distance sleeve
2. O-ring REQUIRED TOOL
Install countershaft oil seal tool. OIL SEAL INSTALLER
(GEARBOX) (P/N 529 035 758)
REQUIRED TOOL
HANDLE (P/N 420 877 650)
COUNTERSHAFT OIL SEAL
PUSHER (P/N 529 036 222)
ing lip toward gearbox.
Shift Drum Shaft Oil Seal
To replace the shift drum shaft oil seal, remove
the GBPS (GEARBOX POSITION SENSOR). See
procedure in this subsection.
Use a suitable tube with the proper diameter to
install the oil seal.
ing lip toward gearbox.
Output Shaft Oil Seal
To replace the output shaft oil seal, proceed as fol-
lows:
12 vmr2016-124
Remove propeller shaft. Refer to REAR DRIVE REQUIRED TOOL

subsection.
OIL SEAL INSTALLER (P/N 529
036 204)
Flat washer (P/N 250 200 102)

M12 x 1.25 x 35 hexagonal screw
Tmr2011-016-015_a
1. Shift shaft oil seal

2. Shift drum shaft oil seal
tmr2011-016-020_a
Punch a sharp screwdriver through oil seal for re- 1. Output shaft oil seal
moval. 3. Flat washer (P/N 250 200 102)
4. M12 x 1.25 x 35 hexagonal screw
NOTE: Position screwdriver only in marked areas 5. Apply engine oil on outer diameter of oil seal
to avoid damaging the ball bearing behind oil seal
during removal. GEARBOX
Removing the Gearbox
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION for the proce-
dure.
Refer to CONTINUOUSLY VARIABLE TRANSMIS-
SION (CVT) subsection to remove following parts:
– CVT cover
– Drive and driven pulleys
– CVT air guide.
Drain gearbox. Refer to GEARBOX OIL DRAIN-
Tmr2011-016-016_a
ING PROCEDURE in PERIODIC MAINTENANCE
1. Marked areas for removal PROCEDURES subsection.
Remove ACTUATOR, see procedure in this sub-
Before beginning the installation ensure gearbox section.
is set to PARK position. Unscrew the four (4) nuts that attach the gearbox
Lubricate sealing lips, refer to OIL SEAL LUBRI- to the engine.
CATION in this subsection.
Apply engine oil on outer diameter of oil seal to
avoid damaging it during installation.
Place oil seal on output shaft and install it using
the following tools.
vmr2016-124 13
Tmr2011-016-038_a Tmr2011-016-043_a
LH SIDE OF ENGINE 1. 3 screws M6 x 35

1. Nut M8 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.
Tmr2011-016-039_a
RH SIDE OF ENGINE
1. Nut M8
Pull gearbox to separate it from engine.
Disassembling the Gearbox Tmr2011-016-044
POSITION FOR SOFT HAMMER

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.
Tmr2011-016-045
14 vmr2016-124
Index Lever and Index Washer

Set gearbox to NEUTRAL position.
Remove screw retaining the index washer to the
shift drum.
Tmr2011-016-075_a
1. Washer
2. Index lever
3. Step ring
4. Index spring
Tmr2011-016-073_a
1. Screw Main Shaft and Shift Forks

2. Index washer
Remove bearing pin, reverse intermediate gear
Insert a flat screwdriver in the slot of index lever. and thrust washers.
Turn screwdriver clockwise and remove index NOTE: Take care not to lose lower thrust washer
washer. during removal.
Tmr2011-016-074_a
Tmr2011-016-046_a
1. Index lever
2. Index washer 1. Bearing pin
3. Shift drum 2. Reverse intermediate gear
3. Needle bearing
Remove the index lever with washer, step ring 4. Thrust washers
and spring. Remove shift fork shaft.
Disengage shift forks from shift drum.
vmr2016-124 15
vmr2012-020-006_a
Tmr2011-016-047_a
1. Shifting sleeve (HIGH range gear)
1. Shift fork shaft 2. Shift fork
2. Shift fork
3. Shift drum
When required, remove from main shaft assem-
Remove main shaft assembly with shift fork. bly:
– Snap ring (discard)
– HIGH range gear
– LOW range gear
– Needle bearings.
Tmr2011-016-048_a
1. Main shaft assembly

2. Shift fork
Remove shifting sleeve (HIGH range gear) and vmr2012-020-007_a

shift fork. 1. Snap ring
2. Free pinion (HIGH range gear)
3. Free pinion (LOW range gear)
4. Needle bearing
Remove from main shaft assembly:

– Shifting sleeve (LOW/REVERSE range gear)
– REVERSE range gear
– Needle bearing.
16 vmr2016-124
Tmr2011-016-032

vmr2012-020-008_a
1. Snap ring
2. Shifting sleeve (LOW/REVERSE range gear)
3. Snap ring
4. Free pinion (REVERSE range gear)
5. Needle bearing
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.
Tmr2011-016-033
Shift Shaft and Shift Drum

Withdraw shift shaft assembly.
Tmr2011-016-031_a
1. 5 screws M8 x 55
2. 2 screws M6 x 85
3. 2 screws M6 x 55
4. 8 screws M6 x 35 Tmr2011-016-071_a

To remove cover, use 2 big screwdrivers.
Remove screw retaining the shifting intermediate
gear.
vmr2016-124 17
Tmr2011-016-072_a Tmr2011-016-077_a
1. Screw 1. Shift drum

2. Washer 2. Thrust washer
4. Dowel pin Output Shaft and 4x4 Coupling Mechanism
Remove shift fork shaft. Remove output shaft from center housing and
Disengage shift forks from shift drum. withdraw 4x4 coupling sleeve.
NOTICE Use a soft hammer to remove output
shaft.
Tmr2011-016-076_a Tmr2011-016-034_a
1. Shift fork shaft 1. Output shaft

2. Shift fork 2. 4x4 coupling sleeve
3. Shift drum 3. Soft hammer
Remove shift drum and thrust washer. Remove hexagonal screw, coupling fork shaft and
coupling fork from right cover.
18 vmr2016-124
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 a blind hole
bearing puller.
Remove screw securing the countershaft bearing
in the left cover.
For ball bearings of countershaft (left cover) and
main shaft (center housing) push with a suitable
puller from outside in.
vmr2015-123-004_a
1. Hexagonal screw
2. Coupling fork shaft
3. Coupling fork
Countershaft
Use a soft hammer to push out countershaft from
gearbox CVT side.
Remove distance sleeve and O-ring.
Tmr2011-016-052_a

2. Right cover
Tmr2011-016-042_a
1. Countershaft
2. Distance sleeve
3. O-ring
Gearbox Bearings
If necessary heat housing up to 100°C (212°F) be- Tmr2011-016-053_a
fore removing ball bearings. 1. Screw

3. Ball bearing main shaft
WARNING 4. Left cover
before heating.
vmr2016-124 19
DIAMETER FREE PINION

29.000 mm to 29.013 mm
NEW
(1.1417 in to 1.1422 in)
Shifting Sleeves
Check shifting sleeves for worn inner splines and
rounded or damaged engagement dogs.
Tmr2011-016-054_a
1. Ball bearing main shaft

2. Center housing
Inspecting the Gearbox

Always verify for the following when inspecting
gearbox components:
– Gear teeth damage
– Worn or scoured bearing surfaces
– Rounded engagement dogs and slots
– Worn shift fork engagement groove vmr2012-020-009_a
– Worn splines on shafts and shifting sleeves. TYPICAL
1. Inner splines
Bearings 2. Engagement dogs
Check if ball bearings turn freely and smoothly. Measure the width of shift fork engagement
Check all bearings, bearing points, tooth flanks groove.
and taper grooves.
Free Pinions
NOTE: Always replace snap rings and use special
pliers to install them.
Check free pinions for wear.
Tmr2013-020-001_a
TYPICAL
1. Shifting sleeve
A. Width of shift fork engagement groove
vmr2006-022-080_a
TYPICAL
1. Micrometer
2. Free pinion
20 vmr2016-124
WIDTH OF SHIFT FORK ENGAGEMENT GROOVE COUNTERSHAFT BEARING JOURNALS

5.30 mm to 5.40 mm MAG SIDE
NEW
(.209 in to .213 in)
CVT SIDE
24.977 mm to 24.990 mm
NEW
(.983 in to .984 in)
Shafts
Check bearing pin of reverse intermediate gear for
wear.
Check main shaft for wear.
Tmr2011-016-057_a
1. Bearing pin
A. Outer diameter
BEARING PIN OUTER DIAMETER Tmr2011-016-059_b
24.987 mm to 25.000 mm A. Bearing journal MAG side

NEW B. Free pinion bearing
(.984 in to .984 in) C. Bearing journal CVT side
MAIN SHAFT
Check countershaft bearing journals for wear. FREE PINION BEARING
24.987 mm to 25.000 mm
NEW
(.984 in to .984 in)
BEARING JOURNAL CVT/MAG SIDE
16.980 mm to 16.991 mm
NEW
(.669 in to .669 in)
Shift Shaft
Check shift shaft for worn splines and gears.
Tmr2011-016-058_a
A. MAG side
Check shift shaft spring for damages.
B. Bearing journal CVT side
Shift Drum
COUNTERSHAFT BEARING JOURNALS NOTICE Do not disassemble shift drum.
MAG SIDE
Check if shifting gates move easily on shift drum
19.977 mm to 19.990 mm splines and check condition of springs.
NEW
(.786 in to .787 in)
Check shift drum tracks for scouring or heavy
SERVICE LIMIT 19.973 mm (.786 in) wear, like rounded engagement slots.
vmr2016-124 21
Output Shaft
Check output shaft and its gear for cracks, bend,
pitting or other visible damages.
Check output shaft splines for wear or other dam-
ages.
Check if the output shaft bearings turn freely and
smoothly.
Replace oil seal if brittle, hard or damaged.
4x4 Coupling Sleeve
Tmr2011-016-080_a Check splines of coupling sleeve for wear or other
1. Track for the low/reverse range gear shift fork damages.
2. Track for the high range gear shift fork
3. Springs
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.
vmr2006-022-030_a
1. Inspect splines
Measure the coupling sleeve groove width.
vmr2006-022-075_a
1. Micrometer
A. Shift fork claw thickness
vmr2006-022-031_a
A. Groove width
SHIFT FORK CLAW THICKNESS
5.10 mm to 5.20 mm COUPLING SLEEVE GROOVE WIDTH
NEW
(.201 in to .205 in)
5.25 mm to 5.35 mm
NEW
Shift Fork Shaft
Check shift fork shaft for visible damage or wear. Coupling Fork
Check if shift fork shaft is straight. Check coupling fork for visible damage, wear or
bent coupling fork claws.
Index Lever and Parking Lever
Check coupling fork claw thickness.
Index lever with roller must move freely.
Check parking lever for cracks or other damages.
22 vmr2016-124
vmr2006-022-032_a
1. Coupling fork
2. Micrometer
vmr2012-020-011_a
COUPLING FORK CLAW THICKNESS 1. Main shaft
2. Free pinion (REVERSE range gear)
4.95 mm to 5.05 mm 3. Snap ring
NEW 4. Shifting sleeve (LOW/REVERSE range gear)
(.195 in to .199 in)
5. Shifting dogs (REVERSE range gear)
Collars of free pinion (LOW range gear) and free
pinion (HIGH range gear) must point together.
Assembling the Gearbox
The assembly of gearbox is essentially the reverse
of disassembly procedure. However, pay atten-
tion to the following details.
Gearbox Bearings
Unless otherwise instructed, never use hammer
to install ball bearings. Use press machine only.
If necessary heat housings up to 100°C (212°F)
before installing ball bearings.
WARNING
before heating.
Tmr2013-020-002_a
1. Free pinion (LOW range gear), 44 T

Place new bearing in freezer for 10 minutes be- 2. Collar
fore installation. 3. Free pinion (HIGH range gear), 36 T
4. Collar
Use a suitable installer for installing ball bearings
of countershaft and main shaft. Place shifting sleeve (HIGH range gear) with shift
NOTE: Place gearbox housings on a wood stand fork in the center of on main shaft bearing in cen-
before installing ball bearings. ter housing.
Install new oil seals with the proper installer (refer
to OIL SEALS in this subsection).
Main Shaft and Shift Forks
Install NEW snap rings.
NOTE: Ensure snap rings are installed in the
grooves properly.
Install free pinion (REVERSE range gear) and shift-
ing sleeve (LOW/REVERSE range gear) properly.
vmr2016-124 23
vmr2012-020-006_a Tmr2011-016-075_b
1. Shifting sleeve (HIGH range gear) 1. Index spring

2. Shift fork 2. Step ring
3. Index lever
4. Washer
Carefully fit main shaft assembly with shift fork 5. Screw
(LOW/REVERSE range gear) into inner splines of
shifting sleeve (HIGH range gear). Install index washer on shift drum.
Install reverse intermediate gear. Insert a flat screwdriver in the slot of the index
lever, turn screwdriver clockwise and engage
lever in index washer in NEUTRAL position as per
following illustration.
Tmr2011-016-046_a
1. Bearing pin
2. Reverse intermediate gear
3. Needle bearing
4. Thrust washers
Finally engage shift forks in shift drum and install

shift fork shaft. Tmr2011-016-086_a
1. Index lever
NOTE: Run all gears as a final function check be- 2. Index washer
fore installing left housing. 3. Neutral position
4. High range gear position
5. Low range gear position
Index Lever and Index Washer 6. Parking position
Fit step ring into index lever. 7. Reverse range gear position
Output Shaft and 4x4 Coupling Mechanism

Install coupling sleeve onto the output shaft.
Place the output shaft with oil seal and coupling
sleeve into the center housing.
NOTE: If same oil seal is installed, turn oil seal 90°
offset to its original position to avoid leakage at
housing mating surface.
24 vmr2016-124
Install coupling fork, coupling fork shaft and Clean all metal components in a solvent.
hexagonal screw in right cover before applying Gearbox housing mating surfaces are best
sealant to the mating surface. cleaned using a combination of LOCTITE CHISEL
(GASKET REMOVER) (P/N 413 708 500) and a brass
brush. Brush a first pass in one direction then
make the final brushing perpendicularly (90°) to
the first pass cross (hatch).
IMPORTANT: When beginning the application of
the gear housing sealant, the assembly and the
save time.
Vmr2015-123-002_a faces.
1. Coupling fork Use a plexiglass plate and apply some sealant
2. Coupling fork shaft
3. Hexagonal screw on it. Use a soft rubber roller (50 mm - 75 mm
(2 in - 3 in)), available in arts products suppliers for
Shift Shaft and Shift Drum printing, and roll the sealant to get a thin uniform
Install shift drum and shift shaft. coat on the plate (spread as necessary). When
Install shifting intermediate gear. Align its marks ready, apply the sealant on gear housing mating
with the marks on shift drum gear and shift shaft. surfaces.
Tmr2011-016-087_a F12R17A

2. Shifting intermediate gear Do not apply in excess as it will spread out inside
3. Shift drum gear
4. Marks gear housing.
Engage both shift fork pins in their corresponding NOTE: It is recommended to apply this specific
groove on the shift drum. sealant as described here to get a uniform appli-
Install shift fork shaft. method, you may use your finger to uniformly dis-
NOTE: Turn gears to validate proper operation. tribute the sealant (using a finger will not affect
the adhesion).
Sealing Compound Application
NOTE: Unless otherwise specify, the procedure Left Cover
to apply the sealant is the same for right or left Apply sealing compound on mating surfaces of
cover. central housing. Refer to SEALING COMPOUND
APPLICATION.
vmr2016-124 25
At installation of left cover, engage parking lock

lever slot onto index washer pin.
Tmr2011-016-067_a
COUNTERSHAFT END CVT SIDE

1. O-ring
2. Distance sleeve
3. Countershaft end CVT side
Right Cover
Tmr2011-016-065_a
1. Left cover Apply sealing compound on mating surfaces of

2. Parking lock lever slot central housing. Refer to SEALING COMPOUND
3. Index washer pin
APPLICATION.
Install all screws on left cover and tighten them as To install the right cover align the coupling fork
per following sequence. with the groove in the coupling sleeve.
Install all screws on right cover and tighten them
as per following sequence.
Tmr2011-016-043_b
TIGHTENING TORQUE
Tmr2011-016-031_b
10 N•m ± 1 N•m
Left cover - M6 screws
(89 lbf•in ± 9 lbf•in) TIGHTENING TORQUE
10 N•m ± 1 N•m
Install O-ring including distance sleeve on counter- Right cover - M6 screws
shaft CVT side.
25 N•m ± 3 N•m
NOTICE Place O-ring including distance Right cover - M8 screws
sleeve right away. Chamfered bore of distance
sleeve has to face the gearbox. Install the actuator, refer to ACTUATOR.
Installing the Gearbox

Pay attention to following.
26 vmr2016-124
Before gearbox installation check O-ring in bearing

cover if brittle, hard or damaged. Replace if nec-
essary.
Tmr2011-016-040_a
1. Bearing cover
2. O-ring
Tighten the four (4) nuts that attach the gearbox

to the engine.
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
25 N•m ± 3 N•m
Gearbox retaining nuts
After installation, refill gearbox oil. Refer to PERI-

ODIC MAINTENANCE PROCEDURES.
vmr2016-124 27
Subsection 15 (SHIFTER (GEARBOX WITH EXTERNAL SWITCHES))
SHIFTER (GEARBOX WITH EXTERNAL

SWITCHES)
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 2
Loctite 243
NEW
5 ± 1 N•m
(44 ± 9 lbf•in) NEW Outlander CE models
NEW
NEW
10 ± 2 N•m
(89 ± 18 lbf•in)
NEW
NEW
9 ± 1 N•m
vmr2016-125-001_a
vmr2016-0125 1
PROCEDURES
HANDLE
Handle Removal
vmr2015-024-004_a
SHIFT LEVER POSITION
3. Secure vehicle using wheel chocks.

4. Remove parts as indicated in following illustra-
tions.
vmr2015-024-002_a
Step 1: Loosen lock nut

Step 2: Unscrew shift lever handle
Handle Installation
SERVICE PRODUCT WHERE USED
LOCTITE 243 (BLUE)
Shift lever threads
(P/N 293 800 060)
SHIFT LEVER
Shift Lever Access
1. Refer to BODY subsection and remove the fol-
lowing components: vmr2015-024-003_a
– Seat 1. Shift lever handle

– Console
– RH side panel.
Shift Lever Removal

1. Remove body parts as required. Refer to SHIFT
LEVER ACCESS in this subsection.
2. Place shift lever in NEUTRAL position.
vmr2015-024-006_a
TYPICAL
1. Remove spring
2 vmr2016-0125
Check ball joint condition.

Replace all damaged parts.
Shift Lever Installation

Adjust shift lever handle as per following illustra-
tion.
vmr2015-024-005_a
TYPICAL
vmr2012-021-005_a
SHIFT LEVER HANDLE ALIGNMENT

1. Handle
2. Ridge
A. Handle parallel with ridge
Check if shift lever works properly in all positions.

Ensure throttle cable does not interfere with shift
vmr2015-024-007_a
lever in all positions.
TYPICAL NOTE: Shift lever must be perfectly centered
with the neutral position indicator when transmis-
sion is engaged in neutral.
vmr2015-024-008_a
TYPICAL
1. Locking tie to cut
vmr2015-024-004_a
5. Remove shift lever with shift lever support. SHIFT LEVER ALIGNMENT WITH NEUTRAL POSITION
INDICATOR
Shift Lever Inspection
If adjustment is required, refer to SHIFT ROD AD-
Check shift lever for bending or cracks. JUSTMENT in this subsection.
Check spring and bushing condition.
vmr2016-0125 3
SHIFT ROD
Shift Rod Adjustment
NOTICE Move vehicle back and forth to en-
sure gearbox is set in neutral position.
4. Loosen shift rod adjustment nuts.
NOTE: Be aware that a nut has LH threads.
vmr2012-021-006_a
SHIFT LEVER CENTERED WITHIN NEUTRAL NOTCH

A. Shift lever
B. Neutral notch
6. Move shift lever in R position then in H position.

8. Check if shift lever is properly centered in neu-
tral notch. Readjust as required.
9. Hold adjuster steady and tighten lock nuts.
vmr2015-037-003_a
1. Adjustment nuts
5. Turn rod adjuster to center shift lever in neutral

notch.
vmr2015-037-002_a
1. Adjuster lock nuts tightened
10. Test the shifter to confirm that the system

works properly in all positions.
NOTE: Ensure shift rod ball joint is parallel with
shift plate. It may be necessary to realign shift rod
ball joint to ensure freedom of movement.
vmr2015-037-003_b
1. Shift rod adjuster
4 vmr2016-0125
3. Trace an index mark on shift plate and shift

shaft.
vmr2015-037-004_a
1. Shift rod ball joint

2. Shift plate
A. Parallel within +/- 5°
vmr2015-037-006_a
WARNING 1. Trace a mark on both parts
After adjustment, make sure the PARK posi-
4. Remove shift plate nut and bolt.
tion is also properly set.
SHIFT PLATE
Shift Plate Removal
NOTE: Do not remove shift plate needlessly.
lowing components:
– Seat
– Console
– RH side panel
2. Remove shift rod from shift plate.
vmr2015-037-007_a
1. Shift plate nut
5. Remove shift plate.
Shift Plate Inspection

Check shift plate for:
– Cracks
– Bending
– Spline condition.
Shift Plate Installation

vmr2015-037-005_a
1. Bolt cedure. However, pay attention to the following.
2. Spacer
3. Nut Place gearbox in NEUTRAL position before shift
plate installation.
vmr2016-0125 5
Position shift plate with the marking "ATV OUT" TIGHTENING TORQUE
visible outward.
9 N•m ± 1 N•m
Align shift plate using marks previously traced. Shift plate nut
If there are no index marks, adjust shift plate as
per following illustrations.
A
OU
T
ATV
3
4
vmr2015-037-010_a
SHIFT PLATE ALIGNMENT

1. "ATV OUT" marking this side
2. Forward edge of shift plate
3. Horizontal plane (top forward surface crankcase)
4. Center of bolt (secondary alignment reference)
A. 110° +/- 2.5°
Ensure that shift shaft protrudes shift plate as per

illustration.
vmr2015-037-009_a
1. Shift shaft end

2. Shift plate
A. 2.5 mm ± 1 mm (.1 in ± .040 in)
Adjust shift rod, refer to SHIFT ROD ADJUST-

MENT in this subsection.
Tighten shift plate nut to specification.
6 vmr2016-0125
Subsection 16 (SHIFTER (GEARBOX WITH GBPS))
SHIFTER (GEARBOX WITH GBPS)

SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 2
Loctite 243
NEW
5 ± 1 N•m
(44 ± 9 lbf•in) NEW Outlander CE models
NEW
NEW
10 ± 2 N•m
(89 ± 18 lbf•in)
NEW
NEW
9 ± 1 N•m
vmr2016-126-001_a
vmr2016-126 1
PROCEDURES
HANDLE
Handle Removal
vmr2012-021-002_a
1. Unhook
6. Detach shift rod from shift lever.
vmr2015-024-002_a
Step 1: Loosen lock nut

Step 2: Unscrew shift lever handle
Handle Installation
SERVICE PRODUCT WHERE USED
LOCTITE 243 (BLUE)
Shift lever threads
(P/N 293 800 060)
SHIFT LEVER
Shift Lever Access
vmr2012-021-003_a
1. Refer to BODY subsection and remove the fol- 1. Detach
lowing components:
– Seat 7. Detach shift lever support.
– Console
– RH side panel.
Shift Lever Removal

4. Unscrew shift lever handle.
5. Unhook spring.
vmr2012-021-004_a
1. Remove bolts
8. Remove shift lever.
2 vmr2016-126
Shift Lever Inspection

Check shift lever for bending or cracks.
Check spring and bushing condition.
Check ball joint condition.
Replace all damaged parts.
Shift Lever Installation

Adjust shift lever handle as per the following illus-
tration.
vmr2012-021-007_a
TYPICAL — SOME PARTS REMOVED FOR CLARITY

1. Adjustment nuts
5. Turn rod adjuster to center shift lever in neutral

notch.
vmr2012-021-005_a
SHIFT LEVER HANDLE ALIGNMENT

1. Handle
2. Ridge
A. Handle parallel with ridge
Check if shift lever works properly in all positions.

Ensure throttle cable does not interfere with shift
lever in all positions.
NOTE: Shift lever must be perfectly centered
with the neutral mark when transmission is en- vmr2012-021-006_a
gaged in neutral. SHIFT LEVER CENTERED WITHIN NEUTRAL NOTCH

A. Shift lever
If adjustment is required, refer to SHIFT ROD AD- B. Neutral notch
JUSTMENT in this subsection.
6. Move shift lever in R position then in H.
SHIFT ROD 7. Place shift lever in NEUTRAL position.
8. Check if shift lever is properly centered in neu-
Shift Rod Adjustment tral notch. Readjust as required.
9. Hold adjuster steady and tighten lock nuts.
NOTICE Move vehicle back and forth to en- 10. Test the shifter to confirm that the system
sure gearbox is set in neutral position. works properly in all positions.
2. Secure vehicle using wheel chocks. NOTE: Make sure the ball joint is properly aligned
with the shift plate. It may be necessary to realign
shift rod ball joints to allow easy movement.
4. Loosen shift rod adjustment nuts.
NOTE: Be aware that a nut has LH threads.
vmr2016-126 3
WARNING 4. Remove shift plate nut and bolt.

After adjustment, make sure that PARK posi-
tion works properly.
SHIFT PLATE
Shift Plate Removal
NOTE: Do not remove shift plate needlessly.
lowing components:
– Seat
– Console
– RH side panel
2. Remove shift rod from shift plate.
vmr2012-021-008_c
1. Shift plate nut
5. Remove shift plate.
Shift Plate Inspection

Check shift plate for:
– Cracks
– Bending
– Spline condition.
Shift Plate Installation

Place gearbox in NEUTRAL position before shift
vmr2012-021-008_a
plate installation.
1. Remove nut Position shift plate with the marking "ATV OUT"
visible outward.
3. Trace an index mark on shift plate and shift
shaft. Align shift plate using marks previously traced.
If there is no mark, adjust shift plate as per follow-
ing illustrations.
vmr2012-021-008_b
1. Trace a mark on both parts
4 vmr2016-126
vmr2012-021-010_a
1. "ATV OUT" marking this side

A. 34°
Ensure that shift shaft protrudes shift plate as per

illustration.
vmr2012-021-011_a
1. Shift shaft end

2. Shift plate
A. 2.5 mm ± 1 mm (.1 in ± .040 in)
Adjust shift rod, refer to SHIFT ROD ADJUST-

MENT in this subsection.
Tighten shift plate nut to specification.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Shift plate nut
vmr2016-126 5
Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS))
ENGINE MANAGEMENT SYSTEM (EMS)

Engine with Gearbox using External Switches
VSS 4WD
GBPS OPS
CTS CPS
INJ 2
ECM INJ 1
IACV
MAPTS
TPS IGN COIL
IN COOLING FAN
ECM IGN SW
START SW
OUT STARTER SOLENOID
ECM
FUEL PUMP
vmr2015-064-001_aen
vmr2016-127 1
Engine with Gearbox using External Switches
HIC2
ECM
HIC1
IACV
TPS
MAPTS
CTS
INJ1
INJ2 BA
VSS CPS
SD
OPS
GBPS
MD
vmr2015-064-002_a
2 vmr2016-127
Engine with Gearbox using GBPS
VSS 4WD
GBPS OPS
CTS CPS
INJ 2
ECM INJ 1
IACV
MAPTS
TPS IGN COIL
IN COOLING FAN
ECM IGN SW
START SW
OUT STARTER SOLENOID
ECM
FUEL PUMP
vmr2015-125-001_a
vmr2016-127 3
Engine with Gearbox using GBPS
HIC2
ECM HIC1
IACV
TPS
CPS INJ1
BA
CTS
MAPTS
INJ2
VSS
OPS
SD
GBPS
MD
vmr2015-125-002_a
4 vmr2016-127
ABBREVIATION DEFINITION
BA Ignition coil
CPS Crankshaft position sensor
CTS Coolant temperature sensor
ECM Electronic control module
GBPS Gear box position sensor
HIC1‡ Harness interconnect 1
HIC2‡ Harness interconnect 2
IACV Idle air control valve vmr2008-132-005
TYPICAL - ECM
INJ1 Injector 1 (front)
The ECM is located behind the LH panel.
INJ2 Injector 2 (rear)
Manifold absolute pressure and
MAPTS
temperature sensor
MD 4WD Actuator
OPS Oil pressure switch
SD 4WD Signal
TPS Throttle position sensor
VSS Vehicle speed sensor
‡Refer to applicable WIRING HARNESS AND
CONNECTORS subsection for the vehicle harness.
GENERAL
vmr2012-022-002_a
SYSTEM DESCRIPTION LH PANEL REMOVED

1. ECM location
The HIC# connectors connect the vehicle harness
to the powertrain harness. The ECM reads input signals from various
switches, controls, and sensors, that it compares
There are 6 main systems that are controlled by
to pre-determined parameters, makes computa-
the engine management system (EMS):
tions, and provides control signal outputs required
1. Electronic Fuel Injection (EFI) for proper engine management.
2. Cooling system (cooling fan)
The ECM also interacts through CAN bus with
3. Ignition system the gauge module for various functions, informa-
4. Starting system tion exchange and display of messages. Refer
5. Fuel pump system to CONTROLLER AREA NETWORK (CAN) and
6. D.E.S.S. system. LIGHTS, GAUGE AND ACCESSORIES subsec-
tions.
NOTE: For further information related to these
systems, refer to the applicable subsection. The ECM also features a permanent memory that
will store the information on the various ignition
The ECM (Engine Control Module) is the central
keys programmed to the vehicle, fault codes, cus-
point of the engine management system.
tomer information, and other engine information,
even when the battery is removed from the vehi-
cle.
vmr2016-127 5
Engine RPM Limiter that they can be monitored. Some problems will
The ECM limits the maximum engine speed with turn on a warning lamp or will set the engine in
the shifter selected to any position. It uses the limp home mode. Refer to DIAGNOSTIC AND
CPS and the GBPS for this function. FAULT CODES section for more information.
An override switch, on the handlebar, allows the
engine to be run at a higher speed than the RPM
limiter when more power is needed in reverse op-
eration. Refer to LIGHTS, GAUGE AND ACCES-
SORIES.
Vehicle Speed Limiter
The ECM will limit the maximum vehicle speed.
For this purpose, the ECM uses the VSS and the
GBPS.
Drowned Mode (Flooded Engine)

If the engine is fuel-flooded and does not start,
this special mode can be activated to prevent fuel
injection and ignition while cranking. Proceed as
follows to activate it.
With the ignition key set to ON and the engine
stopped, press and HOLD the throttle lever to
WOT position (wide open throttle).
Press the start button. Drowned mode is now on.
Releasing the throttle lever will bring back the nor-
mal mode.
Monitoring System
The ECM monitors the electronic components
of the fuel injection system and also parts of the
electrical system.
For more information, refer to DIAGNOSTIC AND
FAULT CODES.
Limp Home Mode
The ECM may automatically set default parame-
ters to the engine management to ensure the ad-
equate operation of the engine if a component of
the fuel injection system is not operating prop-
erly. The engine will operate with reduced per-
formance to protect the engine. In more severe
cases, the engine RPM will be limited, also to pro-
tect the engine.
These performance-reduced modes allow the
rider to go back home which would not be oth-
erwise possible. Refer to the DIAGNOSTIC AND
FAULT CODES subsection.
Diagnostic Mode
The ECM features a self-diagnostic mode when
the ignition key is turned on. However, some
components need the engine to be running so
6 vmr2016-127
Subsection XX (CONTROLLER AREA NETWORK (CAN))
CONTROLLER AREA NETWORK (CAN)

GENERAL
SYSTEM DESCRIPTION
The CAN (Controller Area Network) protocol is an
ISO standard for serial data communication. The
CAN bus links the ECM, multifunction gauge and
DPS module together so that they can communi-
cate to each other and interact as required. The
components (modules) are connected together
by 2 wires and are in constant communication
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 de-
tected, a module (ECM, multifunction gauge or
DPS) may generate a fault code, which it trans-
mits through the CAN bus as a signal. The fault
signal may be used for various functions such
as triggering the display of an error message
in the multifunction gauge cluster, turning on a
fault indicator light, limiting or inhibiting vehicle or
engine operation, or viewed using the B.U.D.S.
software for troubleshooting.
vmr2012-023-001_aen
CLUSTER: Multifunction Gauge

DB: Diagnostic Connector
ECM: Engine Control Module
DPS: Dynamic Power Steering
WHITE/BEIGE: (wire color code)
BEIGE/GREEN: (wire color code)
vmr2013-024 1
Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.)
COMMUNICATION TOOLS AND

B.U.D.S.
SERVICE TOOLS
DIAGNOSTIC CABLE .................................................................... 710 000 851 ......................................... 1, 3
MPI-2 INTERFACE CARD .............................................................. 529 036 018 ............................................. 1
MPI-3 INTERFACE CARD .............................................................. 529 036 353 ............................................. 1
GENERAL Multi-Purpose Interface Card

Refer to PROCEDURES for instructions on the
Connection Troubleshooting
communication tools. MPI Status Lights
If communication problems occur, refer to TROU- The MPI card includes 2 status lights that indicate
BLESHOOTING in this subsection. the connection condition: USB and CAN. Both
lights must be GREEN to function properly. Oth-
REQUIRED TOOLS erwise, refer to the following charts.
MANDATORY TOOLS
A personal computer (laptop or desktop)
MPI-2 INTERFACE CARD

(P/N 529 036 018)
OR
MPI-3 INTERFACE CARD (P/N 529 vdd2006-001-151_b
036 353) MPI-2 CARD
DIAGNOSTIC CABLE
(P/N 710 000 851)
OPTIONAL TOOL
USB
Extension cable
available at electronic retail outlets.
Do not exceed 7.5 m (25 ft) CAN
TROUBLESHOOTING
vmr2016-128-001_a
DIAGNOSTIC TIPS MPI-3 CARD
IMPORTANT: Make sure all connections are Prerequisite for USB Communication:
made and vehicle is powered up before starting – PC Computer turned on.
B.U.D.S. to allow proper communication between
– MPI card connected to PC computer.
the vehicle and the BRP Utility and Diagnostic
Software (B.U.D.S.)
vmr2016-128 1
USB LIGHT If one or more “ECU” is not communicating with

the MPI card, refer to DIAGNOSTIC AND FAULT
STATUS WHAT TO DO CODES.
Check USB connection between
Light is MPI card and PC computer.
No Vehicle is Detected
OFF Check USB operation on PC computer If an “X” is shown in the status bar and the pro-
(hardware or USB drivers) tocol indication is blinking between Kw2000 500K
Connections are GOOD. and KW2000, it means that no "ECU" is communi-
Light is cating with the MPI card.
Communication can take place
GREEN
on USB side
Prerequisite for CAN Communication:

– MPI card connected to diagnostic connector on
vehicle.
– Ignition key installed and turned to ON (electri-
cal system powered up without engine started). rmr2010-020-009
– B.U.D.S. started and logged on.

Check the following:
CAN LIGHT – Connections between the PC computer and the
STATUS WHAT TO DO vehicle.
– The multifunction gauge is powered up.
Light is Check connection between MPI card
OFF and diagnostic connector on vehicle If B.U.D.S. does not automatically exit the follow-
ing message box, click the Retry button. This will
Light is Check CAN wires/connectors on
manually establish the communication with the
RED vehicle
vehicle.
Connections are GOOD.
Light is
Communication can take place
GREEN
on CAN side
Communication Problems when Using

B.U.D.S.
rmr2015-124-005
Missing Module
Ensure the appropriate number of modules is PROCEDURES
shown at the bottom of B.U.D.S. screen.
MODEL NUMBER OF MODULES MULTI-PURPOSE INTERFACE
Models
2
CARD (MPI-2 OR MPI-3)
without
(ECM and multifunction gauge) The MPI (Multi-Purpose Interface) in conjunction
DPS
with the diagnostic cable is used with B.U.D.S. to
Models 3 communicate with the ECM (engine control mod-
with DPS (ECM, DPS and multifunction gauge) ule) and other modules.
MPI Card Power

The MPI card uses the power from the PC com-
puter's USB port.
Diagnostic Connector Location

vmr2016-128-002_a
The 6-pin diagnostic connector is located under
TYPICAL
the seat, stored in it's protective cap.
1. Number of modules
2 vmr2016-128
mmr2006-079-200
vmr2012-023-003_a
MPI CARD CABLE CONNECTED TO USB PORT
1. Diagnostic connector
6. Use B.U.D.S. as described further in B.U.D.S.
Connecting the PC to the Vehicle SOFTWARE topic
WARNING B.U.D.S. SOFTWARE
If the computer you are using is connected
to the 110 Vac power outlet, there is a poten- B.U.D.S. is designed for:
tial risk of electrocution when working in con- – Programming ignition key(s) to the vehicle
tact with water. Be careful not to touch water – Monitoring some electrical and electronic com-
while working with the VCK. ponents
– Activating certain components for diagnostic
1. Locate the 6-pin diagnostic connector, refer to purposes
DIAGNOSTIC CONNECTOR LOCATION in this – Updating electronic module software
subsection. – And, to carry out setting changes.
2. Disconnect the 6-pin diagnostic connector from Always use the latest applicable B.U.D.S. version
it's holder (protective cap). available on Knowledge Center.
3. Connect one end of the DIAGNOSTIC CABLE
(P/N 710 000 851) to the vehicle connector. Reading the Electronic Control Units
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 CONNECTING THE PC TO
THE VEHICLE in this subsection.
1. Turn ignition switch to ON. Do not start the en-
gine.
2. Set the emergency engine stop switch to RUN.
710000851 3. Start B.U.D.S. and logon.
DIAGNOSTIC CABLE CONNECTED TO VEHICLE
4. Ensure the status bar shows the appropriate
4. Connect the other end of diagnostic cable to the protocol and the appropriate number of mod-
MPI card. ules to its right according to the vehicle model.
5. Connect the MPI card to the USB port of a PC
(personal computer).
vmr2016-128 3
tmr2015-028-003_a
TYPICAL - SUCCESSFUL CONNECTION

1. Connection protocol
2. Number of modules read
MODEL NUMBER OF MODULES

Models without 2
DPS (ECM and multifunction gauge)
3
Models with
(ECM, DPS and multifunction smr2010-030-002_a
DPS
gauge) TYPICAL
If the number is less than indicated in NUMBER If the update icon is visible, B.U.D.S. indicates that
OF MODULES table, refer to TROUBLESHOOT- a file is available to update at least one of the elec-
ING in this subsection. tronic modules:
5. Read the ECUs by clicking the Read Data but- NOTE: If an update file is available on KNOWL-
ton. EDGE CENTER but the B.U.D.S. software being
used is not up to date, the update icon will not ap-
pear. 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.
vmr2006-012-100_aen
B.U.D.S. is now ready to use.
Updating Electronic Module (ECU)

Software
NOTICE Failure to strictly follow a procedure
to update a module may permanently damage
the module.
Whenever B.U.D.S. is first connected to a vehicle, lmr2010-019-001
check for an update icon in the status bar at the TYPICAL - MODULE SUBMENU LIST
bottom of the Vehicle page.
1. If the Update option is greyed out, no update
file is available for this module.
2. If the Update option is black, an update file is
available for this module.
4 vmr2016-128
NOTE: When selecting the update menu in

B.U.D.S., a dialog box will appear and the update
file description may give some clue to finding
the vehicle-related information on KNOWLEDGE
CENTER .
vbl2012-007-010_a
1. Greyed out: No update to perform

Black: Update file available
Before applying an update, log onto KNOWL-

EDGE CENTER and search the vehicle's VIN to
find the unit's history.
mbg2008-022-100_a
TYPICAL
1. File description
tmr2015-028-001_a Saving Changes to an ECU

Complete all WARRANTY CAMPAIGNS TO VER- If the word Modified appearsat the end of the ve-
IFY. hicle file name at the top of the B.U.D.S. page,
then a change has been made that requires it to
NOTE: PRODUCT HISTORY will show all repairs be saved to the proper electronic module.
performed and claimed under warranty.
rmr2010-020-008_a
TYPICAL
1. Indicate setting or data modified; Write Data to save
Click the Write Data button.
vmr2006-012-100_ben
NOTE: A message box will confirm a successful

operation.
tmr2015-028-002_a
vmr2016-128 5
In such a case, turn ignition switch OFF, then wait

for the message to disappear before disconnect-
ing the MPI.
Disconnect MPI card and store the vehicle diag-
nostic connector in its protective cap.
vmr2012-023-003_a
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 damage to the terminals.
6 vmr2016-128
Subsection 04 (DIAGNOSTIC AND FAULT CODES)
DIAGNOSTIC AND FAULT CODES

GENERAL NOTE: In some cases, the CHECK ENGINE mes-
sage can be displayed along with other messages.
MONITORING SYSTEM MULTI-
PILOT FUNCTION
The Engine Management System (EMS) features LAMP GAUGE
CAUSE
a monitoring system that self-diagnoses various MESSAGE
electrical and electronic components. This mode
becomes active when the ignition key is turned DESS KEY NOT Module unable to read the
RECOGNIZED key
ON.
Key not programmed for
NOTE: Some components require the engine to BAD KEY
the vehicle
be running to be monitored (fuel injectors for ex-
ample). LO BATT VOLT Low system voltage
The monitoring system continuously validates HIGH BATT VOLT High system voltage
that the components (control modules, sensors LOW OIL
and actuators) are not faulty or defective. When PRESSURE Low engine oil pressure
a malfunction is detected, the related electronic STOP ENGINE
module(s):
An important engine
– Sets an active fault code. management component
LIMP HOME
– Adapts the proper protection strategy accord- is not working properly.
MODE
ing to the failure. Vehicle performance is
– Sends out signals to the multifunction gauge to purposely limited
inform the rider of a particular condition. An engine management
CHECK ENGINE component is not
A fault code is an indication that a glitch or mal- functioning properly
function is detected by the monitoring system of
the vehicle. MAINTENANCE Periodic maintenance
REQUIRED required
If a minor fault occurs, the engine and vehicle will
continue to operate without noticeable loss of per- ECM NOT Communication error
RECOGNIZED between gauge and ECM
formance.
CHECK DPS DPS malfunction
If a more important fault occurs, engine RPM may
be limited. The engine/vehicle will continue to op-
erate with reduced performance. TRANSMISSION Gauge receives an invalid
If a major component of the EMS fails, engine SIGNAL FAULT gear position data
RPM will be limited as well as vehicle speed. Displayed when brake is
BRAKE applied for more than 15
These strategies are used to protect seconds (while riding)
engine/electrical system from damage and
to maintain safe operation of the vehicle. In ex-
treme cases, the engine may also be completely / HI TEMP High engine temperature
shut down.
Pilot Lamps for Problematic

Conditions
Limp Home Mode
When a problem is detected, a pilot lamp will turn
on or blink in the multifunction gauge. If the fault When a major component of the EMS is not oper-
that caused the pilot lamp to come on is momen- ating properly, limp home mode will be set.
tary, the pilot lamp may turn off automatically, or Engine RPM will be limited and/or engine behav-
may need to be reset by powering down the ve- ior and control may be modified depending on the
hicle and then restarting it. cause of the failure.
A message may also be displayed to provide ad- This mode allows the rider to return home, which
ditional information related to the fault that turned would otherwise not be possible without this ad-
on the pilot lamp. Refer to the following chart. vanced system.
vmr2016-129 1
LIMP HOME will be displayed in the multifunction Active Fault Codes

gauge and the CHECK ENGINE light symbol will An active fault code is an indication of a fault that
be on in the gauge. is currently triggered.
The active fault may or may not compromise
FAULT CODES normal operation of the system(s). Service ac-
Fault Code Categories tion should be taken to correct the problem that
caused the fault code.
A fault code consists of an alphanumeric designa-
tor followed by a hexadecimal number of 3 digits. Once the fault condition(s) of the active fault is no
The alphanumeric designator defines the category longer present, its state will change to "occurred".
of the fault code while the hexadecimal number Occurred Fault Codes
refers to a unique fault.
An occurred fault code indicates a fault that was
FAULT CODE CATEGORIES active, but no longer is.
ALPHANUMERIC MODULE/
EXAMPLE The occurred fault does not presently affect sys-
OF FAULT tem or component operation but is retained as a
DESIGNATOR SYSTEM
CODE history of the faults that were detected.
Power train, TCM The fault may have been generated due to a
From P0 to P3 P0116
and DPS system or component that was momentarily op-
Communication erating outside normal parameters. Repeated
From U0 to U3 between module U0073 occurred faults of this type should be considered
and sensors when troubleshooting a problem, and may require
that maintenance action be taken.
RELATED MODULE AND FAULTS An occurred fault may also be generated when
FAULT CODE disconnecting and reconnecting a component, re-
MODULE placing a burnt fuse, when the software update of
CATEGORY
an electronic module has been carried out, or may
ECM P and U
be due to a momentary high or low voltage.
DPS P and U
Inactive Fault Codes
Cluster P and U
An inactive fault code represents a fault code that
is neither active, nor occurred. It is simply part of
Fault Code States a list of all possible faults that can be monitored
Fault codes have 3 possible states: by the ECM and multifunction gauge, which may
– Active become active or occurred if the monitoring sys-
tem detects an applicable fault. These codes can
– Occurred be viewed in B.U.D.S.
– Inactive.
Click the Fault tab then click on the drop-down list How to Display Fault Codes in the
on the LH lower corner. Multifunction Gauge
Choose the fault code state you want to display. NOTE: A fault code must be in an "Active" state to
be displayed in the multifunction gauge. B.U.D.S.
must be used to read all fault codes states.
1. Use the selector button or mode button and
scroll to Engine Hour (EH) on the gauge.
rmr2011-021-001_a
TYPICAL
1. Drop down list
2 vmr2016-129
How to Read Fault Codes Using

B.U.D.S.
NOTE: All fault code (regardless of their state) can
be read with B.U.D.S.
1. Connect vehicle to the latest applicable
B.U.D.S. Refer to COMMUNICATION TOOLS
AND B.U.D.S. subsection.
2. Click on the Read Data button.
3. Click on the Faults tab.
vmo2012-012-029_q
MULTIFUNCTION GAUGE LCD - OUTLANDER EXCEPT XT-P

AND LTD
1. Selector button
M S
M S
rmr2011-070-011_a
1. Fault tab
4. Click on the drop-down list on the LH lower cor-

vmo2013-007-001
ner.
MULTIFUNCTION GAUGE (ANALOG/DIGITAL) - OUTLANDER
XT-P AND LTD 5. Choose the fault state to display.
1. Mode button
2. Press and HOLD mode button while QUICKLY

toggling HI - LO beam.
NOTE: A minimum of 3 HI - LO toggles must be
completed within 2 seconds.
rmr2011-021-001_a
1. Drop down list
FAULT
INFORMATION
STATE
Display all possible faults regardless
All faults
vdd2008-001-097_a
of state
TYPICAL Active Display only faults matching this state
Step 1: Press and hold
Step 2: Quickly toggle HI - LO beam faults Empty area if there is no active fault
Active and Display only faults that have either state
occurred Empty area if there is neither active
faults nor occurred fault
vmr2016-129 3
FAULT NOMENCLATURE
COLUMN INFORMATION
Fault code number.
When 2 stars (**) precedes the
Code code, detailed conditions when the
fault occurred, can be displayed by
clicking the "More details" button
Display the fault state (active, occurred,
State
inactive)
Displays the module that reports the
vbl2012-007-011_a
fault code. This is the module that
FAULT PAGE
1. Fault tab detects or has received a message
2. Fault indicator light of an anomaly and reports it.
3. Fault code state drop box Module
List of modules:
4. Fault description
5. More Details button - Cluster (multifunction gauge)
6. Clear Fault button - DPS (dynamic power steering)
7. Clear Occurred Faults button - ECM (engine control module)
8. Selected fault
Number of times this fault
FAULT PAGE DESCRIPTION Count occurred within the driving cycle.
ITEM INFORMATION Value: From 0 to 255
Fault tab Click tab to display the fault page Not to be used.
Cycle time
Value: From 0 to 255 minutes
Fault When flashing, it indicates there is
indicator light active fault(s) Not to be used.
Total time
Value: From 0 to 64 255 minutes
Fault code
Click drop box to select the type of Description Provides a short description of the fault
state drop
faults to display
box
When reading a fault code in B.U.D.S., pay partic-
Display specific information and ular attention to which module reports a fault. It
Fault
statistics related to the fault (see is indicated in the Module column.
nomenclature
fault nomenclature table)
The Description column gives a short description
To display possible causes and of the fault.
More Details
service actions related to the
button
selected fault
Clear Fault To clear occurred faults one at a
button time
Clear
To clear all occurred faults in related
Occurred
ECU(s)
Faults button
When a fault is selected, additional
information pertaining to that
fault will be displayed when
Selected
clicking the "More details" button.
fault
To select a fault, click on the fault
with the mouse or use the cursor up
or down to scroll to the desired fault rmr2011-021-002_a
SOME COLUMNS REMOVED FOR CLARITY PURPOSE

1. Module that reports a fault
2. Fault description
Click on the More Details button, on the RH lower

corner, to display the "Possible Causes" and the
"Service Actions" to step further in the diagnosis.
4 vmr2016-129
rmr2008-039-009
FAULTS PAGE TAB, CLEAR OCCURRED FAULTS
4. Click YES on the following message box.
rmr2011-021-050_a
1. Click here
vbl2012-007-013
The following message will appear.
rmr2011-070-002_a
MORE DETAILS PAGE vbl2012-007-012
1. Possible causes related to the selected fault

2. Service actions 5. Turn ignition OFF and wait until the message
3. Operating conditions when fault occurred
disappears.
MORE DETAILS PAGE DESCRIPTION This will reset the appropriate counter(s) and will
ITEM INFORMATION also record that the problem has been fixed in the
related ECU memory.
Possible List the possible causes that
causes triggered the fault NOTE: An active fault code cannot be cleared.
In other words, the problem relevant to the fault
Service List the possible actions to perform code must be repaired before the fault can be
actions to solve the fault cleared.
Conditions List the operating conditions of the
when fault engine and/or vehicle when the fault FAULT CODE DIAGNOSTIC
occurred was triggered
Missing Module
How to Clear Fault Codes Using If a module is missing, several fault codes will ap-
B.U.D.S. pear.
1. Connect vehicle to the latest applicable To quickly find which module is missing, perform
B.U.D.S. software. Refer to COMMUNICA- the following:
TION TOOLS AND B.U.D.S. subsection. 1. Connect vehicle to the latest applicable
2. Click on the Read Data button. B.U.D.S. software. Refer to COMMUNICA-
TION TOOLS AND B.U.D.S. subsection.
3. Click on the Faults tab.
The fault(s) (occurred state only) can be cleared by
pressing the Clear Occurred Faultsor Clear Fault 3. Click Module in the menu bar.
buttons in B.U.D.S. 4. Look at the list of modules.
5. If a module is not visible, then it is not commu-
nicating through the CAN bus (controller area
network).
vmr2016-129 5
HISTORY PAGE DESCRIPTION

ITEM INFORMATION
Display the minimum and maximum
Minimum/
values encountered. Click "Clear
Maximum
Min/Max" to reset the values
Display the time proportion in what
Run time
mode the engine was running in
RPM Display the RPM range proportion in
profile which the engine was running in
When a minor fault occurs:

lmr2010-019-001 – Turn ignition key OFF.
TYPICAL - MODULE SUBMENU LIST – Wait 30 seconds.
6. Refer to the following table to find the appropri- – Turn ignition key ON.
ate subsection in this manual to diagnose the This should change the fault state from "Active" to
missing module. "Occurred".
MISSING The vehicle should then operate normally.
SECTION TO REFER TO
MODULE If a sensor-related fault persists, you may try
ECM ELECTRONIC FUEL INJECTION (EFI) disconnecting/reconnecting the sensor.
Cluster LIGHTS, GAUGE AND ACCESSORIES Read the following for a general approach to trou-
bleshoot fault codes (active or occurred).
DPS DYNAMIC POWER STEERING (DPS)
Diagnostic Tips
To see the last minute of operating conditions,
click on the History tab in B.U.D.S.
NOTE: The page displays data whatever there is
fault code(s) or not.
rmr2011-070-003_a
1. History tab
2. Additional history pages
6 vmr2016-129
GENERAL GUIDELINES TO SOLVE FAULT CODES
CONDITION ACTION
Use B.U.D.S. to:

Read fault codes.
Display "Active" faults to see components currently not operating normally.
Display "Occurred" faults to troubleshoot intermittent problems.
Monitor system(s), sensor(s), switches and actual conditions.
Troubleshooting vehicle
Activate component(s) for troubleshooting.
Set components (resets etc).
Know the last minute of operating conditions by using the "History" page.
Know the operating conditions, if available, when a fault code occurred by
using the "More details" button in the fault page.
Check sensor connections or mixed up connections.
Before vehicle maintenance:

Read the electronic modules with B.U.D.S.
New fault(s) appear after a vehicle
After vehicle maintenance:
maintenance or repair
Read the electronic modules with B.U.D.S.
Compare the fault code(s) before and after the maintenance
using the printed copy and the current B.U.D.S. reading.
Investigate only the newly fault codes.
Clear all occurred faults in B.U.D.S.
Communication faults displayed as Normal behavior when flashing a module.
"Occurred" after module flashing Clear all occurred faults and check again.
Read the fault description in B.U.D.S.
Click on the "More Details" button.
Sensor "Active" fault Look at the "Conditions" when available.
Read the "Possible Causes".
Apply the "Service Actions".
Check related fuse(s) and relay.
Check related power and ground wires.
Low system voltage
Check for common power supply to several sensors/modules
on one module.
(refer to POWER DISTRIBUTION AND GROUNDS).
Power problem on sensor(s)
NOTE: Some sensors are supplied by the battery while others are
supplied by a module.
Low system voltage
Check battery condition and connections.
on several modules
(several communication faults
Check voltage regulator/rectifier.
will also appear)
A battery charger has likely been used to substitute the vehicle battery.
High system voltage on several
Clear all occurred faults and check again.
modules
Check voltage regulator/rectifier.
Check the module that is reported as missing.
When all modules report that a
module is missing
Check related power and ground wires.
When several modules are in fault Search for a common problem such as a faulty sensor.
When several modules and sensors report that a module is missing.
The missing module may report CAN bus off.
Check related CAN wires (continuity, short to
CAN bus OFF
ground, short between CAN low and high).
Check module pins and wiring terminals.
Then, the other modules should stop reporting that module is missing.
vmr2016-129 7
GENERAL GUIDELINES TO SOLVE FAULT CODES
CONDITION ACTION
May have been generated due to a system or component that was
momentarily operating outside normal parameters.
May be generated when disconnecting and reconnecting a component,
replacing a burnt fuse, or may be due to a momentary high or low voltage.
Before being "Occurred", a fault has always been "Active"
Occurred fault(s) for a certain time, indicating that an unexpected condition
or problem has been present during the driving cycle.
A frequent momentarily fault or an intermittent fault may never
be seen as "Active" in B.U.D.S. while there is still a pending problem.
This type of malfunctions can be discovered by looking at
the "Occurred" faults and then by evaluating the fault count.
As long as a fault is present, it is displayed as "Active".
Low value: Suggests handling problems
Fault count (connections, terminal contact/shape etc.).
(0 - 255) High value: Suggests a frequent and unsolved problem.
The problem should be investigated.
Fault conditions
Look for abnormal, excessive values.
(more details button)
When the basic troubleshooting has been done and the fault
code(s) persists, often the problem is related to the wiring
harness, connections or electromechanical components.
Hard to find problems Short to ground, to battery or between wires.
Wire splices, chafing, terminal problems
(pulled out, bent, out of shape, corroded etc.).
Bad contacts in switch or relay.
ECUs share information and their systems may interact with each other. Certain faults may cause more
than one ECU to set a fault code or indication (pilot lamp or message) as the failure of some components
may affect the operation of several systems.
FAULT CODE TABLE HOW TO FIND FAULT CODE

ACRONYMS USED IN THE FAULT CODE TABLE DESCRIPTIONS
USED IN For the latest fault code table, use the Info Cen-
FAULT CODE MEANING ter submenu in BOSSWeb and enter the following
TABLE search criteria:
ECM Engine Control Module – Enclose the search within quotes " "
– Enter: "ATV DTC (All engines) 2016".
DPS Dynamic Power Steering
CAN Controller Area Network
TPS Throttle Position Sensor
GBPS Gearbox Position Sensor
SCM Suspension Control Module
8 vmr2016-129
Subsection XX (DIAGNOSTIC AND FAULT CODES)
DIAGNOSTIC AND FAULT CODES

GENERAL
FAULT CODE TABLE
PCODE MODULE DESCRIPTION CAUSE ACTION
1- Go to Activations - SCM and
start Rear Test routine. If the test
passed, the system is working
properly. Check the harness and
connection to see a potential source
of intermittent dysfunction, if nothing
is found clear the occurred fault and
no more actions have to be done.
Mud, dust or water in the release
tube may explain the fault code. If
Pressure did not drop to the Test status shows a Fail_release,
desired set point after proceed to next action step.
predefined delay 2-Verify the release tube (orange)
for obstruction. If nothing is
Release valve tube found go to next action step.
Release valve
momentary blocked 3- Unplug the valves block connector
C2109 SCM-XMR activation delay
Blown valve fuse and measure that 12V is present
exceeded
Damaged circuit between pin D of the connector
wires or connectors on the SCM side and the battery
Faulty valve block negative post. If not, verify the valve
Faulty SCM fuse and relay (refer to schematics
for more information). Verify the
harness and the connection between
the valve and the SCM. If everything
is fine, go to next action step.
4- Verify the release valve activation
by disconnecting the valve block
electrical connector and applying
12V across pin D and H on valve
connector. If the release valve
is operating, change the SCM,
otherwise change the valve block.
vmr2015 1

1- Go to Activations - SCM and start
Rear Test routine. Verify that the
Shock Absorber Pressure and the
Auxiliary Line Pressure correlates
in BUDS. If the test is done with
no fault, the system is working
is found clear the occurred fault
and no more actions have to be
done. If the Test Status shows a
Fail_Comparison_Sensor_Test, verify
for leak. If no leak found, verify
the wiring and connector of the
external sensor and the SCM. In
the next action step, verify which
of Shock absorber or Auxiliary Line
Pressure sensors is defective.
2-Make sure to have no pressure
in the system by activating the
Too many values of the
relief valve in Activation -SCM.
external sensor out of
Connect the supplied air hose into
range (negative pressure)
the compressor fitting and plug
Auxiliary line it to a known pressure supply in
Sensor disconnect
C2111 SCM-XMR pressure sensor the range of 30 to 120 psi (as car
Damaged circuit
value out of range tire) and compare it to the Shock
wires or connectors
absorber pressure and Auxiliary
Faulty auxiliary line sensor
line pressure, it should be similar.
Faulty SCM
If the Shock absorber pressure
is off, change the SCM module.
Go to next action step to perform
Auxiliary Line Pressure sensor test.
3-Back probe the signal coming from
the sensor between the pin 3 of the
SCM electrical connector and the
negative battery post (this action
must be done with special probe
to not damage the connector seal).
The value must be between 0.9
and 8.3 Volts for a pressure range
of 0 - 100 psi. If not go to next
action step. If the value is in the
range, the Auxiliary Line Pressure
sensor is fine, change the SCM.
5- Unplug the Auxiliary Line Pressure
sensor and make sure to have
12V between pin 3 and 1 on the
connector coming from SCM. If 12V
is present change the sensor, if not
change the SCM.
2 vmr2015

1- Check for leaks. If no leak
found go to next action step.
Rear Test routine. If the test is done
with no fault, the system is working
connector to see a potential source
If the compressor is not starting
check the compressor GND, harness
and connection then continue
to the next action step. If the
compressor is running and the Test
Pressure did not reach Status show a Fail_Pumping_Rear
to desired set point after go to action step 6.
predefined delay 3-Test the compressor with an
external power supply (as a 12V
Leak in the system battery). If the compressor is
Jammed compressor functional go to next action step.
intake tube 4-Unplug the relay and make sure to
System rear
Damaged circuit have 12V between battery negative
suspension
C21E0 SCM-XMR wires or connectors post and relay pin 30. If not, check
pumping delay
Blown compressor fuse the compressor fuse and harness.
exceeded
Corroded or disconnected If 12V is present, test the relay.
compressor GND If the relay is functional plug it
Faulty relay back and go to next action step.
Faulty compressor 5- Disconnect the SCM, take a
Jammed check valve jumper wire and connect pin 8 to the
Faulty SCM battery negative post. If then the
compressor starts, change the SCM.
6- Verify that the compressor intake
tube (transparent) is not blocked or
kinked. Unplug the SCM air tube
(yellow) and start the compressor. If
air blow out of the tube change the
SCM. If not go to next action step.
7- During the Rear Test routine
verify the pressure sensors value.
If the Shock Absorber Pressure and
Auxiliary Line Pressure is not going
up verify the first check valve at
the exit of the compressor. If only
the Shock Absorber Pressure is not
going up verify the second check
valve after green tube.
System rear
1- Verify suspension system for air
C21E1 SCM-XMR suspension high Leak in the system
leaks.
leakage detected
vmr2015 3

1- Disconnect the air line to the
rear shocks. Go to Activations -
SCM and start Rear Test routine.
If the air blows out the system is
working properly. Check the harness
and connection to see a potential
source of intermittent dysfunction, if
nothing is found clear the occurred
fault and no more actions have to
be done. If the air do not blow
Too many occurrence of out continue to next action step.
pressure pumping and 2- Verify the air tube (black) from
release in short delay the valve to the rear suspension. If
nothing found go to next action step.
System rear
Rear valve tube blocked 3- Unplug the valve block electrical
C21E2 SCM-XMR suspension valve
Blown valve fuse connector and verify that 12V is
failure
Faulty valve block present between pin A and battery
Damaged circuit negative post. If not verify valve
wires or connectors fuse, relay and harness (refer to
Faulty SCM schematics for more information). If
12V is read go to next action step.
4- Verify the rear valve activation
electrical connector and applying 12V
across pin A and E while compressor
running (Go to Activations - SCM and
start Rear Test routine). If the rear
valve is opening and filling the shocks
change the SCM. If the rear valve is
not opening, change the block valve.
4 vmr2015

Rear Front routine. If the test is done
If the compressor is not starting
check the compressor GND, harness
and connection then continue
to the next action step. If the
compressor is running and the Test
Pressure did not reach Status show a Fail_Pumping_Rear
to desired set point after go to action step 6.
predefined delay 3-Test the compressor with an
Leak in the system battery). If the compressor is
Jammed compressor functional go to next action step.
intake tube 4-Unplug the relay and make sure to
System front
Damaged circuit have 12V between battery negative
suspension
C21F0 SCM-XMR wires or connectors post and relay pin 30. If not, check
pumping delay
Blown compressor fuse the compressor fuse and harness.
exceeded
Corroded or disconnected If 12V is present, test the relay.
compressor GND If the relay is functional plug it
Faulty relay back and go to next action step.
Faulty compressor 5- Disconnect the SCM, take a
Jammed check valve jumper wire and connect pin 8 to the
Faulty SCM battery negative post. If then the
7- During the Front Test routine
verify the pressure sensors value.
If the Shock Absorber Pressure and
Auxiliary Line Pressure is not going
up verify the first check valve at
the exit of the compressor. If only
the Shock Absorber Pressure is not
going up verify the second check
valve after green tube.
System front
1- Verify suspension system for air
C21F1 SCM-XMR suspension high Leak in the system
leaks.
leakage detected
vmr2015 5

1- Disconnect the air line from the
front shocks. Go to Activations -
SCM and start Front Test routine. If
the air blows out of both shocks the
system is working properly. Check
the harness and connection to see
a potential source of intermittent
dysfunction, if nothing is found clear
the occurred fault and no more
actions have to be done. If the air
does not blow out even from one
shock continue to next action step.
2- Verify the air tubes (blue) from
Too many occurrence of the valves to both front shocks.
pressure pumping and If clear go to next action step.
release in short delay 3- Unplug the valve block electrical
connector and verify that 12V is
System front
Front valve tube blocked present between pin B and battery
C21F2 SCM-XMR suspension valve
Blown valve fuse negative post (right) / between pin
failure
Faulty valve block C and battery negative post (left).
Damaged circuit If not verify valve fuse, relay and
wires or connectors harness (refer to schematics for
Faulty SCM more information). If both 12V
are read go to next action step.
4- Verify the front valves activation
12V across pin B and F (right) or C
and G (wrong in wire diagram) (left)
while compressor running (Go to
Activations - SCM and start Front
Test routine.). If the front valves are
opening and filling the shocks change
the SCM. If either of the front valves
are not opening, change the block
valve.
Check for Crankshaft
Position Sensor fault
Lost of Engine Synchronisation Check for dirty Crankshaft
P0008 ECM
Synchronisation Check Failed Position Sensor.
Check compression on engine
6 vmr2015

Make sure sensor
connector is fully inserted.
Measure voltage between
harness connector pins 1 and 3
. (Expected value: 4.8 to 5.1 volts)
Measure resistance from
Damaged sensor, connector: ECM-F3 to MAPTS-2
Manifold Air damaged circuit wires, (Expected value: < 2 ohms)
P0107 ECM Pressure Sensor damaged connector or Measure resistance from
voltage too Low damaged ECM pins, ECM connector: ECM-A1 to MAPTS-3
voltage supply Low (Expected value: < 2 ohms)
connector: ECM-G2 to MAPTS-1
(Expected value: < 2 ohms)
Measure resistance from connector:
ECM-F2 to MAPTS-4 (Expected
value: < 2 ohms)
Make sure sensor
connector: ECM-F3 to MAPTS-2
Damaged sensor, wires
Manifold Air (Expected value: < 2 ohms)
shorted to battery +,
P0108 ECM Pressure Sensor Measure resistance from
ECM voltage supply too
voltage too High connector: ECM-A1 to MAPTS-3
High.
value: < 2 ohms)
Make sure sensor
Intake Air
damaged circuit wires, (Expected value: < 2 ohms)
Temperature
P0112 ECM damaged connector or Measure resistance from
Sensor 1 circuit
damaged ECM pins, ECM connector: ECM-A1 to MAPTS-3
Low
voltage supply Low (Expected value: < 2 ohms)
value: < 2 ohms)
vmr2015 7

Make sure sensor
connector: ECM-F3 to MAPTS-2
Intake Air Damaged sensor, wires
Temperature shorted to battery +,
P0113 ECM Measure resistance from
Sensor 1 circuit ECM voltage supply too
connector: ECM-A1 to MAPTS-3
High High.
value: < 2 ohms)
Make sure sensor
Intake Air
damaged circuit wires, (Expected value: < 2 ohms)
Temperature
P0114 ECM damaged connector or Measure resistance from
Sensor
damaged ECM pins, ECM connector: ECM-A1 to MAPTS-3
Intermittent
voltage supply (Expected value: < 2 ohms)
value: < 2 ohms)
Disconnect the sensor.
connector: ECM-F4 to CTS-1
Engine Coolant (Expected value: < 2 ohms)
Damaged sensor, wires
Temperature Measure resistance from
P0116 ECM shorted to battery +,
Sensor 1 circuit connector: ECM-C3 to CTS-2
ECM voltage supply.
range/performance (Expected value: < 2 ohms)
Measure CTS resistance value
(Expected value: 2280 to 2736 ohms
at 19 to 21°C (66 to 70°F))
Engine temperature sensor
Temperature Measure resistance from
P0117 ECM or circuit wires shorted to
Sensor 1 circuit connector: ECM-C3 to CTS-2
ground.
Low (Expected value: < 2 ohms)
at 19 to 21°C (66 to 70°F))
8 vmr2015

Temperature Disconnected sensor, or Measure resistance from
P0118 ECM
Sensor 1 circuit sensor resistance too High. connector: ECM-C3 to CTS-2
High (Expected value: < 2 ohms)
at 19 to 21°C (66 to 70°F))
Check for coolant fluid
Engine Coolant
leak and coolant fluid level
Temperature
P011A ECM Correlation Check failed Check radiator condition
Correlation Check
Check for other fault, Check
failed
thermostat
Make sure sensor
connector: ECM-A1 to TPS-1
Throttle Position
Damaged circuit wires, (Expected value: < 2 ohms)
Sensor (TPS)
P0122 ECM damaged sensor or Measure resistance from
Short circuit to
damaged ECM pins. connector: ECM-G3 to TPS-3
GND
ECM-G2 to TPS-2 (Expected value:
< 2 ohms)
Make sure sensor
connector: ECM-A1 to TPS-1
Throttle Position
Damaged circuit wires, (Expected value: < 2 ohms)
Sensor (TPS)
P0123 ECM damaged sensor or Measure resistance from
shorted to battery
damaged ECM pins. connector: ECM-G3 to TPS-3
+
ECM-G2 to TPS-2 (Expected value:
< 2 ohms)
Check for coolant fluid
Engine Coolant leak and coolant fluid level
Coolant fluid temperature
P0217 ECM over temperature Check radiator condition
too high
condition Check for other fault, Check
thermostat
Engine
Overspeed
P0219 ECM Engine speed too high
Condition
detected
vmr2015 9

Check fuse
Measure voltage between harness
connector PF1-12B and ground
(Expected value: 11 to 13 volts)
Blown fuse, damaged connector PF1-11B and ground
Fuel Pump or disconnected (Expected value: 11 to 13 volts)
circuit shorted to fuel pump relay, Measure resistance from harness
P0231 ECM
ground, or open damaged circuit wires, connector: ECM-J1 to PF1-12A
circuit damaged connectors or (Expected value: < 2 ohms)
damaged ECM output pins. Measure resistance from harness
connector: PF1-11A to FP-3
Measure resistance from harness
connector: FP-4 to ground (Expected
value: < 2 ohms)
Check fuse
connector PF1-12B and ground
Blown fuse, damaged connector PF1-11B and ground
or disconnected (Expected value: 11 to 13 volts)
Fuel Pump circuit
fuel pump relay, Measure resistance from harness
P0232 ECM shorted to battery
damaged circuit wires, connector: ECM-J1 to PF1-12A
+
damaged connectors or (Expected value: < 2 ohms)
damaged ECM output pins. Measure resistance from harness
connector: PF1-11A to FP-3
connector: FP-4 to ground (Expected
value: < 2 ohms)
Disconnect injector 1
Measure resistance between
injector pin 1 and 2 (Expected
value = 14 to15 ohms).
Blown fuse, damaged Measure resistance from
Cylinder 1 injector or disconnected injector, harness connector: INJ1-1 to
P0261 ECM open circuit or damaged or disconnected INJ1-2 (Expected value: > OPEN)
shorted to ground circuit wires, damaged Measure voltage between harness
ECM output pins. connector INJ1-2 and ground.
connector: ECM-K4 to INJ1-1
10 vmr2015

Damaged injector, Measure resistance from
Cylinder 1 injector damaged circuit wires, harness connector: INJ1-1 to
P0262 ECM shorted to battery damaged connector or INJ1-2 (Expected value: > OPEN)
+ damaged ECM output Measure voltage between harness
pins. connector INJ1-2 and ground.
connector: ECM-K4 to INJ1-1
Blown fuse, damaged Measure resistance from
Cylinder 2 injector or disconnected injector, harness connector: INJ2-1 to
P0264 ECM open circuit or damaged or disconnected INJ2-2 (Expected value: > OPEN)
shorted to ground circuit wires, damaged Measure voltage between harness
ECM output pins. connector INJ2-2 and ground.
connector: ECM-L4 to INJ2-1
Damaged injector, Measure resistance from
Cylinder 2 injector damaged circuit wires, harness connector: INJ2-1 to
P0265 ECM shorted to battery damaged connector or INJ2-2 (Expected value: > OPEN)
+ damaged ECM output Measure voltage between harness
pins. connector INJ2-2 and ground.
connector: ECM-L4 to INJ2-1
Make sure sensor
Damaged CPS, connector is fully inserted.
damaged circuit wires, Measure resistance from
Crankshaft
damaged connector or connector: ECM-E1 to CPS-1
P0338 ECM Position Sensor
damaged ECM output pins. (Expected value: < 2 ohms)
Spike detected
Wrong mounting position Measure resistance from connector:
of sensor ECM-D1 to CPS-2 (Expected value:
< 2 ohms)
incorect nomber Make sure sensor
of tooth detecded connector is fully inserted.
Damaged CPS, Measure resistance from
Crankshaft
damaged circuit wires, connector: ECM-E1 to CPS-1
P0339 ECM Position Sensor
damaged connector or (Expected value: < 2 ohms)
Intermittent
damaged ECM output pins. Measure resistance from connector:
Wrong mounting position ECM-D1 to CPS-2 (Expected value:
of sensor < 2 ohms)
vmr2015 11

Check fuse
Disconnect relay.
Blown fuse, damaged
terminals 85 and 86 on relay.
or disconnected relay,
(Expected value: 70 to 90 Ohms)
Radiator cooling damaged circuit wires
P0480 ECM Measure resistance between
fan relay or connectors, damaged
harness connector PF-1E and
ECM output pins, damaged
ground. (Expected value > OPEN).
Relay.
connector: ECM-B3 to PF1-1E
Check if vehicle speed is available
No vehicle speed available
in Monitoring page in BUDS.
& Vehicle is in (H or
L Gear) with Engine
harness connector CV-A (red)
Invalid or missing RPM over 4000RPM.
P0500 DPS and CV-C (ground black).
vehicle speed Damaged Vehicle Speed
sensor circuit, Damaged
sensor, Wrong mounting
CI-9 to CV-B (pink) (Expected value:
position of speed sensor.
< 5 ohms) on ATV
Make sure IDLE
connector: ECM-D4 to IDLE-D
Damaged IDLE,
Idle Air Control damaged circuit wires,
connector: ECM-D3 to IDLE-A
P0508 ECM System Circuit damaged connector or
Low damaged ECM output
pins.
connector: ECM-E4 to IDLE-B
ECM-C4 to IDLE-C (Expected value:
< 2 ohms)
Make sure IDLE
connector: ECM-D4 to IDLE-D
Damaged IDLE,
Idle Air Control damaged circuit wires,
connector: ECM-D3 to IDLE-A
P0509 ECM System Circuit damaged connector or
High damaged ECM output
pins.
connector: ECM-E4 to IDLE-B
ECM-C4 to IDLE-C (Expected value:
< 2 ohms)
Use a stored access
A non stored access key
Invalid Access key to turn key switch.
P0513 ECM was detected when key
Key Detected If no stored access keys are
switch was turned to ON.
available program one and try again
12 vmr2015

harness connector OPS and
ground When engine stopped.
Damaged switch, (Expected value < 2 ohms)
Engine oil damaged circuit wires, Measure resistance between
P0523 ECM pressure sensor damaged connector, harness connector OPS and
sticking damaged ECM pins. ground When engine running.
(Expected value = open)
connector: OPS to ECM-E2
harness connector OPS and
ground When engine stopped.
Damaged switch, (Expected value < 2 ohms)
damaged circuit wires, Measure resistance between
Engine oil
P0524 ECM damaged connector, harness connector OPS and
pressure too Low
damaged ECM pins. ground When engine running.
(Expected value = open)
connector: OPS to ECM-E2
TORQUE_ External troubleshooting
P0551 DPS SENSOR_ Damaged DPS is not possible
OPEN Replace the DPS.
SHORT_GND Replace the DPS.
SHORT_5V Replace the DPS.
Check the two DPS fuses
Validate that all the DPS
connectors are secured
Blown fuse, battery
low (damaged
connector DPS2-A&B and ground.
System voltage magneto/regulator),
P0562 DPS (Expected value = 11 to 13 volts)
low damaged circuit wires
Measure battery voltage with
or connection, intense
engine stopped. (Expected
winch usage
value: 11 to 13 volts)
Check ground and positive
connections on battery.
Blown fuse FC, engine stopped. (Expected
battery failure, voltage value: 11 to 13 volts)
regulator failure, Measure battery voltage with
damaged circuit wires engine running. (Expected
System voltage
P0562 ECM or connection, damaged value: 13 to 14.7 volts)
low
magneto generator. Check connections
An external battery charger on voltage regulator.
may have been used. Check ground and positive
Intense winch usage connections on battery.
Check ground on vehicle frame
vmr2015 13

system voltage Rectifier failure, damaged engine Running at 3500RPM.
P0563 DPS
high circuit wires or connection. (Expected value: 13 to 14.7 volts)
Check connections
on voltage regulator.
Damaged regulator. engine running. (Expected
System voltage
P0563 ECM An external battery charger value: 13 to 14.7 volts)
high
may have been used. Check connections
CALIBRATION DPS not calibrated or
P0601 DPS Try updating the DPS
FAULT damage DPS
Bad checksum If an update file is available reflash
P0601 SCM-XMR of Calibration Lost of power on reflash the SCM, if not clear the fault, if it
memory section returns, replace the SCM.
Check start button, Check
Run/Stop button, check if free
weeling diode is in the good way.
Disconnect starter solenoid relay
Damaged relay,
Danaged start switch,
connector: ECM-L3 to SS2
Starter Relay damaged circuit wires,
P0615 ECM (Expected value: < 2 ohms)
circuit open damaged connector,
damaged ECM pins.
connector: MG2-6 to SS1
terminals SS1 and SS2. (Expected
value: 3 to 6 ohms)
Damaged relay,
Starter Relay connector: ECM-L3 to SS2
damaged circuit wires,
P0616 ECM circuit shorted (Expected value: < 2 ohms)
damaged connector,
to ground Measure resistance from harness
damaged ECM pins.
value: 3 to 6 ohms)
14 vmr2015

Damaged relay,
Starter Relay connector: ECM-L3 to SS2
damaged circuit wires,
P0617 ECM circuit shorted (Expected value: < 2 ohms)
damaged connector,
to battery + Measure resistance from harness
damaged ECM pins.
value: 3 to 6 ohms)
External troubleshooting
MOTOR LOW Internal error or damaged
P0636 DPS is not possible
CURRENT FAULT DPS
Replace the DPS.
MOTOR HIGH Internal error or damaged
P0637 DPS is not possible
CURRENT FAULT DPS
Replace the DPS.
Damaged sensor Measure voltage between harness
connected to ECM connector ECM-A1 and ground.
Sensor Reference
P0642 ECM voltage supply, (Expected value: 4.8 to 5.1 volts)
Voltage Low
Damaged ECM voltage Check sensor connected to ECM
supply output. voltage supply output
Damaged sensor Measure voltage between harness
connected to ECM connector ECM-A1 and ground.
Sensor Reference
P0643 ECM voltage supply, (Expected value: 4.8 to 5.1 volts)
Voltage High
Damaged ECM voltage Check sensor connected to ECM
supply output. voltage supply output
DPS motor supply
P0658 DPS PHASE A_LOW is not possible
Damaged DPS
Replace the DPS.
DPS motor supply
P0659 DPS PHASE A_HIGH is not possible
Damaged DPS
Replace the DPS.
High temperature of the
HIGH
P0666 DPS DPS. Extreme usage of the Let the unit cool down.
TEMPERATURE
unit.
vmr2015 15

Check fuse
Disconnect Accessory relay
and Lights relay & turn
key switch (on w/lights)
connector PF1-10E and ground.
diagnosis related to (Expected value: 11 to 13 volts)
Accessories or Light relay, Measure voltage between harness
Blown fuse, damaged connector PF1-6D and ground.
Accessory relay
P0685 ECM or disconnected relay, (Expected value: 11 to 13 volts)
circuit
damaged circuit wires, Measure resistance from harness
damaged connectors or connector: ECM-K2 to PF1-12D
damaged ECM output pins (Expected value: < 2 ohms)
connector: ECM-K2 to PF1-7C
terminals 85 and 86 on the 2 relays.
(Expected value: 70 to 90 ohms)
Check fuse
Accessory relay
Blown fuse, damaged connector PF1-6D and ground.
circuit shorted to
P0686 ECM or disconnected relay, (Expected value: 11 to 13 volts)
ground or open
damaged circuit wires, Measure resistance from harness
circuit
damaged connectors or connector: ECM-K2 to PF1-12D
damaged ECM output pins (Expected value: < 2 ohms)
Check fuse
Accessory relay Damaged relay, connector PF1-6D and ground.
P0687 ECM circuit shorted to damaged circuit wires, (Expected value: 11 to 13 volts)
battery + damaged connector or Measure resistance from harness
damaged ECM output connector: ECM-K2 to PF1-12D
pins. (Expected value: < 2 ohms)
16 vmr2015

Check fuse
Disconnect radiator fan relay
Blown fuse, damaged or connector PF1-3D and ground.
Radiator fan
disconnected fan relay, (Expected value: 11 to 13 volts)
circuit shorted
P0691 ECM damaged circuit wires, Measure resistance from harness
to ground or open
damaged connectors or connector: ECM-B3 to PF1-1E
circuit
damaged ECM output pins. (Expected value: < 2 ohms)
Check fuse
Disconnect radiator fan relay
Damaged fan relay, connector PF1-3D and ground.
Radiator fan damaged circuit wires, (Expected value: 11 to 13 volts)
P0692 ECM circuit shorted damaged connector or Measure resistance from harness
to battery + damaged ECM output connector: ECM-B3 to PF1-1E
pins. (Expected value: < 2 ohms)
Check for disconnected
transmission connector.
Check for misplaced
terminal on gearbox
Measure resistance form each
switch to ground in all position
Wrong Switch
(PR & N) (Expected value if
Subtransmission Combinations
switch activated: < 2 ohms)
Internal switch Damaged Switch,
P0705 ECM Measure resistance from harness
Combinations damaged circuit wires,
connector: ECM-J3 to PRN-1
error damaged connectors or
damaged ECM pins.
connector: ECM-H2 to PRN-2
connector: ECM-H4 to PRN-3
Verify that gear position information
change when you change the
position of gear on vehicle.
Disconnect GBPS
connector GBPS-1 and GBPS-3.
GBPS invalide GBPS position not (Expected value: 4.8 to 5.1 volts)
P0706 ECM
gear position plausible Measure resistance from
connector: ECM-D2 to GBPS-2
connector: ECM-C3 to GBPS-3
Replace GBPS sensor
vmr2015 17

Disconnect GBPS
Gear position connector GBPS-1 and GBPS-3.
sensor shorted to (Expected value: 4.8 to 5.1 volts)
P0707 ECM
ground, or open Measure resistance from
circuit connector: ECM-D2 to GBPS-2
Replace GBPS sensor
Disconnect GBPS
Gear position connector GBPS-1 and GBPS-3.
sensor circuit (Expected value: 4.8 to 5.1 volts)
P0708 ECM
shorted to battery Measure resistance from
+ connector: ECM-D2 to GBPS-2
Replace GBPS sensor
Blown fuse FC,
battery failure, voltage
regulator failure,
System voltage engine running. (Expected
damaged circuit wires
P1562 ECM low (from Key value: 13 to 14.7 volts)
or connection, damaged
switch) Check connections
magneto generator.
An external battery charger
may have been used.
System voltage Damaged regulator. engine running. (Expected
P1563 ECM high (from Key An external battery charger value: 13 to 14.7 volts)
switch) may have been used. Check connections
Wrong throttle body
mechanical position during
TPS adaptation
P1619 ECM reset of closed TPS Replace gauge if necessary.
failure
or no initialization after
ECM replacement.
18 vmr2015

Power output Motor short circuit or Reset fault, If fault re-occur, replace
P1F01 DPS
overload power output failed DPS unit
Power output High voltage at the unit Measure battery voltage with
P1F02 DPS
overload (18V). input. engine running. (Expected
value: 13 to 14.7 volts)
test charging system as per
shop manual
Fault may become Active
Hi temperature detected in extreme use situations.
Electronic Circuit
P1F03 DPS by on board temperature Reset fault and let DPS cool down.
Overheat
sensor. If fault re-occur in normal riding
conditions, replace DPS unit
Motor Motor input vs output External troubleshooting
P1F05 DPS current sensor Current correlation check is not possible
range/performance failed Replace the DPS.
Open the ECM
Activation page in BUDS
Perform an ignition coil
activation and check if ignition
coil is reacting as expected
Damaged ignition coil,
Cyllinder 1 damaged circuit wires,
connector: ECM-M2 to BA-3
P2300 ECM Ignition output damaged connector or
shorted to ground damaged ECM output
pins.
connector BA-2 and ground.
Refer to the service manual
for detailed ignition coil testing
procedure.
Open the ECM
short to V + damaged ECM output
pins.
procedure.
vmr2015 19

Open the ECM
shorted to ground damaged ECM output
pins.
procedure.
Open the ECM
short to V + damaged ECM output
pins.
procedure.
DPS motor supply
P2670 DPS PHASE B_LOW is not possible
Damaged DPS
Replace the DPS.
DPS motor supply
P2671 DPS PHASE B_HIGH is not possible
Damaged DPS
Replace the DPS.
GBPS learning
position failure
Gear position Wrong transmission
Using BUDS performe a GBPS
P280A ECM sensor adaptation mechanical position
initialization.
not plausible during GBPS reset,
No initialization after
ECM replacement.
20 vmr2015

1- Go to Activations - SCM and
start Test routine. Verify that the
Shock Absorber Pressure and the
Auxiliary Line Pressure correlates
in BUDS. If the test is done with
no fault, the system is working
is found clear the occurred fault
and no more actions have to be
done. If the Test Status shows a
Fail_Comparison_Sensor_Test, verify
for leak. If no leak found, verify
the wiring and connector of the
external sensor and the SCM. In
the next action step, verify which
of Shock absorber or Auxiliary Line
Pressure sensors is defective.
2-Make sure to have no pressure
Too many values of the in the system by activating the
external sensor out of relief valve in Activation -SCM.
range (negative pressure) Connect the supplied air hose into
the compressor fitting and plug
Auxiliary line
Sensor disconnect it to a known pressure supply in
P3000 SCM-LTD pressure sensor
Damaged circuit the range of 30 to 120 psi (as car
value out of range
wires or connectors tire) and compare it to the Shock
Faulty auxiliary line sensor absorber pressure and Auxiliary
Faulty SCM line pressure, it should be similar.
If the Shock absorber pressure
is off, change the SCM module.
Go to next action step to perform
Auxiliary Line Pressure sensor test.
4-Back probe the signal coming
from the sensor between the pin
3 of the SCM electrical connector
and the negative battery post (this
action must be done with special
probe to not damage the connector
seal). The value must be between
0.9 and 8.3 Volts for a pressure
range of 0 - 100 psi. If not go to
next action step. If the value is
in the range, change the SCM.
5- Unplug the Auxiliary Line Pressure
sensor and make sure to have
12V between pin 3 and 1 on the
connector coming from SCM. If 12V
is present change the sensor, if not
change the SCM.
vmr2015 21

Test routine. If the test is done
no more actions have to be done. If
the compressor is not starting check
the compressor GND, harness and
connection then continue to the next
action step. If the compressor is
running and the Test Status show
Pressure did not reach
a Fail_Pumping go to action step 6.
to desired set point after
3-Test the compressor with an
predefined delay
battery). If the compressor is
Leak in the system
functional go to next action step.
Jammed compressor
4-Unplug the relay and make sure to
intake tube
System have 12V between battery negative
Damaged circuit
suspension post and relay pin 30. If not, check
P3001 SCM-LTD wires or connectors
pumping delay the compressor fuse and harness.
Blown compressor fuse
exceeded If 12V is present, test the relay.
Corroded or disconnected
If the relay is functional plug it
compressor GND
back and go to next action step.
Faulty relay
5- Disconnect the SCM, take a
Faulty compressor
jumper wire and connect pin 8 to the
Jammed check valve
battery negative post. If then the
Faulty SCM
7- During the Test routine verify the
pressure sensors value. If the Shock
Absorber Pressure and Auxiliary
Line Pressure is not going up verify
the first check valve at the exit of
the compressor. If only the Shock
Absorber Pressure is not going up
verify the second check valve after
green tube.
22 vmr2015

Test routine. If the test passed, the
system is working properly. Check
the harness and connection to see
a potential source of intermittent
dysfunction, if nothing is found clear
the occurred fault and no more
actions have to be done. Mud,
dust or water in the release valve
may explain the fault code. If the
Test status shows a Fail_release,
Pressure did not drop to
proceed to next action step.
desired set point after
2-Verify the release valve
predefined delay
for obstruction. If nothing is
Release valve Release valve
3- Unplug the valve connector and
P3002 SCM-LTD activation delay momentary blocked
verify that 12V is present between
exceeded Blown valve fuse
pin 1 of the connector on the SCM
Damaged circuit
side and the battery negative post.
wires or connectors
If not, verify the valve fuse and
Faulty valve block
relay (refer to schematics for more
Faulty SCM
information). Verify the harness
and the connection between the
valve and the SCM. If everything
is fine, go to next action step.
4- Verify the release valve activation
12V across pin 1 and 2 on valve
connector. If the release valve
is operating, change the SCM,
otherwise change the valve block.
System high 1- Verify suspension system for air
P3003 SCM-LTD Leak in the system
leakage detected leaks
Bad checksum If an update file is available reflash
P3004 SCM-LTD of Calibration Lost of power on reflash the SCM, if not clear the fault, if it
memory section returns, replace the SCM.
1- Verify if all the module
are present in BUDS (under
Communication
Lost of CAN Module Menu), if they are the
P3005 SCM-LTD network
communication vehicle is working properly.
disconnected
2- Check continuity between the
cluster, ECM and SCM CAN network.
Disconnect MPI2 from DB connector.
DB-1 and DB-2 (Expected
value = 50 to 70 ohms).
CAN bus off, no Damaged circuit wires or Measure resistance
U0073 DPS
messages damaged DPS pins. between DB-1 and DPS1-C
(Expected value < 5 ohms).
Measure resistance between DB-2
and DPS1-D (Expected value < 5
ohms).
vmr2015 23

CAN bus off, no Damaged circuit wires or Measure resistance
U0073 ECM
messages damaged CLUSTER pins. between DB-1 and ECM-B1
and ECM-C1 (Expected value < 2
ohms).
Lost value = 50 to 70 ohms).
Damaged CAN Bus
communication Measure resistance
U0100 DPS wires to ECM, damaged
with ECM (lost of between DB-1 and ECM B1
DPS/ECM pins.
CAN ID’s) (Expected value < 5 ohms).
and ECM C1 (Expected value < 5
ohms).
connector CL-17 and ground.
(Expected value = 11 to 13 volts)
Damage CAN Bus
Lost wires to cluster
U0155 DPS communication Damaged circuit wires or
with CLUSTER damaged Cluster module
pins.
and CL-4 (Expected value < 5 ohms).
and CL-19 (Expected value < 5
ohms).
Missing CLUSTER CAN ID Measure resistance
Lost
Module internal error between DB-1 and ECM-B1
U0155 ECM communication
Damaged circuit wires or (Expected value < 2 ohms).
with CLUSTER
damaged module pins. Measure resistance
between DB-2 and ECM-C1
ohms).
24 vmr2015

Check for Cluster fault or ECM fault
Lost Missing CAN ID
communication Module internal error
U0155 ECM DB-1 and ECMB-C1
with CLUSTER Damaged circuit wires or
(lost of CAN ID’s) damaged module pins.
DB-2 and ECMB-C2
ohms).
1- Verify if all the module
are present in BUDS (under
Communication
Lost of CAN Module Menu), if they are the
U0155 SCM-XMR network
communication vehicle is working properly.
disconnected
2- Check continuity between the
cluster, ECM and SCM CAN network.
Check for dirty or oxidized Key
contact. Clean key contact if needed.
Check for broke key contact
Lost Ensure sensor connector
communication The Vehicle Immobilizer is is fully inserted.
U0167 ECM with Vehicle reporting an electrical fault Measure resistance between
Immobilizer on the communication line. ECMB-A1 and CC-C
Control Module (Expected value < 2 ohms).
ECMB-C2 and CC-E (Expected value
< 2 ohms).
Lost Ensure sensor connector
communication The Vehicle Immobilizer is is fully inserted.
U0167 ECM with Vehicle reporting an electrical fault Measure resistance between
Immobilizer on the communication line. ECMB-A1 and CC-C
< 2 ohms).
Install the proper ECM
Invalid Security Incorrect ECM
or CLUSTER on vehicle.
U0300 ECM Exchange or CLUSTER,
Update security coding using
received Incorrect software version.
BUDS
Check in the BUDS Tab
Variant Coding "vehicle configuration" if
Faulty variant coding
U0400 DPS failure Software the DPS option is checked.
Faulty programming
incompatibility Reflash the DPS with the latest
software
vmr2015 25

1- Verify in Setting - Vehicle
Configuration page is correctly set up.
Variant coding Faulty variant coding
U0400 SCM-XMR 2- If Update File is available reflash
failure Faulty programming
the SCM. If not, clear the fault, if it
returns replace the SCM.
1- Verify in Setting - Vehicle
Configuration page is correctly set up.
Variant coding Faulty variant coding
U0400 SCM-LTD 2- If Update File is available reflash
failure Faulty programming
the SCM. If not, clear the fault, if it
returns replace the SCM.
Invalid Data Ensure sensor connector
Received The Vehicle Immobilizer is fully inserted.
U0426 ECM From Vehicle could not read the number Measure resistance between
Immobilizer of the access key. ECMB-A1 and CC-C
< 2 ohms).
Check the two DPS fuses
Ensure DPS connector
Lost of power on DPS
is fully inserted.
that can be caused by
Module improper Check for Damaged tail
U3001 DPS damaged circuit wires
shutdown light, DPS, Cluster circuit wires
or damaged DPS pins.
Check for damaged DPS pins.
26 vmr2015
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))
ELECTRONIC FUEL INJECTION (EFI)

SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ................. 5, 9, 15, 18, 20–22
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ....................... 5, 9, 15, 20–22
OETIKER PLIERS........................................................................... 295 000 070 ........................................... 11
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................... 11, 16, 22
GENERAL Electrical System

WARNING ECM (Electronic Control Module)
Fuel is flammable and explosive under cer- The ECM controls the electrical system and the
tain conditions. Ensure work area is well ven- engine management functions, by processing the
tilated. Do not smoke or allow open flames or information given by various sensors.
sparks in the vicinity. EFI Sensors
The ECM reads the inputs from the sensors
WARNING which it compares to predetermined parameters
Fuel lines remain under pressure at all times. stored in the ECM, makes computations, and ac-
Always proceed with care and use appropri- tivates the outputs accordingly (injectors, ignition
ate safety equipment when working on pres- coils etc.).
surized fuel system. Wear safety glasses.
Signals from sensors are used by the ECM to de-
Wipe off any fuel spillage. Do not allow fuel
termine the injection and ignition parameters (ref-
to spill on hot engine parts and/or on electri-
erenced to fuel maps) as required to maintain the
cal connectors.
optimum air-fuel ratio.
WARNING Air Intake System
Replace any damaged, leaking or deteri- Refer to the applicable AIR INTAKE SYSTEM sub-
orated fuel lines or connections. Always, section for additional information.
pressurize the fuel system if any fuel related
component was disconnected or removed. Throttle Body
Proceed with care when removing/installing The throttle body is mounted on the intake mani-
high pressure test equipment. fold.
Air for combustion, drawn in by the engine, flows
SYSTEM DESCRIPTION through the air intake system, then through the
Refer to the appropriate ENGINE MANAGEMENT throttle body where it is regulated by a throttle
SYSTEM subsection for a general layout of the plate.
various EFI system components.
The electronic 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.
vmr2016-130 1
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 cylinder.
Fuel Pump
An electric fuel pump with an integrated pressure
regulator and fuel system filters is used. For more
details on the fuel pump unit, refer to FUEL TANK
AND FUEL PUMP subsection.
vmr2015-073-001_a
TYPICAL
1. Throttle body
ADJUSTMENT
2. Idle air control valve (IACV)
3. Intake manifold
IDLE SPEED
Fitted on the throttle body, a throttle plate regu- Idle speed is not adjustable. The ECM controls
lates the amount of air that enters the engine. the IACV.
A TPS is incorporated on the throttle body. It pro-
vides a signal to the ECM of the actual throttle NOTICE Never attempt to adjust the sealed
plate position. idle stop screw. It is calibrated at the factory.
If the screw adjustment is changed, the throt-
An idle air control valve (IACV) is also incorporated tle body must be replaced.
on the throttle body, It allows the ECM to control
the idle speed while the throttle plate is closed. The vehicle multifunction gauge can provide an ac-
curate digital readout of the engine's idle speed.
Fuel System The engine RPM may also be verified using the ap-
Refer to the applicable FUEL TANK AND FUEL plicable B.U.D.S. software version, refer to COM-
PUMP subsection for additional information. MUNICATION TOOLS AND B.U.D.S. subsection.
In B.U.D.S., click the following:
– Read Data button
– Monitoring tab
– ECM tab.
vmr2015-073-002_a
1. Fuel rail
2. Fuel Injector
3. Intake manifold
Fuel Rail
Two fuel rails, one for each injector, are mounted
vmr2012-026-150_a
on the intake manifold. The fuel rails, which are
VERIFYING ENGINE RPM USING B.U.D.S.
used to secure the injectors to the manifold, also 1. Monitoring tab
provide to the injectors the fuel pressure that they 2. Engine RPM indication
receive from the fuel pump.
2 vmr2016-130
NOTE: The multifunction gauge and B.U.D.S. use Open throttle approximately one quarter then
the same signal to provide the engine RPM indi- quickly release. Repeat 2 - 3 times to settle throt-
cation. tle plate. If stopper does not rest against its stop
lever, perform throttle cable adjustment. Refer to
CLOSED THROTTLE AND IDLE THROTTLE CABLE in this subsection.
ACTUATOR RESET To reset IACV and TPS, perform the following:
This operation performs a reset of the values in 1. Connect the vehicle to the latest applicable
the ECM. B.U.D.S. version, refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection.
This reset is very important. The setting of the
TPS will determine the basic parameters for all 2. In B.U.D.S., click the following:
fuel mapping and several ECM calculations and – Read Data button
the setting of the idle air control valve will deter- – Setting tab
mine the basic parameters for the idle speed con- – ECM tab
trol of the engine. 3. Click on the Reset button in the Closed Throt-
Closed throttle and idle actuator reset must be tle and Idle Actuator area.
done if:
– TPS is loosened, removed or replaced
– Throttle body is replaced
– Idle air control valve is replaced
– ECM is replaced.
NOTICE An improperly set TPS or IACV may
lead to poor engine performance and emission
compliance could possibly be affected. In ad-
dition, improper IACV reset may lead to poor
engine starting, improper idle (too low or too vmr2016-045-010_a
high) and engine stop on deceleration.

If operation is wrong, an error message will be dis-
Remove throttle body cap and ensure the throttle played.
cam of throttle body rests against set screw with- If TPS is not within the allowed range while re-
out any tension in the cable. setting the Closed Throttle and Idle Actuator, the
ECM will generate a fault code and will not accept
the setting. Repeat the reset procedure.
4. Start engine and make sure it operates nor-
mally through its full engine RPM range. If
fault codes appear, refer to DIAGNOSTIC AND
FAULT CODES subsection for more informa-
tion.
TROUBLESHOOTING
DIAGNOSTIC TIPS
Engine problems are not necessarily related to the
fuel injection system.
It is important to ensure that the engine and
vmr2006-014-064_b
propulsion system, fuel delivery and electrical
1. Contact here systems are functioning normally.
2. Free-play here
For diagnostics purposes, use B.U.D.S. software.
See COMMUNICATION TOOLS AND B.U.D.S.
subsection.
vmr2016-130 3
After a problem has been solved, be sure to clear NOTE: This wakes up the ECM, which then turns
the fault(s) in the ECM using the B.U.D.S. soft- on the following. If the following do not turn on,
ware. check ECM fuse (PF1 (F5 and F8)).
WARNING QUICK INDICATION THAT ECM IS FUNCTIONING
(assuming the observed component is
Electrical actuators and electronic modules in good working order)
may be powered up as soon as the ignition
switch is set to ON and emergency engine Multifunction gauge turns ON.
stop switch is set to RUN. Always disconnect Fuel pump turns on for approx. 5 seconds.
the battery prior to disconnecting any elec-
trical or electronic parts. Rear lights turn on.
Headlamps turn on (ignition key on with lights
Never use a battery charger to temporarily substi- position).
tute the battery as it may cause the ECM to func-
tion erratically, or not at all. ECM Access
Check related-circuit fuse solidity and condition Refer to BODY and remove the LH panel.
with an ohmmeter. A visual inspection could lead
to a false diagnosis.
Electrical Related 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 vmr2012-022-002_a
LH PANEL REMOVED
Pay particular attention to ensure that terminals 1. ECM location
and pins are not out of their connectors, corroded,
or out of shape. ECM Connector
When probing terminals, pay attention not to de- There is one connector connected to the ECM. It
form the terminals as this could cause a loose or links:
intermittent connection that would be difficult to – Engine harness
troubleshoot. – Vehicle system control harness.
For connector information, cleaning and probing,
PROCEDURES refer to WIRING HARNESS AND CONNECTORS
subsection.
ENGINE CONTROL MODULE
(ECM)
As a first troubleshooting step, always check for
applicable fault codes using B.U.D.S. software.
Quick Test to Validate ECM Operation

Turn ignition key to ON.
4 vmr2016-130
Testing the ECM Power Supply

REQUIRED TOOL
ECM ADAPTER TOOL

(P/N 529 036 166)

(P/N 529 035 868)
smr2009-030-010_a
1. Disconnect ECM connector. If any measurement is out of specification, refer to

2. Install ECM connector on the ECM ADAPTER POWER DISTRIBUTION and check all grounds.
TOOL (P/N 529 036 166).
3. Install a jumper wire between K1 and M4 on the
Testing the CAN Resistor
ECM adapter tool. Remove the DPS1 connector (4-pin connector)
from DPS module (if so equipped). Refer to
4. Turn the ignition switch to ON.
STEERING SYSTEM subsection.
1. Remove seat to access the diagnostic link con-
6. Set multimeter to Vdc and check for voltage as nector (DB).
follows.
2. Remove diagnostic link connector from its
ECM
BATTERY VOLTAGE
holder.
ADAPTER
L1 Negative post Battery voltage
If voltage is not measured, check the following:

– ECM fuse
– Main relay
– Wiring and connections, refer to the WIRING
DIAGRAM.
Testing the Continuity of ECM Ground
Circuits
REQUIRED TOOL
ECM ADAPTER TOOL

(P/N 529 036 166) smr2012-023-003_a
TYPICAL
1. Diagnostic link connector (DB)
FLUKE 115 MULTIMETER 3. Set a multimeter to setting.

(P/N 529 035 868)
REQUIRED TOOL
1. Disconnect ECM connector. FLUKE 115 MULTIMETER

2. Install the ECM ADAPTER TOOL (P/N 529 036 166) (P/N 529 035 868)
on ECM connector.
3. Set multimeter to and probe adapter termi-
nals as per following table. 4. Measure the resistance of the CAN resistors as
per following table.
ECM BATTERY
RESISTANCE
ADAPTER POST
Pins M3 and Close to 0
Ground
M4 (continuity)
vmr2016-130 5
CAN RESISTOR TEST WARNING

DIAGNOSTIC LINK Always reconnect the RED (+) battery cable
RESISTANCE
CONNECTOR first, then reconnect BLACK (–) cable.
Pins 1 and 2 Approximately 60
3. If a new ECM is installed, refer to ECM RE-
TEST RESULT PLACEMENT in this subsection.
READING RESULT Replacing the ECM
Approximately ECM and CLUSTER CAN wires 1. Transfer ECM data. Refer to ECM DATA
60 and resistors good TRANSFER for complete procedure.
ECM CAN resistor open, or 2. Perform the CLOSED THROTTLE AND IDLE
CLUSTER CAN resistor ACTUATOR RESET.
Approximately
open, or
120 3. Program the vehicle ignition key(s) in the new
CAN wire to CLUSTER
or ECM open ECM.
Infinite CAN wire to DB connector 4. Calibrate the IACV. Refer to IACV CALIBRA-
(open circuit) open circuit TION in this subsection.
If 120 ohms is read, isolate the CLUSTER from ECM Data Transfer
CAN by disconnecting it and measuring again at To transfer the original ECM recorded information
the diagnostic link connector. to the new ECM, use the B.U.D.S. software and
If 120 ohms is still read, the ECM CAN resistor and proceed as follows.
wires are good. Check for continuity of the CLUS- 1. Connect the original ECM to vehicle.
TER CAN wires, refer to WIRING DIAGRAM. 2. In B.U.D.S., click the Read Data button to load
If an open circuit is read, the ECM CAN resistor the information from the original ECM.
(or wire) is open. Check for continuity of the ECM
CAN wires, refer to WIRING DIAGRAM to deter-
mine if the wires or the resistor is at fault.
If the CAN resistor of a module is at fault, replace
that module.
If a module cannot communicate and the CAN re-
sistor and wires test good, try a new module.
5. Reconnect DPS1 to DPS module,
Removing the ECM vmr2006-012-100_aen
NOTE: If a new ECM is to be installed, first read

the procedures in ECM REPLACEMENT in this NOTE: Keep B.U.D.S. running while replacing
subsection. ECMs. The data will remain stored in the PC
computer as long as B.U.D.S. is running.
1. Disconnect battery cables.
3. Get the Data from the saved .mpem file.
NOTICE Always disconnect the BLACK (–) 3.1 Click on the Open button.
battery cable first, then disconnect RED (+)
cable.
2. Disconnect ECM connector.
3. Unscrew all retaining screws and pull out ECM.
Installing the ECM

Reverse removal procedure however, pay atten-
tion to the following.
1. Reconnect ECM connector.
2. Reconnect battery cables.
mmr2009-023-080
6 vmr2016-130
3.2 Click once on the Folder Up button in the

open box.
vmr2015-042-012_a
IMPORTANT: Ensure to use the file that specifi-

cally matches the vehicle you are servicing.
vmr2015-042-010_a
NOTE: The file name structure is as follows:
3.3 Double click on the AutoSave folder.
BUDS version_VIN_date read (yyyymmdd)_hour read
(hhmmss).mpem
Example:
A3.5.0.3_3JBLKCK11DJ000319_20130924_093618.mpem
B.U.D.S. version = A3.5.0.3
VIN = 3JBLKCK11DJ000319
Date file was read = 2013-09-24
Hour file was read = 09h 36m 18s
4. Go to the Vehicle tab and record the following

information.
– Vehicle (V.I.N.) number
– Engine number (without the leading “M”)
– Model number
vmr2015-042-011_a
– Customer.
NOTE: You may have to go to another Au-

toSave folder from a previous version of
B.U.D.S.
3.4 Choose the latest file saved for this spe-
cific vehicle.
vmr2008-022-008
5. Remove the original ECM.

6. Install the new ECM.
7. In B.U.D.S., click the Read Data button to read
the new ECM.
vmr2016-130 7
vmr2006-012-100_aen
8. Select the Vehicle tab and enter the informa-

tion you recorded previously.
– Vehicle serial number
tmr2011-022-017_a
– Engine number (do not enter the “M” at the
ADDING PART IN HISTORY
beginning of the engine number) 1. History tab
– Enter model number. 2. Part Replacement tab
3. Add part in history button
– Customer name. 4. ECM selection
5. Add ECM serial number here
NOTE: The ECM serial number can be found on

the ECM sticker that also identifies the part num-
ber.
11. Click on the OK button.
12. Click on the Write Data button.
smr2009-030-007_a
VEHICLE TAB
9. Click on the following tabs:

– History
– Part Replacement
– Add Part in History.
10. Enter the old ECM serial number in the Add
vmr2006-012-100_ben
Part In History window.
FUEL INJECTOR
Refer to the applicable ENGINE MANAGEMENT
SYSTEM subsection for component and connec-
tor locations.
Fuel Injector Leak Test

Carry out the FUEL PUMP PRESSURE TEST as
detailed in the FUEL TANK AND FUEL PUMP sub-
section.
Testing the Fuel Injector Input Voltage

Disconnect the fuel injector electrical connector.
Turn on ignition switch.
8 vmr2016-130
NOTE: Ensure to read voltage before ECM auto- Testing the Fuel Injector Resistance
matically turns off. Disconnect ECM connector.
Use a multimeter and set it to Vdc. Read voltage. Install the ECM connector on the ECM ADAPTER
INJECTOR TOOL (P/N 529 036 166).
CYLINDER CONNECTOR MEASUREMENT Connect the fuel injector connector.
WIRE Using a FLUKE 115 MULTIMETER (P/N 529 035 868),
FRONT INJ1-2 check resistance value between terminals as fol-
BAT2 lows.
Battery voltage
REAR INJ2-2 (-)
FUEL INJECTOR RESISTANCE TEST
AT ECM ADAPTER
FUSE BOX ECM RESISTANCE
INJECTOR
TERMINAL ADAPTER @ 20°C (68°F)
FRONT K4
PF1-B2 11.4 - 12.6
REAR L4
If resistance value obtained is incorrect, perform

an INJECTOR GROUND CIRCUIT RESISTANCE
TEST.
Testing the Injector Ground Circuit
Resistance
Disconnect the fuel injector connector.
vmr2006-014-075_a
Disconnect ECM connector.
TYPICAL
Install ECM connector on the ECM ADAPTER TOOL
If supply voltage is not good, check fuse and if (P/N 529 036 166).
good, perform an INJECTOR POWER CIRCUIT Using a FLUKE 115 MULTIMETER (P/N 529 035 868),
RESISTANCE TEST. check resistance value between terminals as fol-
If supply voltage is good, perform a FUEL INJEC- lows.
TOR RESISTANCE TEST.
INJECTOR
Testing the Injector Power Circuit GROUND CIRCUIT
CYLINDER MEASUREMENT
Resistance WIRE
ECM
ADAPTER
Check continuity between main relay and injector
as follows: FRONT INJ1-1 K4
Close to 0
– Remove main relay. REAR INJ2-1 L4
– Disconnect the fuel injector connector.
– Use a multimeter and set it to . If continuity is not good, repair or replace wiring
– Read resistance. going to injector.
If continuity is good, replace the injector.
INJECTOR
CYLINDER CIRCUIT MEASUREMENT Removing the Fuel Injector
WIRE Remove the fuel rail. Refer to FUEL RAIL in this
FRONT INJ1-2 subsection.
PF1-B2 Close to 0
REAR INJ2-2
If continuity is not good, repair or replace wiring

going to injector.
If continuity is good, perform the FUEL INJECTOR
RESISTANCE TEST.
vmr2016-130 9
vmr2009-022-001_a
TYPICAL - FUEL RAIL ASS’Y

1. Fuel rail
2. Fuel injector
3. Injector top O-ring
4. Injector bottom O-ring
5. Manifold O-ring
vmr2006-014-072_a
Pull fuel injector out of the fuel rail.
Firmly push injector until it bottoms out.
Installing the Fuel Injector Reinstall fuel rail.
dure. Pay attention to the following details. FUEL RAIL
Apply a thin film of engine oil to O-rings to ease
insertion in rail. Replacing the Fuel Rail
Install fuel injector with your hand. Do not use any Removing the Fuel Rail
tool. 1. Disconnect fuel line to reach the rear injector.
FUEL INJECTOR INSTALLATION Refer to FUEL TANK AND FUEL PUMP subsec-
tion.
O-RINGS New Lubricate with engine oil
2. Unscrew rail retaining screws.
Position the manifold O-ring on injector as in fol- 3. Gently pull rail off by hand.
lowing illustration.
vmr2006-014-071_a
TYPICAL - MANIFOLD O-RING POSITION

vmr2006-014-073_a
Carefully insert injector in manifold paying atten- TYPICAL

tion to the manifold O-ring. To disconnect fuel rail from hose, cut clamp on
NOTICE Gently push O-ring in evenly all fuel hose. Refer to FUEL TANK AND FUEL PUMP
around while inserting injector. O-ring must for clamp removal/installation procedures.
be completely inserted and not visible, before
completing the insertion of the injector.
10 vmr2016-130
REQUIRED TOOL Adjusting the Throttle Cable

Mechanically adjust the throttle cable as follows.
OETIKER PLIERS (P/N 295 Handlebar and throttle cable must be at their
000 070) normal position. Throttle cable routing must have
been performed before adjusting cable.
NOTE: If fuel rail is removed for access to fuel in- Activate throttle lever a few times. Make sure
jector, it is not necessary to cut hose clamp. Only throttle cam of throttle body rests against set
to replace fuel rail. screw without any tension in the cable.
Installing the Fuel Rail
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).
Apply a thin film of engine oil to injector O-rings to
ease insertion in rail.
INJECTOR O-RINGS
SERVICE PRODUCT Lubricate with engine oil
Install fuel rail and evenly tighten screws a little at

a time each side.
TIGHTENING TORQUE
vmr2006-014-064_b
LOCTITE 243 (BLUE) 1. Contact here

Service product 2. Free-play here
(P/N 293 800 060)
10 N•m ± 1 N•m
Fuel rail retaining screws CAUTION If there is no free-play at idle
position, it may cause poor idling and starta-
NOTE: Activate fuel pump a few times to built bility problems. Improper cable adjustment
fuel pressure. will cause strain on cable and/or damage cable
bracket or throttle lever at handlebar.
WARNING WARNING
Perform a fuel pressure test and ensure that Make sure idle speed stopper contacts throt-
there is no leak. Refer to FUEL TANK AND tle cam when throttle lever is fully released at
FUEL PUMP. handlebar.
THROTTLE CABLE If adjustment is needed, proceed with adjuster at
handlebar. Adjust to have 2 mm (.079 in) free-play
Removing the Throttle Cable at the end of throttle lever. When done, slide back
Remove steering cover. cable protector over adjuster.
Remove LH side panel.
Disconnect throttle cable from throttle body. Re-
fer to procedure in this subsection.
Disconnect throttle cable from throttle lever.
Remove throttle cable.
Installing the Throttle Cable

Reverse removal procedure.
Proceed with THROTTLE CABLE ADJUSTMENT
in this subsection.
vmr2016-130 11
THROTTLE BODY
Throttle Body Description
vmr2006-014-067_a
TYPICAL
1. Adjuster lock nut
2. Adjuster
Turn handlebar side to side and ensure there is still

free-play in each position.
To ensure there is no strain in the cable at wide
open position:
vmr2006-014-010_a
– Fully depress throttle lever and hold. 1. Throttle body
– Loosen adjuster lock nut/adjuster until it just re- 2. Throttle cable attachment
3. Throttle plate
leases lever. 4. TPS
5. Idle air bypass channel
– Turn adjuster clockwise until it touches lever 6. Idle air control valve
again.
– From there, tighten adjuster 1/2 turn (to remove Throttle Body Access
strain in cable). Remove the RH side panel. Refer to BODY sub-
– Tighten lock nut. section.
– Release throttle lever.
Inspecting the Throttle Body
Check that the throttle plate moves freely and
smoothly when depressing throttle lever.
– Check if throttle body idle set screw is loose or
worn.
– Check if TPS is loose.
– Check if idle air control valve is loose.
– Check for corroded or damaged connectors.
NOTICE The throttle body must be replaced
if idle set screw is loose or worn.
Cleaning the Throttle Body

vmr2006-014-068_a
1. Check throttle body cleanliness using a flash-
1. Adjuster lock nut light. Fully open throttle plate and verify:
2. Adjuster – Throttle body bore
Reinstall throttle cable cover. – Throttle plate edge.
Look for:
– Dirt
– Oily surfaces
– Carbon and salt deposits on throttle plate and
the surrounding bore.
2. Clean as necessary.
12 vmr2016-130
3. Use a throttle body cleaner such as GUNK IN-

TAKE MEDIC or an equivalent. Refer to manu-
facturer's instructions.
NOTICE Only use an appropriate throttle
body cleaner that will not damage O-rings and
EFI sensors.
4. To avoid getting dirt into engine, spray cleaner
on a clean rag then rub rag against throttle plate
and bore. A toothbrush may also be used.
5. Gently open throttle plate and hold fully open to
reach all surfaces.
6. To remove residual dirt, spray cleaner on throt-
tle plate and on bore. vmr2012-026-004_a
7. Reinstall removed parts. TYPICAL

Step 1: Loosen
Step 2: Rotate
Removing the Throttle Body Step 3: Remove
1. Remove the air intake silencer retaining 7. Rotate throttle lever and pull out cable barrel.
screws.
vmr2006-014-060_b
vmr2012-026-003_a TYPICAL
TYPICAL 1. Throttle lever
1. Remove these screws 2. Cable barrel
2. Lift rear of air intake silencer as much as possi- 8. Remove barrel from cable.
ble and block in this position. 9. Pull out throttle cable.
3. Unplug connectors from TPS and IACV. 10. Pull out throttle body.
4. Loosen both throttle body clamps.
Installing the Throttle Body
5. Rotate throttle body to gain access to throttle
cable. Installation of the throttle body is the reverse of
the removal procedure. However, pay attention to
6. Remove throttle cable cover. the following.
Temporarily install throttle body into position.
Properly install cable barrel to throttle cable end.
vmr2016-130 13
vmr2006-014-65_a
vmr2006-014-063_a
Tighten clamps.
Hook cable to throttle lever. – Check throttle cable adjustment. Refer to
THROTTLE CABLE in this subsection.
– If throttle body was replaced, perform the
CLOSED THROTTLE AND IDLE ACTUATOR
RESET and the IACV CALIBRATION. See pro-
cedures in this subsection.
THROTTLE POSITION SENSOR

(TPS)
tor locations.
General
The throttle position sensor (TPS) is a potentiome-
vmr2006-014-064_a
ter that sends a signal to the ECM which is propor-
Rotate throttle body into position and ensure to tional to the throttle plate angle.
index throttle body tab with boot notch.
vmr2008-022-010_b
1. Throttle position sensor (TPS)

vmr2006-014-065_a
14 vmr2016-130
The ECM may generate several fault codes per- Slowly and regularly depress the throttle. Ob-
taining to the TPS. Refer to DIAGNOSTIC AND serve the needle movement. It must change
FAULT CODES subsection for more information. gradually and regularly as you move the throt-
tle. If the needle “sticks”, bounces, suddenly
TPS Access drops or if any discrepancy between the throttle
Remove the RH side panel. Refer to BODY sub- movement and the needle movement is noticed,
section. it indicates that the TPS needs to be replaced or
the computer used may be too slow to transfer
Loosen both throttle body clamps. data fast enough for real time display.
Rotate throttle body to gain access to TPS.
Testing the TPS Resistance
Ensure correct throttle cable adjustment. Refer to
THROTTLE CABLE ADJUSTMENT in this subsec-
tion.
Ensure TPS is connected to wiring harness.
Disconnect the ECM connector.
Using the following tools, check resistance val-
ues.
REQUIRED TOOL
FLUKE 115 MULTIMETER (P/N 529 035 868)
570, 650 and 1000 Engines

vmr2012-026-004_b
TYPICAL THROTTLE WIDE OPEN

Step 1: Loosen ECM ADAPTER IDLE THROTTLE
Step 2: Rotate
POSITION POSITION
Testing the TPS Wear PIN
RESISTANCE ( ) @ 20°C
(68°F)
IMPORTANT: Prior to testing the TPS, ensure
that mechanical components of throttle body are G3 G2 900-1600 2600-3100
checked. G2 A1 1800-2200 1800-2200
While engine is not running, activate throttle and
G3 A1 2200-3100 800-1200
pay attention for smooth operation without phys-
ical stops of the cable.
Using the B.U.D.S. software, use the Throttle
Opening display under Monitoring. THROTTLE WIDE OPEN
ECM ADAPTER IDLE THROTTLE
POSITION POSITION
RESISTANCE ( ) @ 20°C
PIN
(68°F)
A1 G2 900-1600 2600-3100
G2 G3 1800-2200 1800-2200
G3 A1 2200-3100 800-1200
vmr2006-014-083_aen
TYPICAL
vmr2016-130 15
If voltage test is not good, check/repair wiring

harness. If wiring tests good, refer to ECM RE-
PLACEMENT.
If voltage test is good, everything is in order (as-
suming resistance test was performed).
TPS Replacement
Refer to TPS ACCESS in this subsection to gain
access to TPS.
vmr2008-022-005_a Unplug connector from TPS.
NOTE: The resistance value should change Loosen TPS retaining screws.
smoothly and proportionally to throttle move- Remove TPS.
ment. Otherwise, replace TPS.
If resistance values are correct, perform the TPS
INPUT VOLTAGE TEST below.
If resistance values are incorrect, check wiring
harness. If wiring is faulty, repair/replace. If
wiring is good, replace TPS.
Reconnect ECM connector.
Testing the TPS Input Voltage

Disconnect connector from TPS.
Turn ignition key ON.
Check the voltage readings from harness connec-
tor as follows.
ENGINES CONNECTION VOLTAGE
570
Pin 1 with
650
battery ground
1000 0 V vmr2006-012-004_c
TYPICAL – THROTTLE BODY

850 Pin 3 with 1. TPS
1000R battery ground 2. Screws
Pin 2 with Install the new TPS and tighten retaining screws
All 5.0 V
battery ground to specification.
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
TPS retaining screws 3 N•m (27 lbf•in)
Perform the Closed Throttle And Idle Actuator

Reset procedure. Refer to CLOSED THROTTLE
AND IDLE ACTUATOR RESET in this subsection.
IDLE AIR CONTROL VALVE (IACV)

BAT tor locations.
smr2005-056-016_a
16 vmr2016-130
An idle air control valve with good resistance

measurement can still be faulty. It is also pos-
sible that a mechanical failure occurs which is
not detectable without measuring the air flow.
Replacing the IACV may be necessary as a test.
vmr2015-042-004_a
If the resistance of any winding is not good, re-

place the idle air control valve.
If resistance test of valve windings is good, check
continuity of circuits C4, D3, D4, E4. If not good,
vmr2015-042-004_a
check/repair wiring/connectors.
IACV Access Inspecting the IACV Visual

Refer to TPS ACCESS in this subsection to gain NOTE: Make sure the ignition key is turned off
access to IACV. during the following procedure.
Remove Idle air control valve from throttle body.
Testing the IACV Resistance Check the piston and bypass channel for dirt/de-
Disconnect IACV from the wiring harness. posits which can cause a sticking piston.
Using a multimeter, check the resistance in both NOTICE Always keep the ignition key turned
windings. OFF, while the idle air control valve is removed.
Check the resistance between pins as shown.
NOTICE Do not try to operate the piston
IDLE AIR CONTROL VALVE MEASUREMENT of the idle air control valve when it is dis-
RESISTANCE ( ) mounted. Also do not move the piston by
PIN hand. The drive screw is very sensitive and
@ 20°C (68°F)
may be destroyed.
A D
50 ± 5 Using a part cleaner, clean idle bypass in throttle
B C
body from contamination then blow compressed
air to dry it.
vmr2016-130 17
Install ECM connector on ECM ADAPTER TOOL

(P/N 529 036 166).
vmr2006-014-085_a 529036166
1. Clean bore from contamination

Using a multimeter, measure resistance as per ta-
Clean all remaining parts and install the idle air ble.
control valve on the throttle body. ECM ADAPTER MEASUREMENT
Proceed with the Closed Throttle and Idle Actu-
RESISTANCE
ator Resetand the IACV CALIBRATION. See pro- PIN
@ 20°C (68°F)
cedures in this subsection.
D1 E1 700 - 900
IACV Calibration
If resistance value is incorrect, check or repair the
The IACV calibration is required to avoid a poten-
connectors and the wiring harness between ECM
tial erratic or frozen RPM needle.
connector and the CPS. If resistance value is still
1. Start the vehicle to increase engine tempera- incorrect, replace CPS.
ture.
2. Let engine run at idle until the cooling fan per- CPS Replacement
formed a complete cycle (ON/OFF). Refer to CPS ACCESS in this subsection to reach
3. When the cycle is done, turn ignition key to OFF CPS.
position. Disconnect CPS connector and cut harness lock-
4. The calibration is completed. ing tie (if applicable).
Remove CPS retaining screw and pull up on CPS
CRANKSHAFT POSITION to remove it.
SENSOR (CPS)
Refer to applicable ENGINE MANAGEMENT SYS-
TEM subsection for component and connector lo-
cations.
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 AND STARTER subsections.
CPS Access
Remove the RH side panel. Refer to BODY sub-
section. vmr2016-130-001_a
To reach the CPS connector, remove protector 1. CPS

2. Retaining screw
from engine.
Lubricate O-ring of CPS.
Testing the CPS Resistance
Disconnect the ECM connector.
18 vmr2016-130
O-RING
XPS SYNTHETIC
Service product GREASE
(P/N 293 550 010)
Install new CPS and secure harness with a new

locking tie (as applicable).
Tighten CPS retaining screw to specification.
TIGHTENING TORQUE
10 N•m ± 1 N•m
CPS retaining screw
vmr2015-042-006_a
MANIFOLD ABSOLUTE NOTE: This sensor is a multifunction device.

PRESSURE AND TEMPERATURE
SENSOR (MAPTS) MAPTS Access
Remove the RH side panel. Refer to BODY sub-
Refer to applicable ENGINE MANAGEMENT SYS- section.
TEM subsection for component and connector lo-
cations. MAPTS Pressure Function
Before the engine is started, when power is ap-
plied to the system, the sensor measures the
ambient air atmospheric pressure. The ambient
pressure is, at that moment, stored in the ECM.
Thereafter, once the engine is started, it mea-
sures the air pressure in the intake manifold at
operating RPMs.
The sensor must be correctly installed on intake
manifold. Otherwise, the MAPTS could generate
a fault code for an unexpected sensor range at idle
when it reads the atmospheric pressure. If this
is the case, remove sensor and check for oil or
dirt on its end and if problem persists, check throt-
tle plate condition/position and the wiring harness.
Perform the following tests.
MAPTS Pressure Function Quick Test
B.U.D.S. software version.
vmr2006-012-004_d 2. In B.U.D.S., click the following:
1. Manifold absolute pressure and temperature sensor (MAPTS)
– Monitoring tab
– ECM tab.
vmr2016-130 19
If voltage test is not good, carry out the MAPTS

CIRCUIT CONTINUITY TEST (PRESSURE FUNC-
TION).
Testing the MAPTS Circuit Continuity
(Pressure Function)
1. Disconnect the ECM connector.
2. Install ECM connector on ECM ADAPTER TOOL
(P/N 529 036 166).
3. Using a multimeter, check continuity of the fol-
lowing circuits.
MAPTS CIRCUIT CONTINUITY TEST
(PRESSURE FUNCTION)
vmr2012-026-150_b
TYPICAL ECM MAPTS RESISTANCE

1. Monitoring tab ADAPTER CONNECTOR VALUE
2. MAPTS pressure reading
A1 Pin 3
3. Look for and take note of the MAPTS pressure
reading while the engine is stopped. F2 Pin 4 Close to 0
4. Perform the same test with a new MAPTS and G2 Pin 1

compare both readings.
If resistance is not within specification, repair or
Values have to be within ± 3.4 kPa (.5 PSI). replace the wiring harness between ECM connec-
MAPTS PRESSURE FUNCTION QUICK TEST tor and the MAPTS.
RESULT SERVICE ACTION MAPTS Temperature Function
Circuit The sensor monitors the temperature in the intake
continuity MAPTS manifold.
Repair or
NO test of input
replace
READING MAPTS voltage
wiring
Testing the MAPTS Temperature Function
pressure test
1. Connect vehicle to the applicable B.U.D.S. soft-
function
ware version.
VALUE IS 2. In B.U.D.S., click the following:
OUT OF Replace MAPTS
RANGE – Monitoring tab
– ECM tab.
Testing the MAPTS Input Voltage 3. Look for the Intake Air temperature reading
Check the voltage output from ECM to the pres- while the engine is stopped.
sure sensor.
3. Remove electrical connector from MAPTS.
4. Using a FLUKE 115 MULTIMETER (P/N 529 035
868), measure for input voltage as per following
table.
MAPTS CONNECTOR MEASUREMENT
PIN VOLTAGE
1 3 5 Vdc
If voltage test is good, replace the MAPTS. vmr2016-045-001_a
TYPICAL
1. Monitoring tab
2. MAPTS temperature reading
20 vmr2016-130
4. Perform the same test with a new MAPTS and MAPTS TEMPERATURE SENSOR TEST RESULTS
compare both readings.
RESULT SERVICE ACTION
If the engine MAPTS temperature reading is sig-
nificantly different than the new MAPTS, replace Circuit
it. Continuity MAPTS
Repair or
NO Test of Input
NOTE: Both sensors must feel the same ambient replace
READING MAPTS Voltage
air temperature. wiring
Temperature Test
If there is no reading, carry out a MAPTS RESIS- Function
TANCE TEST (TEMPERATURE FUNCTION). INCORRECT
RESISTANCE Replace MAPTS
Testing the MAPTS Resistance (Temperature VALUE
Function)
Disconnect the connector from the MAPTS. Testing the MAPTS Circuit Continuity
Using the FLUKE 115 MULTIMETER (P/N 529 035 (Temperature Function)
868), check the resistance of the sensor itself as MAPTS CIRCUIT CONTINUITY TEST
shown. (TEMPERATURE FUNCTION)
MAPTS MEASUREMENT ECM MAPTS RESISTANCE
ADAPTER CONNECTOR VALUE
RESISTANCE
PIN
@ 20°C (68°F) G2 Pin 1
Close to 0
1 2 2280 - 2740 F3 Pin 2
If resistance is not within specification, replace

the MAPTS.
MAPTS Replacement
If resistance tests good, reconnect the MAPTS
and disconnect the ECM connector.
Install ECM connector on ECM ADAPTER TOOL
(P/N 529 036 166).
529036166
Using a multimeter, recheck resistance value as

per following table.
ECM ADAPTER MEASUREMENT vmr2006-012-004_e
TYPICAL - INTAKE MANIFOLD

RESISTANCE 1. MAPTS
PIN 2. Retaining screw
@ 20°C (68°F)
F3 G2 2280 - 2740 Disconnect MAPTS connector and remove the
MAPTS.
Install new MAPTS as per following table.
vmr2016-130 21
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
6 N•m ± 0.7 N•m
MAPTS retaining screw
CTS (COOLANT TEMPERATURE

SENSOR)
Refer to appropriate ENGINE MANAGEMENT
tor locations.
vmr2012-026-006_a
TYPICAL
1. Pull out
Testing the CTS Resistance

1. Disconnect the ECM connector.
2. Using the following tools, check resistance val-
ues.
REQUIRED TOOL
ECM ADAPTER TOOL

(P/N 529 036 166)
vmr2016-130-002_a
1. CTS FLUKE 115 MULTIMETER (P/N 529 035 868)
3. Install ECM connector on the following tool.

ECM ADAPTER MEASUREMENT
RESISTANCE ( )
PIN
@ 20°C (68°F)
C3 F4 2280 - 2736
If resistance value is incorrect, check wiring con-

tinuity between ECM connector and the CTS. Re-
fer to CTS CIRCUIT CONTINUITY TEST in this sub-
section.
Testing the CTS Circuit Continuity

1. Disconnect connector from CTS and check the
circuit continuity.
vmr2012-026-007_a
LH SIDE OF VEHICLE
1. CTS
CTS Access
Remove the LH panel. Refer to BODY subsection.
Remove the CVT duct.
22 vmr2016-130
CTS CIRCUIT CONTINUITY TEST

ECM CTS RESISTANCE
ADAPTER CONNECTOR VALUE
Pin F4 Pin 1
Close to 0
Pin C3 Pin 2
If resistance value is incorrect, repair or replace

wiring or connectors/terminals.
If resistance test is good, replace the CTS.
Replacing the CTS

1. Refer to CTS ACCESS in this subsection to
reach CTS.
2. Remove heat shield over exhaust pipe to ex-
pose CTS. Refer to EXHAUST SYSTEM subsec-
tion.
vmr2012-026-008_a
1. CTS
3. Disconnect CTS connector and remove CTS.

4. Install the new CTS and torque as specified.
TIGHTENING TORQUE
16 N•m ± 2 N•m
CTS
5. Reinstall remaining removed parts.

6. Refill and bleed the cooling system. Refer to
COOLING SYSTEM subsection.
vmr2016-130 23
Subsection 02 (FUEL TANK AND FUEL PUMP)
FUEL TANK AND FUEL PUMP

SERVICE TOOLS
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 12
FUEL HOSE ADAPTER.................................................................. 529 036 023 ............................................. 5
FUEL PUMP NUT TOOL ............................................................... 529 035 899 ........................................... 13
OETIKER PLIERS........................................................................... 295 000 070 ............................................. 8
PRESSURE GAUGE....................................................................... 529 035 709 ............................................. 5
SMALL HOSE PINCHER ............................................................... 295 000 076 ........................................... 18
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ....................................... 4, 19

FLUKE RIGID BACK PROBE ......................................................... TP88 ........................................... 12
vmr2016-131 1
NEW
NEW
To engine
NEW
NEW
EUROPE NEW NEW
NEW NEW
NEW NEW
vmr2015-043-100_a
2 vmr2016-131
GENERAL Air can enter the fuel tank at all times through
the vent system INLET check valve. This prevents
WARNING negative pressure within the fuel tank which could
Fuel is flammable and explosive under cer- cause fuel starvation.
tain conditions. Ensure work area is well ven-
tilated. Do not smoke or allow open flames or
sparks in the vicinity.
WARNING
Always disconnect battery prior disconnect-
ing a fuel system pressure hose.
WARNING
Always proceed with care and use appropri-
ate safety equipment when working on pres-
surized fuel system. Wear safety glasses.
WARNING vmr2015-130-002_a
Do not allow fuel to spill on hot engine parts TYPICAL - AMBIENT AIR PRESSURE IN
and/or on electrical connectors. 1. Vent inlet check valve
The vent inlet check valve also prevents fuel from

When the repair is completed, ensure that all flowing out through the inlet of the vent system.
hoses are connected and secured. Perform the
FUEL PRESSURE TEST and the FUEL TANK LEAK If the pressure in the fuel tank builds up and
TEST as explained in this subsection. exceeds 2.5 kPa - 7.6 kPa (.36 PSI - 1.1 PSI), the
pressure relief valve opens and lets the excess
Fuel lines remain under pressure at all times. pressure evacuate through the vent system OUT-
Proceed with care when removing/installing high LET hose.
pressure test equipment.
SYSTEM DESCRIPTION
Fuel Tank Vent System
The fuel tank is equipped with a vent system that
provides over pressure relief and negative pres-
sure relief of the fuel tank.
vmr2015-130-002_b
TYPICAL - OVER PRESSURE RELIEF

vmr2015-130-001_a 1. Outlet pressure relief valve
TYPICAL - FUEL TANK VENT SYSTEM
1. Vent hose Fuel Tank Vent Breather Filter
2. Vent system hose inlet
3. Vent system connected to fuel pump The vent system is equipped with an in-line
4. Fuel tank breather filter that prevents entry of particles
5. Engine air intake system
such as dust or small insects. It is located next
to the fuel pump, on the inlet hose, before the air
inlet check valve.
vmr2016-131 3
To access the fuel tank vent breather filter, re- INSPECTION

move the rear body module.
FUEL TANK LEAK TEST
WARNING
Always carry out a fuel tank leak test when-
ever the fuel tank shows signs of wear or
damage which may cause a leak, or when the
fuel pump has been removed or replaced,
or if you suspect a leak. If the fuel tank is
damaged, the fuel tank should be replaced
even if no leak is present. Do not attempt to
repair the fuel tank.
1. Refill fuel tank and ensure fuel tank cap is in

good condition and properly installed.
vmr2015-130-002_c
2. Remove the gauge support for access to the
TYPICAL
fuel vent inlet hose.
1. Fuel tank vent breather filter 3. Pressurize the fuel tank through the vent hose.
Fuel Pump Module REQUIRED TOOL
The fuel pump module is inserted in the fuel tank.
It provides fuel delivery for the EFI system and en- VACUUM/PRESSURE PUMP
compasses the following components: (P/N 529 021 800)
– Electric fuel pump
– Fuel pump pre-filter
– Fuel pump filter (650, 850 and 1000 engines)
– Fuel pressure regulator
– Fuel level sender.
Fuel Filters
The system comprises two levels of filtration:
– A replaceable pre-filter element attached to the
bottom of the fuel pump.
– On 650, 850 and 1000R models, a non-replace-
able fine filter element that is integral to the fuel
pump module.
Fuel Pump Pressure Regulator vmr2012-028-008_a
1. Fuel tank vent inlet hose

The fuel pressure regulator is integral to the fuel 2. Gauge connector
pump module. The pressure regulator maintains
proper fuel pressure for the EFI system. TIME WITHOUT
PRESSURE
PRESSURE DROP
14 kPa (2 PSI) 3 minutes
If pressure drops, locate fuel leak(s) and repair or

replace leaking component(s).
To locate a leak, check for a fuel smell or leaking
fuel.
To ease locating leak(s), spray soapy water on all
hose connections and components; bubbles will
indicate the leak location(s).
4 vmr2016-131
NOTE: For access to the fuel tank vent system, REQUIRED TOOLS
refer to FUEL PUMP ACCESS in this subsection.
PRESSURE GAUGE
FUEL SYSTEM PRESSURE TEST (P/N 529 035 709)
The pressure test will show the available pressure
in the system. It validates the pressure regulator
and the fuel pump, and allows for checking the FUEL HOSE ADAPTER
fuel system for leaks (high pressure side). (P/N 529 036 023)
NOTE: Refer to the FUEL SYSTEM DIAGNOSTIC
FLOW CHART in this subsection to help diagnose
a fuel system related problem.
1. Ensure the fuel level in the tank is sufficient.
2. Ensure the battery voltage is over 12 volts.
3. Remove seat.
4. Remove RH side body panel, refer to BODY
subsection.
5. Disconnect the fuel pressure hose from the fuel
injector fuel rail. Refer to DISCONNECTING A
FUEL PRESSURE HOSE in FUEL HOSE AND
OETIKER CLAMPS.
6. Remove the 2 most forward locking ties secur-
vmr2012-028-010_a
ing the fuel hose to the upper cable support.
TYPICAL - PRESSURE GAUGE SETUP
NOTE: This is required to provide more hose 1. Pressure gauge to fuel hose adapter
2. Fuel hose adapter to fuel rail
length for proper connection to test equipment. 3. Fuel hose adapter to fuel pump pressure hose
8. Reinstall the fuel pump relay (R4) in the forward

fuse box.
9. Turn ignition key ON and observe fuel pressure.
FUEL PRESSURE 350 kPa ± 10 kPa
(Valid at 12v ± 0.1v) (51 PSI ± 1 PSI)
10. Start engine and observe fuel pressure.

11. Stop engine.
12. Remove test equipment and reconnect fuel
hose to injector fuel rail by proceeding in the
same manner as for its installation.
Test Conclusion
vmr2012-028-009_a
TYPICAL The fuel pressure should be within specification in

1. Forward injector rail fitting static or dynamic tests.
2. Locking ties
Rapid Pressure Drop
7. Install the fuel pressure gauge and fuel hose
adapter between the disconnected injector If there is a rapid pressure drop after the engine is
hose and fuel rail (in-line installation). stopped, check for leakage at:
– A fuel hose
– A fuel rail.
NOTE: The fuel pump check valve integral to the
fuel pump module may also be at fault.
If no leak is detected, replace fuel pump.
vmr2016-131 5
Slow Pressure Drop

If there is a slow pressure drop after the engine
is stopped, check for a fuel injector leak. Refer to
ELECTRONIC FUEL INJECTION (EFI) subsection.
NOTE: The fuel pressure regulator or fuel pump
check valve integral to the fuel pump module may
also be at fault.
If no leak is detected, replace fuel pump.
6 vmr2016-131
TROUBLESHOOTING
FUEL SYSTEM DIAGNOSTIC FLOW CHART
Fuel pump does not run Activate electric system to enable fuel pump Fuel pump runs
for 2 sec. then stops
Check fuse, relay and connections. Install fuel pressure gauge

Check fuel pump operation. on fuel pressure line
Repair or replace if necessary.
Activate electric system to enable fuel pump Replace fuel

pump module
Fuel pump runs
Repair or Fuel pressure less Fuel pressure within Fuel pressure more
replace than specifications specifications than specifications
Fails
Check fuel line/
rail for leaks
Fails OK Crank or
Perform fuel pump test start
OK
Fast Fuel pressure less Fuel pressure more Fuel pressure within
pressure drop than specifications than specifications specifications
No
Yes
Check
OK fuel line/
Verify fuel
pump check rail for leaks Repair or
valve Fails
replace FUEL SYSTEM OK
Fails OK
Fails
OK
Check fuel Perform fuel Replace fuel
injector pump test pump module Retest
OK
vmr2016-047-001_aen
vmr2016-131 7
PROCEDURES 3. Disconnect and remove the battery, refer to

CHARGING SYSTEM subsection.
FUEL HOSE AND OETIKER 4. Remove the rear body module, refer to BODY
CLAMPS subsection.
5. Refer to EXHAUST SYSTEM and remove the
Disconnecting a Fuel Pressure Hose following:
1. Remove the fuel pump relay (R4) in the front – Muffler assembly
fuse box. – Muffler/exhaust pipe heat shield.
2. Release fuel pressure by running engine until it 6. Remove rear frame. Refer to FRAME subsec-
runs out of fuel. tion.
3. Carefully disconnect the fuel hose fitting from 7. Disconnect the following from the fuel pump
the injector fuel rail by pressing on the release module:
tab of the quick disconnect fitting.
– Fuel pump electric connector
Fuel Hose Replacement – Fuel system vent hose
When replacing fuel hoses, be sure to use hoses – Fuel pump pressure hose.
and clamps as available from BRP parts depart-
ment. This will ensure continued proper and safe
operation.
WARNING
Use of fuel lines other than those recom-
mended by BRP may compromise fuel sys-
tem integrity.
WARNING
Whenever removing a hose in the fuel sys-
tem, always use new Oetiker clamps at as-
sembly. Then validate fuel system tightness
by performing a fuel pressure test.
vmr2015-130-005_a
Oetiker Clamp Replacement 1. Fuel pump connector

2. Vent hose
3. High pressure fuel hose
REQUIRED TOOL
8. Disconnect the RED (+) battery cable from the
OETIKER PLIERS starter solenoid.
(P/N 295 000 070)
9. Remove the 2 screws that secure the front of
the battery support.
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
in this subsection.
2. Disconnect the fuel pressure hose from the fuel
injector fuel rail. Refer to DISCONNECTING A
FUEL PRESSURE HOSE in FUEL HOSE AND
OETIKER CLAMPS.
8 vmr2016-131
vmr2012-028-013_a
1. Battery support sfvmr2014-010-071_a

2. Support retaining screws TYPICAL
1. Upper shock mounting bolts
NOTE: It is not necessary to remove the wiring
harness or other components from the battery 12. Block the front wheels with wheel chocks.
support. 13. Lift back end of vehicle and properly support
10. Flip the battery support over towards the RH under the lower rear portion of the frame, near
side of the vehicle for access to the rear frame the final drive.
extension.
CAUTION Before working on vehicle, en-
sure the vehicle is securely supported.
14. Remove vent tube from final drive.
vmr2012-028-014_a
TYPICAL
1. Battery support
2. Rear frame extension
11. Remove the upper mounting bolt from both

vmr2012-028-017_a
rear shock absorbers.
1. Final drive unit
2. Vent tube to remove
15. Remove fuel tank retaining screws (4).

NOTE: Note position of washers and bushings on
each screw.
vmr2016-131 9
18. Remove 2 nuts and screws securing rear

frame support to rear frame section.
vmr2015-130-003_a
vmr2015-043-010_a
16. Loosen the front 2 nuts and remove the 4

bolts retaining the frame extension.
vmr2015-043-011_a
19. Lift up on frame extension and pull fuel tank

out of vehicle.
vmr2015-043-008_a
NOTE: When lifting up on the frame extension,
17. Remove nuts and screws securing trailer the shock absorbers will fall backwards.
hitch/final drive protector and rear frame sup-
port to rear final drive.
vmr2012-028-021_a
TYPICAL
vmr2012-028-019_a 1. Rear shock absorbers
2. Fuel tank
TYPICAL
1. Trailer hitch
2. Bolts to remove
10 vmr2016-131
Fuel Tank Inspection NOTE: Fuel pump should come ON for a few sec-
Inspect fuel tank for any damages or cracks which onds, then stop.
may result in fuel leaks. If fuel pump does not come ON, carry out the fol-
Inspect fuel tank and fuel tank protector on frame lowing:
for damages. – Check fuel pump relay fuse (F15) and fuel pump
relay (R4).
Inspect protector for damages.
– Check in B.U.D.S. for applicable fault codes.
If cracks, gouges or other damages which may Refer to COMMUNICATION TOOLS AND
lead to a fuel leak, or damages to attachment B.U.D.S. subsection.
points that could prevent the tank from being
– Carry out a fuel pump input voltage test.
secure are found, replace fuel tank.
Fuel Tank Installation

Installation is the reverse of the removal proce-
Install a bushing on each fuel tank mounting
screw. The bushing inserts within the fuel tank
screw hole cavity.
Be sure to install the washers between the fuel
tank and the fastener as noted at removal.
Install all fuel tank fasteners loosely.
NOTICE The fuel tank fasteners must not be vmr2012-028-006_b
tightened to specified torque until complete as- 1. Fuel pump relay fuse
sembly in vehicle.
Fuel Pump Connector Access
Install all frame component fasteners loosely,
then apply torque as specified in the FRAME 570 Engine
subsection. Remove rear body module. Refer to BODY sub-
Apply specified torque to fuel tank retaining section.
screws.
TIGHTENING TORQUE
Fuel tank retaining 6.5 N•m ± 0.5 N•m
Be sure to properly connect and route:

– Fuel tank vent tube
– Fuel pump pressure hose
– Electrical connectors.
Refuel tank and ensure there are no leaks by
performing a FUEL TANK LEAK TEST and a FUEL
PUMP PRESSURE TEST as described in this sub-
section.
vmr2015-043-025_a
FUEL PUMP 650, 850 and 1000R Engines

Fuel Pump Pressure Test The fuel pump connector can be accessed from
Refer to INSPECTION in this subsection. under the RH rear fender, just above the forward
end of the fuel tank.
Fuel Pump Quick Test
1. Turn ignition key to ON.
2. Listen for fuel pump operation.
vmr2016-131 11
If battery voltage is now read, check fuel pump

ground circuit between fuel pump connector FP-4
and battery ground.
If battery voltage is still not read, check the follow-
ing:
– Fuse (F15)
– Fuel pump relay (R4)
– Fuel pump relay input voltage (control and
power circuits)
– Fuel pump relay control circuit continuity to
ECM-J1
– Wiring and connectors.
vmr2012-028-025_a Fuel Pump Resistance Test

TYPICAL 1. Ensure fuel pump connector is properly con-
1. Fuel pump connector
2. Fuel tank nected.
3. Underside of RH rear fender
2. Remove fuel pump relay (R4).
Fuel Pump Input Voltage Test
1. Disconnect the fuel pump connector.
3. Read voltage as follows.
NOTE: The fuel pump voltage will be read only
when the fuel pump is activated.
REQUIRED TOOLS

(P/N 529 035 868)
vmr2012-028-006c
1. Fuel pump relay

FLUKE RIGID BACK PROBE
(P/N TP88) 3. Measure fuel pump resistance as follows.
FUEL PUMP INPUT VOLTAGE TEST FUEL PUMP RESISTANCE TEST

(AT FUSE BOX)
VOLTAGE
TEST PROBES RESISTANCE
READING TEST PROBES
@ 20°C (68°F)
Fuel pump Fuel pump
connector connector Battery voltage Fuse box Battery
Approximately 2
Pin 3 Pin 4 contact A11 ground
If battery voltage is read, carry out a fuel pump

resistance test.
If battery voltage is not read, test fuel pump
power input as follows.
FUEL PUMP POWER WIRE TEST
VOLTAGE
TEST PROBES
READING
Fuel pump
connector Battery ground Battery voltage
Pin 3
12 vmr2016-131
vmr2012-028-006_a
FUSE BOX COORDINATES

vmr2015-043-005_a
If resistance test failed, disconnect fuel pump 570 ENGINE
connector and measure resistance at fuel pump 1. Fuel pump connector
connector. 2. Vent hose
FUEL PUMP RESISTANCE TEST
(AT FUEL PUMP CONNECTOR)
If test failed at pump connector, replace fuel

pump.
If test succeeded at pump connector, check
wiring and connectors from:
– Fuse box to fuel pump
– Fuel pump to battery ground.
Repair or replace as necessary.
Fuel Pump Access

Remove rear body module, refer to BODY subsec-
vmr2015-130-005_a
tion.
TYPICAL - 650, 850 AND 1000R ENGINES
1. Fuel pump connector
Fuel System Pressure Release 2. Vent hose
Refer to DISCONNECTING A FUEL PRESSURE
HOSE in this subsection. 3. Remove fuel pump retaining nut.
Fuel Pump Removal WARNING

1. Release the pressure of the fuel system. Fuel vapors are flammable and explosive un-
2. Disconnect the following from the fuel pump: der certain conditions. Use only non-spark-
ing tools.
– Fuel pump electric connector
– Fuel system vent hose
CAUTION Replace fuel pump gasket
– Fuel pump pressure hose. whenever fuel pump retaining nut is loosened.
REQUIRED TOOL
FUEL PUMP NUT TOOL

(P/N 529 035 899)
vmr2016-131 13
vmr2015-130-004_a
vmr2012-028-026_a
TYPICAL
TYPICAL - FUEL PUMP REMOVAL 1. Gasket ring here
1. Fuel pump retaining nut 2. Fuel pump flange
4. Carefully pull out and rotate fuel pump as re- WARNING

quired.
Ensure gasket ring makes good contact all
NOTICE Pay attention not to damage fuel around fuel pump and fuel pump mounting
sender and fuel pump prefilter. neck on fuel tank.
5. Discard gasket ring. 3. Ensure proper fuel pump orientation as in fol-
6. Wipe off any fuel spillage. lowing illustration.
Fuel Pump Installation

Rotate fuel pump during insertion as per removal
procedure.
CAUTION Pay attention not to damage

fuel sender and fuel pump pre-filter.
1. Install a NEW gasket ring.
2. Place gasket so that it is properly located be-
tween fuel pump and fuel pump mounting neck
on fuel tank.
vmr2015-043-017_a
570 ENGINE
1. Fuel tank pump index
2. Fuel pump index
14 vmr2016-131
TIGHTENING TORQUE
29 N•m ± 1 N•m
Fuel pump retaining nut
7. Install fuel pressure hose on fuel pump using a

NEW Oetiker clamp.
8. Install fuel vent tube on fuel pump.
9. Install electrical connector on fuel pump.
10. Install fuel pump relay (R4).
11. Refuel tank and ensure there are no leaks by
performing a FUEL TANK LEAK TEST and a
FUEL PUMP PRESSURE TEST as described in
vmr2012-028-007_a
this subsection.
650, 850 AND 1000R ENGINES
1. Fuel tank pump index 12. Check fuel level sender operation.
2. Fuel pump index
4. Insert fuel pump retaining nut over the fuel FUEL PUMP PRE-FILTER
pressure hose and electrical wiring connector. (STRAINER)
5. While firmly holding pump against tank, engage
fuel pump retaining nut on fuel tank flange. Fuel Pump Pre-filter Replacement
(570 Engine)
NOTE: If necessary, move the pump in order to
ensure the flange is sitting completely flat on the 1. Remove FUEL PUMP, see FUEL PUMP RE-
tank. MOVAL in this subsection.
6. Tighten fuel pump retaining nut to specification. 2. Unlock 3 tabs on strainer plastic ring.
6.1 Ensure pump locking ring is fully engaged.
6.2 To apply the proper torque to the fuel
pump retaining nut, install the fuel pump
nut tool on a torque wrench with it's han-
dle perpendicularly (90°) to the torque
wrench.
6.3 Ensure pump is properly aligned with in-
dex marks after nut it tightened to speci-
fication.
vmr2015-043-027_a
3. Remove rubber pad.
vmr2015-043-024_a
TORQUE WRENCH PERPENDICULAR TO TOOL HANDLE
vmr2016-131 15
6. Lubricate assembly area of new strainer and

fuel pump with O-ring lubricant or clean oil
vmr2015-043-028_a
vmr2015-043-031_a
4. Remove push nut securing strainer to fuel
pump. Be careful not to break the assembly 7. Insert the new strainer on fuel pump making
locator pin. sure to press it in tightly against the fuel pump
surface.
8. Using a small socket, press in a NEW push nut
to secure strainer.
Fuel Pump Pre-filter Replacement

(650, 850 and 1000R Engines)
1. Remove FUEL PUMP, see FUEL PUMP RE-
MOVAL in this subsection.
2. Unlock 3 tabs on strainer plastic ring.
vmr2015-043-029_a
5. Pull strainer off fuel pump.
vmr2008-135-220_a
Step 1: Lift these tabs to unlock ring

Step 2: Pull ring off pump inlet
3. Remove rubber pad.
vmr2015-043-030_a
16 vmr2016-131
7. Press in a NEW push nut to secure strainer.

FUEL LEVEL SENDER

The fuel level sender is a float actuated variable
resistance type that is part of the fuel pump.
vmr2008-135-221_a
4. Remove push nut securing strainer to fuel

pump. Be careful not to break the plastic pin.
vmr2015-043-023_a
570 ENGINE
vmr2008-135-222_a
vmr2008-135-901_a
5. Pull strainer off fuel pump. 650, 850 AND 1000R ENGINES
1. Fuel level sender
Fuel Level Sender Resistance Test

(Fuel Pump Module Installed)
1. Disconnect multifunction gauge, refer to the
LIGHTS/GAUGE/ACCESSORIES subsection.
2. Measure the resistance of the fuel level sender
as follows.
vmr2008-135-223_a
NOTE: A non-serviceable filter is located within

the fuel pump module. If it is clogged, replace fuel
pump.
6. Insert the new strainer on fuel pump making
sure to press it in tightly against the fuel pump
surface.
vmr2016-131 17
FUEL LEVEL SENDER RESISTANCE TEST FUEL LEVEL SENDER INPUT VOLTAGE TEST
RESISTANCE FUEL PUMP
GAUGE BATTERY VOLTAGE
FUEL LEVEL CONNECTOR
CONNECTOR
@ 20°C (68°F)
Negative
Pin 2 5V
Full 5 ±1 terminal
Pins 4 and 21
Empty 100 ±5
TEST RESULT SERVICE ACTION
Test wiring continuity
between fuel level
5V is not read
sender and multifunction
gauge
Replace multifunction
Wiring continuity is good
gauge
Wiring continuity is not
Repair or replace wiring
obtained
Fuel Level Sender Replacement

Replace fuel pump. Refer to FUEL PUMP in this
subsection.
FUEL TANK VENT VALVES

Fuel Tank Vent Valve Test
Inlet Check Valve Test
vmr2006-020-052_c
1. Remove rear body module, refer to BODY sub-
section.
If readings are out of specification, refer to FUEL
LEVEL SENDER RESISTANCE TEST (AT FUEL 2. Remove multifunction gauge for access to the
PUMP CONNECTOR). vent system inlet hose, refer to the LIGHTS,
If readings are as specified, refer to FUEL LEVEL
GAUGE AND ACCESSORIES subsection.
SENDER INPUT VOLTAGE TEST. 3. Install a small hose pincher between the vent
pressure relief valve and the fuel pump vent in-
Fuel Level Sender Resistance Test let.
(at Fuel Pump Connector) REQUIRED TOOL
FUEL LEVEL SENDER RESISTANCE TEST
FUEL PUMP RESISTANCE SMALL HOSE PINCHER
FUEL LEVEL (P/N 295 000 076)
CONNECTOR @ 20°C (68°F)
Full 5 ±1
Pins 1 and 2
Empty 100 ±5
If resistance test at fuel pump connector is failed,

replace fuel pump module.
Fuel Level Sender Input Voltage Test

1. Set ignition switch to ON.
2. Disconnect fuel pump connector, refer to FUEL
PUMP CONNECTOR ACCESS in this subsec-
tion.
3. Measure for input voltage as follows.
18 vmr2016-131
– Ensure inlet check valve is properly installed, re-

fer to FUEL TANK VENT VALVE INSTALLATION
in this subsection.
– Test inlet check valve separately. If good, re-
place the breather filter, refer to PERIODIC
MAINTENANCE PROCEDURES.
Pressure Relief Valve Test
1. Install the small hose pincher between the inlet
check valve and the fuel pump vent inlet fitting.
vmr2015-130-002_d
TYPICAL
1. Pressure relief valve
2. Fuel pump vent inlet
3. Install small hose pincher here
4. Connect the vacuum/pressure pump to the fuel

tank vent hose inlet.
REQUIRED TOOL
VACUUM/PRESSURE PUMP
(P/N 529 021 800)
vmr2015-130-002_e
TYPICAL
1. Inlet check valve
2. Fuel pump vent inlet fitting
3. Install small hose pincher here
2. Set vacuum/pressure pump to PRESSURE and

activate pump. The gauge should increase in
reading.
3. Set vacuum/pressure pump to VACUUM and
activate pump. The gauge on the pump should
not change in reading.
If the test failed, carry out the following:
– Ensure pressure relief valve is properly in-
stalled, refer to PRESSURE RELIEF VALVE
INSTALLATION in this subsection.
vmr2012-028-008_a – Replace pressure relief valve if it fails the test.
TYPICAL
1. Fuel tank vent hose inlet
2. Gauge connector
5. Remove fuel tank cap.

6. Set vacuum/pressure pump to PRESSURE and
activate pump. The gauge on the pump should
not change in reading.
7. Set vacuum/pressure pump to VACUUM and
activate pump. The gauge should increase in
reading.
If the test failed, carry out the following:
– Ensure breather filter is properly installed, refer
to PERIODIC MAINTENANCE PROCEDURES.
vmr2016-131 19
vmr2015-130-002_f vmr2015-130-002_f
TYPICAL TYPICAL
1. Pressure relief valve flow direction arrow 1. Pressure relief valve flow direction arrow
Fuel Tank Vent Valve Installation

Inlet Check Valve Installation
Ensure white portion of inlet check valve is to-
wards the vent breather filter.
vmr2015-130-002_g
TYPICAL
1. Vent breather filter
2. White portion of inlet check valve
Pressure Relief Valve Installation

Ensure pressure relief valve flow arrow is pointing
away from fuel pump vent fitting.
20 vmr2016-131
Subsection 01 (POWER DISTRIBUTION AND GROUNDS)
POWER DISTRIBUTION AND GROUNDS

GENERAL
POWER DISTRIBUTION DIAGRAM
DPS2
COMMUNICATION
CONNECTOR DB-5
BAT FUSE BOX 1
MAIN GAUGE
RELAY (R2)
F4 5A COMMUNICATION
16 awg CONNECTOR DB-4
FL-1
IGNITION COIL DPS1-A
16 awg
FL-2
F5 5A FUEL INJECTORS HICA-C
FUEL PUMP
FUSE BOX 2 RELAY (R4) VEHICLE
F6 5A SPEED SENSOR
F3 40A
ECM
FUEL PUMP
VOLTAGE F15 5A
REGULATOR/
RECTIFIER 2WD/4WD SWITCH
ACCESSORIES
RELAY (R3) WINCH SWITCH
STARTER F7 5A POSITION LIGHTS
SOLENOID
(OUTLANDER EUROPE)
F8 5A ECM (WAKE UP)

WINCH RELAY
IGNITION SWITCH
F9 25A
FAN RELAY (R1)
FAN MOTOR
CLOCK / HAZARD
F10 5A
HORN / FLASHERS
(EUROPE)
F11 30A POSITION LIGHTS
(RENEGADE EUROPE)
HEADLIGHT COMMUNICATION
RELAY (R5) CONNECTOR (DB-6)
IGNITION SWITCH F12 15A 12 V POWER OUTLET
DC OPTION
CONNECTOR (DC3)
BRAKE LIGHT HEADLIGHTS

RELAY (R8)
F14 15A DC OPTION BRAKE SWITCH
CONNECTORS (DC5/DC6)
TAILLIGHTS /
LICENSE PL
BRAKE LT PR
vmr2016-132-001_aen
vmr2016-132 1
FUSE BOX 1
FUSE IDENTIFICATION
4 5 A
5 5 A
6 5 A
7 5 A
8 5 A
9 25 A
Fuse
10 5 A
vmr2012-028-006_g
11 30 A
FUSES
12 20 A
14 20 A
15 5 A
JP1 Jumper 1 (or 20 A fuse)
vmr2012-028-006_h
RELAYS
RELAY
RELAY STATE (ON) RELAY STATE (OFF)
IDENTIFICATION
R1 Cooling fan See COOLING SYSTEM
When ignition key is turned ON
Approximately 30 seconds after ignition
R2 Main AND
key is turned OFF
Run/Stop switch is set to RUN
When ignition key is turned OFF
OR
R3 Accessories Same as main relay
When engine speed is less than
1000 RPM for at least 50 minutes
R4 Fuel pump See FUEL TANK AND FUEL PUMP
When ignition key is turned OFF
OR
R5 Headlights Same as main relay
When engine speed is less than
1000 RPM for at least 50 minutes
R8 Brake lights See BRAKES
2 vmr2016-132
FUSE LINKS AND FUSE BOX 2
vmr2015-131-001_a
vmr2016-132-002_a TYPICAL - RH SIDE

1. Battery ground
LOCATION OF FUSE LINKS AND FB2 2. Engine ground
1. Connector support (right side of vehicle) 3. DPS ground
2. Fuse box 2 4. Wiring harness ground
3. Fuse links 1 and 2
4. Starter solenoid
5. Battery
6. Battery support PROCEDURES
TESTING A FUSE LINK
Measure the fuse link output voltage (at the fuse
box). Refer to the WIRING DIAGRAM.
If no voltage is measured, carry out the following:
– Remove the right side panel and extension
panel.
– Grab each end of the fuse link and gently pull in
opposite directions.
If the fuse link is open, the insulator should stretch
vmr2015-044-004_a
and break where the link has failed.
FUSE BOX 2
NOTE: Failure of a fuse link is usually due to a se-
FUSE LINK IDENTIFICATION vere overload (or short circuit) between the fuse
link and the load it protects (the fuse box).
Fuse 1 Main 16 awg
links 2 Fan/accessories 16 awg REPLACING A FUSE LINK
FUSE IN FUSE BOX 2 IDENTIFICATION
DPS
NOTICE Before replacing a fuse link, be sure
Fuse 3 40 A to find and repair the cause of the failure.
(dynamic power steering)
The gauge of the fuse link can be identified by the
GROUNDS color of its insulator, and by an identification label.
Be sure to replace a fuse link by an identical fuse
All grounds are grouped at the same location on link.
RH side of frame. – blue = 18 awg
– black = 16 awg
– gray = 14 awg
vmr2016-132 3
vmr2016-132-003_a
PRE-ASSEMBLED REPLACEMENT FUSE LINK

1. Insulated fuse link wire
2. Butt end terminal
3. Terminal factory crimped on fuse link
4. Crimp here when installing in circuit
5. Solder ring
1. Disconnect the battery.

2. Cut the circuit wiring as close as possible to the
fuse link terminals.
3. Remove 8 mm (5/16 in) of insulator from the
ends of the circuit wiring.
4. Insert the circuit wire end in the link terminal
making sure the wire end bottoms out in the
center of the terminal.
5. Crimp the terminal on the bare wire.
6. Using a heat gun, carefully heat the link ter-
minal until the solder ring has melted into the
wiring, and the terminal insulator has shrunk
tightly around the terminals and wire insulators.
7. Reconnect the battery.
4 vmr2016-132
Subsection 02 (WIRING HARNESS AND CONNECTORS)
WIRING HARNESS AND CONNECTORS

SERVICE TOOLS
CRIMPING TOOL (HEAVY GAUGE WIRE) .................................... 529 035 730 ........................................... 14
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 12
ECM TERMINAL REMOVER 2.25................................................. 529 036 175 ........................................... 12
ECM TERMINAL REMOVER 3.36................................................. 529 036 174 ........................................... 12

GM TERMINAL EXTRACTOR........................................................ 12094430 ........................................... 13
SNAP-ON TERMINAL REMOVER TOOL ...................................... TT600-4 ........................................... 9
GENERAL ABBREVIATION DESCRIPTION
The illustrations in this subsection are typical. DC5 Accessory outlet

Several variants of the connector types, such as DC6 Accessory outlet
different number of pin cavities, are used on the
DC7 Accessory outlet
vehicle.
DPS1 Dynamic power steering
CONNECTOR ABBREVIATION DPS2 Dynamic power steering
DESCRIPTION DPS3 Dynamic power steering
ABBREVIATION DESCRIPTION FL Fuse link
BD RH multifunction switch FP Fuel pump
BN1 Ground terminal FRR Rear brake light switch
BN2 Ground terminal FT Cooling fan
BN4 Ground terminal HIC1 Harness interconnect
BP1 Positive terminal to PF2 HIC2 Harness interconnect
BP2 Positive terminal from battery Harness interconnect
BP3 Positive terminal to SM HICa (Used on European models
only)
CC Ignition switch
MG1 LH multifunction switch
CL Cluster
MG2 LH multifunction switch
Rear RH turn light
CRD (Used on European models PDB RH lower headlight
only) PDH RH upper headlight
Rear LH turn light PF1 Front Fuse box
CRG (Used on European models
only) PF2 Rear fuse holder
DB Diagnostic connector PGB LH LO beam headlight
DC1 Accessory outlet PGH LH HI beam headlight
DC2 Accessory outlet License plate light
PL (Used on European models
DC3 Accessory outlet only)
vmr2016-133 1
ABBREVIATION DESCRIPTION
RH License plate light
PLD (Used on European models
only)
LH License plate light
PLG (Used on European models
only)
PRD Rear RH light
PRG Rear LH light
Trailer harness
RBL (Used on European models
only)
RD1 Voltage regulator/rectifier
SM Starter motor
SS1 Starter solenoid
SS2 Starter solenoid
SW1 Winch relay
SW2 Winch relay
SW4 Winch relay
SWW Winch remote switch
2 vmr2016-133
WIRING HARNESS ROUTING

Main Harness (Front 1/2)
DC3
DC2 BD
MG1
DC1
MG2
CC DC5
SWW
HIC1
PDH
HIC2
PDB
SW2 SW1
DB DPS2
SW4
vmr2015-132-100_a
vmr2016-133 3
Main Harness (Front 2/2)
CI
PF2
HICa
SM
DPS3
DPS1
FT
PGH PGB
vmr2016-133-100_a
4 vmr2016-133
Main Harness (Rear)
BN4
BN DC6
BN2
BN1
PL
FRR
PF2
FT
CRD
BP1
SS
RD1
SS2
PRD
SS1
BP3
vmr2016-133-101_a
vmr2016-133 5
WIRING HARNESS SPLICE LOCATION

Main Harness (Rear Part)
DB
DC6
JT RD
D2
JT WH/OR JT WH/BK
Jt WH/BE
JT RD/PK
JT BK2
PF2 FRR
FL
vmr2016-133-102_a
Main Harness (Front Part 1/2)
SW4
Diode 5
Diode 6
JT RD/GN
JT RD/GY
DPS1
DPS2
vmr2015-132-105_a
6 vmr2016-133
Main Harness (Front Part 2/2)
PF1
JT RD/YL
JT VI/RD
JT RD/BE
JT BU/GY
DC1
DC2
JT OR/BK
JT BE
JT BK/WH HICa
JT VI/BE JT BU
JT RD/BU JT GN
JT BK/BR JT RD/BK
JT RD/BR JT BK3
JT VI/GY JT RD/VI
JT BK1
JT RD/WH
JT RD/OR
Diode 11
FT
vmr2015-132-106_a
vmr2016-133 7
PROCEDURES
DEUTSCH CONNECTORS
Deutsch Connector Application
A variety of Deutsch connectors are used on var-
ious systems:
– Diagnostic connector
– Vehicle speed sensor (VSS) connector.
The following procedures may be used on each as
they are similar in construction.
Deutsch Connector Disassembly and

Reassembly
3 1
V01G0OA 1
TYPICAL — FEMALE CONNECTOR
1. Female lock
3
2
4
F00H1CA
TYPICAL —DEUTSCH CONNECTOR

1. 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:
V01G0PA 1
1. Using long nose pliers, pull out the secondary
TYPICAL — MALE CONNECTOR
plastic lock from between the terminals. 1. Male lock
NOTE: Before pin extraction, push wire forward

to relieve pressure on retaining tab.
2. Insert a 4.8 mm (.189 in) wide screwdriver
blade inside the front of the terminal cavity.
3. Pry the retaining tab away from the terminal
while gently pulling the wire and terminal out
of the back of the connector.
8 vmr2016-133
1 PACKARD CONNECTORS
Packard Connector Application
Packard connectors are used to connect:
– Electrical harnesses
– Gauges.
3-Pin Packard Connector
1
V01G0QA 1
TYPICAL — FEMALE CONNECTOR
1. Retaining tabs
Terminal Insertion C B A
1. For insertion of a terminal, ensure the sec-
ondary plastic lock is removed.
2. Insert terminal through the back of the connec- F04H45A
tor in the appropriate position, and push it in as VIEW OF A 3-PIN PACKARD CONNECTOR
far as it will go. You should feel or hear the ter- 1. Identification letters
minal lock engage.
NOTE: This type of connector also comes in other
3. Pull back on the terminal wire to be sure the pin configurations.
retaining tabs are holding the terminal.
To remove a terminal from a 3-pin Packard connec-
4. After all required terminals have been inserted, tor, use the SNAP-ON TERMINAL REMOVER TOOL
the lock must be installed. (P/N TT600-4).
F01B1JA
WARNING
1 1 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-
F04H6LA
tor while pulling it out.
TYPICAL — CONNECTOR PIN-OUT
1. Terminal position identification numbers
vmr2016-133 9
A33Z01A 2 1
TYPICAL
1. Retainer
2. Tab (one on each side)
vmr2006-032-001_a
Open housing by lifting 4 tabs.
A33Z02A 1
TYPICAL
1. Tabs (2 on each side)
Lift the top plastic lock of the female terminal to

be removed and hold in position. Lift the female
vmr2006-032-001_b terminal to unlock from the housing and push out
CONNECTOR PINOUT of housing.
Push on both tabs to remove retainer.
10 vmr2016-133
vmr2008-022-014_a
A32E3XA
TYPICAL Pull out connector.

1. Lift and hold plastic lock
2. Lift to unlock and push out
MOLEX CONNECTOR
Molex Connector Application
Molex connectors are used on the following sys-
tem:
– ECM
Molex Connector Removal

Push and hold the locking tab.
vmr2008-022-015_a
Molex Connector Installation

Fully open connector lock.
vmr2008-022-013_a
Rotate connector lock until it stops.
vmr2008-022-015_b
Install connector to ECM.
vmr2016-133 11
Rotate connector lock until it snaps locked.
vmr2008-139-016_a
1. ECM connector (harness side)

2. ECM adapter
NOTICE Never probe directly on ECM har-

ness connector. This could change the shape
or enlarge the terminals and create intermit-
vmr2008-022-013 _b tent or permanent contact problems.
1. Locked here
Molex Connector Inspection
Molex Connector Probing Before replacing an ECM, always check electrical
The most recommended and safest method to connections.
probe ECM connector terminals is to use the ECM 1. Ensure connector locking mechanism is func-
ADAPTER TOOL (P/N 529 036 166). This tool will tioning properly.
prevent deforming or enlarging terminals which
would lead to bad ECM terminal contact creating 2. Ensure all wire terminals (pins) are properly
intermittent or permanent problems. 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
529036166
to the pins of the ECM connector.
Disconnect the ECM connector and reconnect on
the tool connector. Probe required terminals di- Molex Connector Terminal Removal
rectly in the tool holes. (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).
12 vmr2016-133
529036175
1. Remove rear protector from connector.

2. Pull out the connector lock.
smr2009-045-027_a
NOTICE Before installing wire terminals in

the connector, ensure all terminals are prop-
erly crimped on wires. After installation of
wire terminals in the connectors, ensure they
are properly locked by gently pulling on them
as if to extract them.
FURUKAWA CONNECTOR
Furukawa Connector Application
Voltage regulator/rectifier.
smr2009-045-025_a Terminal Removal

3. Insert tool to unlock terminal. 1. Remove the secondary lock (plastic insert).
smr2010-050-021_a
smr2009-045-026_a
Step 1: Remove the secondary lock
1. Unlock here
2. Carefully insert the GM TERMINAL EXTRACTOR
4. Gently pull on the wire to extract the terminal (P/N 12094430) between the lock and the pin to
out the back of the connector. release the pin.
smr2010-052-003
GM TERMINAL EXTRACTOR (P/N 12094430)
vmr2016-133 13
A
A32E2QA
A. 10 mm (3/8 in)
smr2010-050-022_a
Step 2: Insert GM terminal extractor tool (P/N 12094430)

NOTE: Make sure not to cut wire strands while
3. Gently pull on the wire to extract the pin out the stripping the wire.
back of the connector. Install the appropriate terminal on the wire ac-
cording to the requirement. Refer to appropriate
PARTS CATALOG.
A32E2RA
INSTALLATION OF TERMINAL
Follow the instructions provided with the CRIMP-

ING TOOL (HEAVY GAUGE WIRE) (P/N 529 035 730)
smr2010-050-023_a
to select the proper position of the tool.
Step 3: Pull wire to extract pin
NOTICE Before installing terminals in the

connectors, ensure all terminals are properly
crimped on the wires. After installation of the
wire terminals in the connectors, ensure they
529035730
are properly locked by gently pushing on them
as if to extract them. NOTE: Different wires require different crimping
pliers settings.
BATTERY AND STARTER CABLE
TERMINALS
Cable Crimping
Carefully strip the wire approximately to 10 mm
(3/8 in) in length, using a wire stripping tool or
sharp blade/knife.
14 vmr2016-133
Install the protective heat shrink rubber tube on

the terminal. Heat the heat shrink rubber tube us-
ing the heat gun so that it grasps the wire and the
1
terminal.
NOTICE Make sure that the protective heat
shrink rubber tube has been properly installed
and no part of wire is exposed.
2
A32E2SA
POSITIONING THE CRIMPING PLIERS

Step 1: Press
Step 2: Rotate
After positioning the crimping pliers, crimp the ter-

minal already installed on wire.
A32E2TA
CRIMPING OF WIRE
A32E2UA
PROPERLY CRIMPED WIRE
To verify, if the wire is properly crimped, apply

some pulling force on wire and the terminal at the
same time from both directions.
NOTICE Never weld the wire to the terminal.
Welding can change the property of the wire
and it can become brittle and break.
vmr2016-133 15
Subsection 03 (IGNITION SYSTEM)
IGNITION SYSTEM
SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 2, 4
GENERAL 2. Defective CPS

- Check operation of CPS and replace if necessary.
SYSTEM DESCRIPTION Refer to ELECTRONIC FUEL INJECTION (EFI)
subsection.
The battery supplies the primary side of ignition
3. Defective trigger wheel
coils through the main relay (R2) while the ECM
completes the circuit for each cylinder by switch- - Inspect trigger wheel. Refer to MAGNETO AND
STARTER subsection.
ing it to ground at the right moment. The ECM
can detect an open and short circuit in the primary 4. Defective ignition circuit
winding but it does not check the secondary wind- - Check fuse 5 of fuse box 1, ignition coil and wiring
ing. condition.
The Engine Management System (EMS) controls 5. Defective fuel pump
the ignition system. For more information, refer - Check fuel pump, refer to FUEL TANK AND FUEL
to ENGINE MANAGEMENT subsection. PUMP subsection.
Ignition Timing 6. Defective fuel injectors or circuit

- Check fuel injectors, refer to ENGINE MANAGE-
Ignition timing is not adjustable. MENT SYSTEM subsection.
TROUBLESHOOTING ENGINE HARD TO START

It is good practice to check for fault codes using 1. Spark plug faulty, fouled or worn out
the B.U.D.S. software as a first troubleshooting - Check spark plug condition. Replace if necessary.
step. Refer to DIAGNOSTIC AND FAULT CODES
subsection. 2. Low fuel pressure
- Test fuel pressure, refer to FUEL TANK AND
Always refer to the WIRING DIAGRAM when FUEL PUMP subsection.
troubleshooting an electrical circuit.
Refer to POWER DISTRIBUTION AND GROUNDS ENGINE MISFIRES, RUNS IRREGULARLY
for fuse and relay information. 1. Fouled, defective, worn spark plugs
Refer to WIRING HARNESS AND CONNECTORS - Check/verify heat range/gap/replace.
for vehicle wiring harness layout and component
locations. 2. Damaged trigger wheel/loose CPS
- Inspect trigger wheel. Refer to MAGNETO AND
Refer to ENGINE MANAGEMENT SYSTEM (EMS) STARTER subsection.
for powertrain wiring harness layout and compo-
nent locations. 3. Defective ignition circuit
- Check ignition coil, fuse 5, and wiring condition.
DIAGNOSTIC GUIDELINES 4. Poor engine grounds
The following is provided to help in diagnosing the - Check/clean/repair.
probable cause of a problem. It is a guideline and
should not be assumed to list all possible causes. ENGINE CONTINUALLY BACKFIRES
1. Fouled, defective spark plugs
ENGINE WILL NOT START (ENGINE
- Clean/replace spark plugs.
TURNS OVER)
1. Fouled or defective spark plug
- Replace.
vmr2016-134 1
2. Damaged trigger wheel/defective or loose CPS EMERGENCY ENGINE STOP

- Inspect trigger wheel and CPS, refer to MAG- SWITCH
NETO AND STARTER and ELECTRONIC FUEL
INJECTION (EFI) subsections. Testing the Emergency Engine Stop
Switch at ECM
PROCEDURES 1. Disconnect ECM connector and install it on the
ECM adapter tool.
IGNITION SWITCH
Ignition Switch Quick Test
Turn ignition switch to ON position.
If multifunction gauge turns on (assuming it
works), the ignition switch is good.
If multifunction gauge does not turn on, check the
following in this order:
– Battery
– Fuse link 1
– Fuse 4, 5 and 8 of fuse box 1
– ECM is properly powered (refer to ELEC-
TRONIC FUEL INJECTION (EFI) subsection)
vmr2012-031-005_b
– Ignition switch TYPICAL
– Emergency engine stop switch. 1. ECM
2. ECM connector cover
Ignition Switch Access REQUIRED TOOL
Refer to BODY subsection and remove the LH
side panel. ECM ADAPTER TOOL
(P/N 529 036 166)
2. Remove ignition key switch fuse (F8), refer to

POWER DISTRIBUTION AND GROUNDS sub-
section.
3. Turn ignition key to ON position.
4. Test for continuity as per following table.
EMERGENCY ENGINE STOP SWITCH
TEST AT ECM
FUSE BOX ECM
FUNCTION RESULT
CONTACT ADAPTER
Close to
RUN 5E A4
vmr2012-031-001_a 0
TYPICAL position
1. Ignition key — G2 to K3 Open
2. Ignition switch connector
3. ECM 5E A4 circuit
STOP
position — Close to
G2 to K3
0
If switch fails the test, refer to TESTING THE

EMERGENCY ENGINE STOP SWITCH AT MUL-
TIFUNCTION SWITCH CONNECTORS.
2 vmr2016-134
Testing the Emergency Engine Stop

Switch at Multifunction Switch
Connectors
Refer to WIRING HARNESS AND CONNECTORS
subsection for connector locations.
The emergency engine stop switch is wired into
the LH multifunction switch connectors (MG1 and
MG2).
1. Remove gauge support, refer to LIGHTS,
GAUGE AND ACCESSORIES subsection.
2. Disconnect MG1 and MG2 connectors.
3. Test switch continuity as per following table.
vmr2012-031-002_a
EMERGENCY ENGINE STOP SWITCH PIN-OUT TYPICAL
1. Ignition coil location
FUNCTION PROBE RESULT
MG1-3 to Installing the Ignition Coil
Open circuit
MG2-3 Install a new elastic nut and tighten to the speci-
RUN position
MG1-1 to fied torque.
MG1-2 TIGHTENING TORQUE
Close to 0
MG1-3 to 8 N•m ± 1 N•m
MG2-3 Ignition coil retaining bolt
STOP position (71 lbf•in ± 9 lbf•in)
MG1-1 to
Open circuit
MG1-2 Testing the Ignition Coil Input Voltage
If switch tests good, test continuity of wiring. Re- 1. Disconnect the 3-pin connector from the igni-
fer to WIRING DIAGRAM. tion coil. Refer to IGNITION COIL ACCESS.
IGNITION COIL
tmr2011-026-002_a
1. Ignition coil connector

3. Turn ignition switch to ON.
4. Read voltage as per following table.
REQUIRED TOOL
vmr2006-018-100
Ignition Coil Access FLUKE 115 MULTIMETER

Refer to BODY subsection and remove RH inner (P/N 529 035 868)
fender panel(s) for access to the ignition coil.
vmr2016-134 3
IGNITION COIL INPUT VOLTAGE TEST Testing the Ignition Coil Resistance
CONNECTORS VOLTAGE An ignition coil with good resistance measure-
ment can still be faulty. Voltage leakage can occur
Pin 2 with battery ground Battery voltage at high voltage levels which is not detectable with
an ohmmeter. Replacing the ignition coil may be
If battery voltage is NOT read, check continuity of necessary as a test.
ignition coil supply circuit. Refer to WIRING DIA-
GRAM. Primary Windings
1. Disconnect HIC2 connector.
Testing the Ignition Coil Ground Circuit
Continuity
1. Disconnect the ECM connector and connect
it to the ECM adapter tool. Refer to ELEC-
TRONIC FUEL INJECTION (EFI) subsection.
vmr2012-031-005_a
TYPICAL
1. ECM
2. ECM connector cover
3. HIC2 connector
2. Disconnect ECM connector and connect it to

vmr2012-031-005_b
the ECM adapter tool.
TYPICAL
1. ECM
2. ECM connector cover REQUIRED TOOL
REQUIRED TOOLS ECM ADAPTER TOOL

(P/N 529 036 166)
ECM ADAPTER TOOL
(P/N 529 036 166)
3. Using a multimeter set to , check resistance
in primary windings as follows.
FLUKE 115 MULTIMETER IGNITION COIL RESISTANCE TEST
(P/N 529 035 868)
ENGINE RESISTANCE
PRIMARY ECM
CONNECTOR @ 20°C
CIRCUIT CONNECTOR
(HIC2) (68°F)
2. Check wiring continuity as per following table.
Cylinder 1
IGNITION COIL GROUND CIRCUIT M1
(front)
CONTINUITY TEST Pin C .3 - .6
Cylinder 2
PIN M2
PIN (rear)
(IGNITION
COMPONENT (ECM
COIL If any resistance is not good, measure resistance
CONNECTOR)
CONNECTOR) directly on coil. If second test is ok, check wiring.
Cylinder 1 (front) 1 M1
Secondary Windings
Cylinder 2 (rear) 3 M2 Due to the integrated diode, it is not possible
to take any resistance measurement of the sec-
ondary winding.
4 vmr2016-134
SPARK PLUG
For spark plug replacement procedure, refer to
PERIODIC MAINTENANCE PROCEDURES sub-
section.
Troubleshooting Fouled Spark Plug

Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed
due to misfiring, reduced performance, and in-
creased fuel consumption. This is due to a loss
of compression. Other possible causes are: pro-
longed idling or low-speed riding, a clogged air
filter, incorrect fuel, defective ignition system,
incorrect spark plug gap, lubricating oil entering
the combustion chamber, or too cold spark plug.
The plug face of a fouled spark plug has either a
wet black deposit or a black carbon fouling. Such
coatings form a conductive connection between
the center electrode and ground.
Spark Plug Analysis
A00E0AA 1 2 3
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).
vmr2016-134 5
Subsection 04 (CHARGING SYSTEM)
CHARGING SYSTEM
EXTECH INDUCTIVE AMMETER .................................................. 380941 ............................................. 2
NAPA ULTRA PRO BATTERY LOAD TESTER ............................... 95260 ......................................... 2–4
GENERAL The voltage regulator output voltage is distributed

as follows:
SYSTEM DESCRIPTION – Fuse links
– Battery.
The purpose of the charging system is to keep the
battery at a full state of charge. The voltage regulator limits voltage to prevent any
damage to electrical components.
NOTE: For an overview of the vehicle electrical
system, refer to ENGINE MANAGEMENT SYS- COMPONENT VOLTAGE Vdc
TEM section. Minimum 12.5
Voltage Regulator
Magneto Maximum 15
The magneto is the primary source of electrical
energy. It transforms a magnetic field into electric
current (AC).
The alternating current is regulated and trans-
formed into direct current (DC) by the voltage
regulator, and normally powers all of the vehicle's
systems and accessories.
The magneto has a 3 phase delta wound stator.
vmr2006-017-002
TYPICAL
Battery
The battery supplies DC power to every electri-
cal and electronic system in the vehicle as well as
all accessories. At low engine RPM operation and
high current load conditions, it supplements the
vmr2006-017-001
magneto's output as required, and helps to main-
TYPICAL tain a steady system voltage.
Voltage Regulator TROUBLESHOOTING

The regulator receives AC current from the mag- It is good practice to check for fault codes using
neto and transforms it into direct current (DC). the B.U.D.S. software as a first troubleshooting
step. Refer to DIAGNOSTIC AND FAULT CODES
subsection.
vmr2016-135 1
BATTERY REGULARLY DISCHARGED OR If battery voltage drops below specification dur-

WEAK ing test, replace battery and perform a CHARG-
ING SYSTEM LOAD TEST.
1. Loose or corroded battery cable connections.
- Tighten or repair battery cable connections.
CHARGING SYSTEM LOAD TEST
2. Worn or defective battery.
- Charge and test battery.
3. Defective magneto stator.
- Test stator, refer to MAGNETO AND STARTER 12V,18AH
SYSTEM subsection. RD1-1

BN4 BAT2 BAT1
4. Defective regulator/rectifier. RD RD1-3 BN1
- Test system voltage.

SS-1 BP3
5. Damaged magneto rotor or Woodruff key. BP1
- Replace magneto rotor or Woodruff key, refer to

MAGNETO AND STARTER SYSTEM subsection.
vmr2015-047-006_a
PROCEDURES 1. Remove seat.

Ensure battery is fully charged. 2. Connect a battery load tester such as the NAPA
Refer to WIRING HARNESS AND CONNECTORS ULTRA PRO BATTERY LOAD TESTER (P/N 95260).
subsection for harness layout and connector loca- 3. Start vehicle and read voltage on tester.
tions on vehicle.
SPECIFICATION
Refer to appropriate WIRING DIAGRAM for addi-
tional information. Voltage 12.5 - 15 Vdc
The magneto is covered in MAGNETO AND If voltage is above specification, replace regulator
STARTER subsection. and continue CHARGING SYSTEM LOAD TEST.
WARNING 4. Connect an ammeter such as EXTECH INDUC-
TIVE AMMETER (P/N 380941) around RD1-1 wire.
Ensure vehicle is in PARK when performing
charging system tests.
BATTERY LOAD TEST

1. Remove seat.
2. Connect a battery load tester such as the NAPA
ULTRA PRO BATTERY LOAD TESTER (P/N 95260).
3. Ensure proper test conditions.
TEST CONDITIONS
Initial battery voltage‡ Above 12.5 Vdc
Engine OFF
vmr2008-138-001_a
3 times the amp-hour DC CURRENT TEST WITH INDUCTIVE AMMETER
Load
(AH) rating 1. Output connector of voltage regulator
2. Ammeter clamped over RED wire
Time 15 seconds
‡ Required for accurate testing
TEST CONDITIONS
SPECIFICATION
Battery voltage at idle‡ Above 12.6 Vdc
Battery Above 9.6 Vdc
Engine Increase to 4000 RPM
2 vmr2016-135
TEST CONDITIONS
As required to decrease
Load
battery voltage to 12 Vdc
Time 15 seconds
‡ Required for accurate testing
6. Read amperage on ammeter.

MODEL SPECIFICATION
Base models (no-DPS,
35 ± 5 Amps
not CE)
DPS models 41 ± 5 Amps vmr2016-135-001_a
All CE models 41 ± 5 Amps

Voltage Regulator Continuity Test
If amperage or voltage is not within specification, Due to internal circuitry, there is no static test
verify magneto and wires. Refer to MAGNETO available.
AND STARTER subsection. Replace:
– Voltage regulator if magneto test is within spec- Voltage Regulator Power Test
ifications. 1. Check voltage at RD1-1.
– Magneto if magneto test is not within specifi-
cations. TEST CONDITIONS
RD1-1 Hot at all times
VOLTAGE REGULATOR (RD)
BACKPROBE PROBE SPECIFICATION
RD1-1 BAT2 (-) Battery voltage

12V,18AH
RD2-1
RD1-1
BN4 BAT2 BAT1
3. Start vehicle.
R D2-2
RD RD1-3
RD2-3
BN1
SS-1 BP3
TEST CONDITIONS
BP1
Battery voltage at idle‡ Above 12.6 Vdc
Engine Increase to 4000 RPM
Load
vmr2015-047-001_a
Time 15 seconds
Voltage Regulator Access ‡ Required for accurate testing
The voltage regulator/rectifier is accessible on the
RH rear side of the vehicle. 5. Measure voltage drop.
RD1-1 BAT1 (+) Under 0.2 Vdc
If voltage drop is above specification, locate and

repair damaged connector/wire.
Voltage Regulator Ground Test

1. Check ground at RD1-3.
vmr2016-135 3
TEST CONDITIONS
RD1-3 Permanent ground

RD1-3 BAT1 (+) Battery voltage

3. Start vehicle.
TEST CONDITIONS
Battery voltage at idle‡ Above 12.6 Vdc vmr2012-032-002_a
TYPICAL
Engine Increase to 4000 RPM 1. Battery retaining plate
2. Retaining plate screws (3)
Load 4. Remove battery.
Time 15 seconds Battery Cleaning
‡ Required for accurate testing Clean the battery support, cables and battery
posts using a solution of baking soda and water.
5. Measure voltage drop.
Remove corrosion (if so) from battery cable ter-
BACKPROBE PROBE SPECIFICATION minals and battery posts using a firm wire brush.
RD1-3 BAT2 (-) Under 0.4 Vdc Rinse with clear water and dry well.
If voltage drop is above specification, locate and Battery Inspection

repair damaged connector/wire. Visually inspect battery casing for cracks or any
other damages. If casing is damaged, replace bat-
BATTERY tery and thoroughly clean battery support with a
water and baking soda solution.
Battery Information Inspect condition of battery posts, battery sup-
These vehicles are equipped with a VRLA battery port, holding strap and strap attachment points
(Valve Regulated Lead Acid). It is a maintenance- and wire terminal lugs.
free type battery.
Refer to battery manufacturer's instructions for Battery Storage
proper filling, activation and routine charging pro- It is not necessary to remove the battery during
cedures. vehicle storage but it is recommended for long
term storage.
Battery Removal If the battery is left in the vehicle during storage or
1. Remove seat. used infrequently, disconnect the BLACK (-) nega-
2. Disconnect BLACK (-) cable first, then the RED tive battery cable to eliminate battery current drain
(+) cable. from the electrical equipment.
NOTICE Always respect this order for re- Recharge the battery once a month with an ap-
proved battery charger as per manufacturer's rec-
moval; disconnect BLACK (-) cable first.
ommendations.
3. Remove battery retaining plate. Clean battery, battery support and connections as
required, refer to BATTERY CLEANING in this sec-
tion.
For other recommendations during storage, refer
to battery manufacturers instructions.
4 vmr2016-135
WARNING TIGHTENING TORQUE

Ensure battery is stored in a safe place, out of
Battery retaining plate 4.5 N•m ± 0.5 N•m
reach for children. screws (40 lbf•in ± 4 lbf•in)
New Battery Activation
Refer to the instructions provided with the battery.
Battery Charging
WARNING
Always wear safety glasses and charge in a
well ventilated area. Never charge or boost a
battery while it is installed on vehicle. Do not
open the sealed cap during charging. Do not
place battery near open flame.
NOTICE If battery becomes hot, stop charg-

ing and allow it to cool before continuing.
NOTE: Sealed VRLA batteries have an internal
safety valve. If battery pressure increases due to
overcharging, the valve opens to release excess
pressure, preventing battery damage.
An automatic charger is a fast and convenient way
for error-proof charging.
Always follow the battery manufacturer's charg-
ing instructions.
When using a constant current charger, charge
battery according to the chart below.
Battery Voltage Below 12.8 V and Above 11.5
V
STANDARD CHARGING
(RECOMMENDED)
BATTERY
TIME CHARGE
TYPE
YTX20L-BS 4 - 9 HOURS 2 A
QUICK CHARGING
BATTERY
TIME CHARGE
TYPE
YTX20L-BS 50 MINUTES 10 A
Battery Installation
NOTICE Always connect RED (+) cable first
then BLACK (-) cable.
Installation is the reverse of removal procedure,
however pay attention to the following.
vmr2016-135 5
Subsection 05 (STARTING SYSTEM)
STARTING SYSTEM
SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 4
GENERAL 4. Starter (refer to MAGNETO AND STARTER

subsection)
STARTING SYSTEM OPERATION 5. Wiring and connections.
When the START button is pressed, 12 Vdc is ap-
plied through the start switch (MG1) to the starter ENGINE TURNS
solenoid coil. If the engine cranking conditions are Starting system is OK.
met, the ECM completes the starter solenoid con-
1. Verify ignition system. Refer to IGNITION SYS-
trol circuit by providing a ground. The starter so-
TEM subsection.
lenoid then closes its contacts and battery power
is applied to the starter for cranking the engine. 2. Verify EFI systems. Refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
Engine Cranking Conditions 3. Verify mechanical condition of engine. Refer to
The following conditions must be met to allow en- ENGINE, CVT AND GEARBOX section.
gine cranking.
– Ignition switch turned ON PROCEDURES
– Engine stop switch to RUN Ensure battery is fully charged.
– Transmission in Park, Neutral or a brake
pedal/lever is applied Refer to applicable WIRING HARNESS AND CON-
NECTORS for harness layout and connector loca-
– Start button is pressed and held. tions on vehicle.
Refer to applicable WIRING DIAGRAM for addi-
TROUBLESHOOTING tional information.
Check for fault codes. Refer to: DIAGNOSTIC
AND FAULT CODES subsection. WARNING
Ensure vehicle is in PARK when performing
ENGINE WILL NOT TURN starting system tests.
If the starter cranks over the engine with the

brakes applied, check the following:
1. Shifter rod adjustment, (refer to appropriate
SHIFTER subsection
2. Gearbox position indicator switches or the
gearbox position sensor (GBPS), (refer to ap-
propriate GEARBOX AND 4X4 COUPLING
UNIT subsection
3. Switches or sensor wires and connectors, (re-
fer to appropriate WIRING DIAGRAM).
If the “Engine cranking conditions” are met and
the starter will not crank the engine, check the fol-
lowing:
1. Battery and connections (refer to CHARGING
SYSTEM)
2. Starter solenoid
3. Start button switch
vmr2016-136 1
STARTING SYSTEM TESTS 4. If starter does not turn, verify STARTER SOLE-
NOID CONTINUITY.
Starter Solenoid
Starter Solenoid Control Circuit
+
-
+
-
F8 5 A
vmr2015-135-001_a
ECM
vmr2015-135-003_a
1. Disconnect SS1 and SS2
TEST CONDITION
Engine stop switch RUN
Ignition switch ON
Start button Pressed
vmr2015-048-012_a
1. SS1
2. Activate the starter solenoid.

2.1 Apply 12Vdc to SS1
2.2 Ground SS2
vmr2015-048-003_a
SS1 IS ON THE RIGHT
PROBE PROBE SPECIFICATION

SS1 SS2 Battery voltage
SS1 BAT - Battery voltage
BAT + SS2 Battery voltage
If voltage is as per specification replace starter so-

lenoid.
If voltage is not as per specification, ver-
ify STARTER SOLENOID CONTROL POWER
vmr2015-048-003_c
CIRCUIT or STARTER SOLENOID CONTROL
SS1 IS ON THE RIGHT GROUND CIRCUIT as applicable.
3. If starter turns, verify STARTER SOLENOID Starter Solenoid Control Power Circuit
CONTROL CIRCUIT. NOTE: This procedure also tests the start button.
2 vmr2016-136
ECM If start switch tests as specified, repair wire to
ON/
OFF
ON/
F8 starter solenoid SS1 terminal.
WO LIGHT
W LIGHT
B
5A
B
2
F
F
Starter Power Circuit Voltage Drop
1
A
NOTE: Engine must be in starting condition for
D
this test. Do not perform on a «No Start» vehicle.
STOP
1 C
RUN
E
TEST CONDITION
6
START
FREE
Fuse F5 Removed‡
vmr2016-136-101_a
Ignition switch ON
1. Disconnect MG2 connector.
Engine Cranking
‡ Will prevent engine from starting
1. Measure voltage drop.
+
-
vmr2008-139-003_a
TYPICAL - MG2 STEERING HARNESS CONNECTOR PIN-OUT
TEST CONDITION
vmr2015-135-004_a
Ignition switch ON
MG2-1 BAT - Battery voltage. Starter B+
BAT1 Below 0.4 Vdc
terminal
2. If voltage is not as per specification:
1. Check fuse(s) If voltage drop is above specification, repair or re-
place sources of high resistance in circuit.
2. Test engine stop switch. Refer to IGNITION
SYSTEM subsection
3. Test ignition switch Refer toIGNITION SYS-
TEM subsection.
3. Test start button.
TEST CONDITION

MG2-1 MG2-6 Close to 0
If start button does not test as specified, replace

the multifunction switch assembly.
vmr2016-136 3
Starter Solenoid Control Ground Starter Solenoid Continuity

Circuit
SS2- SS1- BAT2 BAT1

L3 HIC1-J
B4
BP3
BP
M BP1
BP
ECM
G2
K3
A4
vmr2016-136-100_a
vmr2015-048-005_a
1. Disconnect the BLACK (-) negative battery ca-
1. Disconnect SS2. ble.
2. Install the ECM connector onto the ECM 2. Disconnect SS1 and SS2
ADAPTER TOOL (P/N 529 036 166)
vmr2008-139-016_a vmr2015-048-012_a
1. ECM connector 1. SS1

2. ECM adapter tool

SS2 ECM-L3 Close to 0
If resistance is not as specified, repair or replace

wiring/connections.
If solenoid power control circuit and ground con-
trol circuit both test good, test ECM ground
circuits. Refer to ELECTRONIC FUEL INJECTION
(EFI) subsection.
NOTE: Supply a ground with a jumper wire if you vmr2015-048-003_d
suspect that the ECM is not supplying a ground to

the solenoid. SPECIFICATION
PROBE PROBE
@ 20°C (68°F)
SS1 SS2 Close to 6
If resistance is not as per specification, replace the

solenoid.
3. Disconnect BP3.
4 vmr2016-136
Solenoid Diode Test
SS2- SS1-
vmr2015-048-013_a
vmr2015-048-007_a
PROBE PROBE SPECIFICATION 1. Disconnect SS1 and SS2 from starter solenoid.
Terminal to
BP3 O.L.
starter motor
4. Jump starter solenoid.
vmr2015-048-012_a
1. SS1
2. Use the FLUKE 115 MULTIMETER (P/N 529 035

868) and set it to the diode symbol as shown.
vmr2015-048-009_a
SS1 IS ON THE RIGHT

Terminal to
BP3 Close to 0
starter motor
If resistance is not as per specification, replace the

solenoid.
If starter power and ground circuits are good, re-
fer to MAGNETO AND STARTER subsection for
starter diagnosis and replacement.
vmr2006-020-005
3. Probe wires while paying attention to the diode

polarity.
vmr2016-136 5
vmr2015-048-011_a
FORWARD POLARITY, MUST BE AROUND 0.5 V
vmr2015-048-010_a
REVERSE POLARITY, MUST BE OPEN CIRCUIT

1. SS1
If test failed, replace diode. Refer to WIRING

HARNESS AND CONNECTORS for diode loca-
tion.
NOTE: The diode is integrated in the harness near
the starter solenoid.
6 vmr2016-136
Subsection XX (RF DIGITALLY ENCODED SECURITY SYSTEM (RF D.E.S.S.))
RF DIGITALLY ENCODED SECURITY

SYSTEM (RF D.E.S.S.)
GENERAL PROCEDURES
SYSTEM DESCRIPTION D.E.S.S. KEY
The following components are specially designed D.E.S.S. Key Programming
for this system: ECM, D.E.S.S. key and engine 1. Connect the vehicle to the applicable B.U.D.S.
cut-off switch. version.
This system allows the engine to start only if a Refer to the B.U.D.S. directory on KNOWLEDGE
D.E.S.S. key is installed on engine cut-off switch CENTER for all diagnostic software related infor-
and the key is recognized as valid by the ECM. mation, including:
The D.E.S.S. key contains a magnet and a RFID – Diagnostic software version required according
chip. to the vehicle
– The magnet closes the hall effect switch inside – Current version download link
the engine cut-off switch. – User manual (programming keys, reading fault
– The RFID chip contains a unique digital code. It codes, writing data to modules etc.)
is the equivalent of the tooth-pattern cut on a – Installation instructions
conventional ignition key.
– Navigation through menus
Up to 8 D.E.S.S. keys may be programmed in the – BRP BUDS chart
ECM memory using the appropriate diagnostic
software. The keys can also be erased individu- 2. Search keyword: "BUDS".
ally.
NOTE: If desired, a D.E.S.S. key can be used on
another vehicle equipped with the D.E.S.S. sys-
tem. It only needs to be programmed for that ve-
hicle. mmr2017-025-001
D.E.S.S. Messages 3. Install a D.E.S.S. key on the post.

When starting the engine with a D.E.S.S. key on 4. Briefly press on START button. DO NOT start
the engine cut-off switch, the key is identified by the engine.
the ECM and D.E.S.S. messages will be displayed 5. Click the Read Data button in B.U.D.S.
in the multifunction gauge according to the key
recognition. See table.
MESSAGE DESCRIPTION
Displayed when a wrong
BAD KEY
key is used.
Displayed when key is not
recognized by the ECM.
DESS KEY NOT This may occur because
RECOGNIZED magnetic interference,
remove and clean key and vmr2006-012-100_aen
D.E.S.S. post.
6. Click on Keys tab.
Displayed at power up
NORMAL KEY when a normal key is
used.
Displayed at power up
PERFORMANCE KEY when a performance key
is used.
vmr2017-108 1
13. Briefly press START button. DO NOT start the

engine.
14. Click on the appropriate Add Key button.
15. Repeat to program more keys if needed.
16. Click on Write Data button to transfer new
settings and information to the ECM.
tmr2011-029-001
KEYS TAB
7. Click on Erase All Keys button.
vmr2006-012-100_ben
WRITE DATA BUTTON
17. Erase occurred fault(s) in the fault tabs.

18. Remove the D.E.S.S. key from the post and
wait for the vehicle electrical system to com-
pletely shut down.
tbl2011-001-052_a
19. Click on EXIT button to end the B.U.D.S. ses-
1. Click here to erase all keys sion.
20. Disconnect all cables and hardware from the
8. Click "YES" to confirm the action. vehicle.
9. Check the color of the key to be programmed. 21. Ensure to reinstall the connector into its hous-
KEY KEY TYPE ing.
GRAY key Performance key
DIAGNOSTIC TIPS
GREEN key Normal key
Check for fault codes as first step.
10. Click on the appropriate Add Key button. IMPORTANT: When troubleshooting an electrical
system fault, check battery condition, cables and
connections first.
RFID Pin Identification

Refer to WIRING DIAGRAM.
SPECIFICATIONS with
RFID CONNECTOR PIN RFID post connected
tbl2011-001-053_d
and key installed
TYPICAL A ECM ground
1. Add Performance Key button
2. Add Normal Key button B 12 - 15 Vdc
NOTE: The Add Work Key button is not used for C 5 Vdc
these vehicles.
D 12 Vdc
11. Remove the key.
12. Insert the next key to be programmed.
2 vmr2017-108
Stop / No Key Indicator
vmr2017-108-001
MONITORING PAGE, ECM TAB
Possible causes:
– No key installed
– Engine stop button in STOP position
– No voltage at RFID-B connector
– No ground at RFID-A connector
Condition can be duplicated by unplugging the
RFID connector.
vmr2017-108 3
Subsection XX (LIGHTS)
LIGHTS
SERVICE TOOLS
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ............................................. 1
GENERAL Ensure all wire terminals are properly crimped on

wires, and connector housings are properly fas-
NOTICE It is recommended to always discon- tened.
nect the battery when replacing any electric
or electronic parts. Always disconnect battery Check for signs of moisture, corrosion or dullness.
exactly in the specified order, BLACK (-) cable Clean pins properly and coat them with DIELEC-
first. TRIC GREASE (P/N 293 550 004) or other appropriate
lubricant when reassembling them, except if oth-
erwise specified such as for the ECM connector.
TROUBLESHOOTING
Pay attention to ground wires.
DIAGNOSTIC TIPS For wiring harness connector locations, refer to
WIRING HARNESS AND CONNECTORS subsec-
NOTE: It is a good practice to check for fault tion.
codes using B.U.D.S. software as a first trou-
bleshooting step. Refer to COMMUNICATION
DIAGNOSTIC GUIDELINES
IMPORTANT: When troubleshooting an electrical LOW AND HIGH BEAM HEADLIGHTS WILL
system fault, check battery condition, cables and NOT COME ON SIMULTANEOUSLY (650,
connections first. 850 AND 1000R MODELS)
1. Jumper JP1 is open circuit or missing.
Testing a Circuit
- Check jumper (fuse) JP1 in front fuse box, refer
Check the related-circuit fuse condition with a to POWER DISTRIBUTION subsection.
fuse tester or test lamp (a visual inspection could
lead to a wrong conclusion). BRAKE LIGHTS WILL NOT COME ON
NOTE: If the electrical system is left activated for WHEN BRAKES ARE APPLIED
a certain period of time, the accessory relay will 1. Defective fuse.
shut down. See ACTIVATING THE ELECTRICAL - Check fuse, refer to the appropriate BRAKE
SYSTEM in this subsection for details. LIGHT CIRCUIT PROTECTION in this subsection.
Inspecting an Electrical Connection 2. Defective brake relay.

- Test brake relay (R8), refer to POWER DISTRIBU-
When replacing an electric or electronic compo- TION subsection.
nent, always check electrical connections. Make
sure they are tight, make good contact, and are 3. Defective brake light switch(es).
corrosion-free. Dirty, loose or corroded contacts - Refer to BRAKE LIGHT SWITCHES in the BRAKE
are poor conductors and are often the source of a subsection.
system or component malfunction. 4. Defective wiring/connectors.
Pay particular attention to ensure that pins are not - Test wiring continuity, refer to applicable WIRING
bent or pushed out of their connectors. DIAGRAM.
vmr2017-109 1
TURN SIGNAL LIGHTS WILL NOT COME TURN SIGNAL/HAZARD LIGHTS

ON WHEN SELECTED (CE MODELS) INDICATOR IN MULTIFUNCTION GAUGE
WILL NOT COME ON WITH TURN SIGNAL
1. Defective fuse. OR HAZARD LIGHTS SELECTED ON,
- Check fuse, refer to the appropriate TURN SIG- IGNITION SWITCH ON (CE MODELS
NAL/HAZARD CIRCUIT PROTECTION in this sub- ONLY)
section.
2. Defective Flasher Module. 1. Signal wire from flasher module to multifunc-
tion gauge open circuit.
- Replace flasher module, refer to TURN SIG-
NALS/HAZARD in this subsection. - Test circuit continuity from flasher module
(MC2–4) to multifunction gauge (C1–8).
3. Defective wiring/connectors.
2. Defective flasher module.
- Test wiring continuity, refer to applicable WIRING
DIAGRAM. - Replace flasher module, refer to the appropriate
FLASHER MODULE in this subsection.
4. Defective Turn Signal Switch.
3. Defective multifunction gauge.
- Test switch, refer to appropriate TURN SIG-
NALS/HAZARD in this subsection and to applica- - Replace multifunction gauge, refer to GAUGE
ble WIRING DIAGRAM. subsection.
HAZARD LIGHTS WILL NOT COME ON HAZARD LIGHTS INDICATOR NOT

WHEN SELECTED (CE MODELS ONLY) WORKING WITH IGNITION SWITCH OFF
(OUTLANDER 450 / 570 CE MODELS
1. Defective fuse. ONLY)
- Check fuse, refer to TURN SIGNAL/HAZARD CIR-
CUIT PROTECTION in this subsection. 1. Defective hazard LED indicator.
- Test LED. Observe polarity.
2. Hazard lights 12 Vdc input circuit open.
- Check wiring and connectors, refer to the appro- HAZARD LIGHTS INDICATOR NOT
priate TURN SIGNAL/HAZARD in this subsection. WORKING WITH IGNITION SWITCH
Refer to WIRING DIAGRAM.
OFF (OUTLANDER 650 / 850 / 1000R CE
3. Hazard lights selector switch defective. MODELS ONLY)
- Test switch, refer to the appropriate TURN 1. Diode D10 open circuit.
SIGNAL/HAZARD in this subsection. Refer to
WIRING DIAGRAM. - Test diode, refer to applicable WIRING DIA-
GRAM.
4. Defective wiring/connector between hazard
lights selector switch and flasher module. POSITION LIGHTS WILL NOT COME ON
- Refer to applicable WIRING DIAGRAM. (CE MODELS ONLY)
5. Flasher module ground circuit open. 1. Defective fuse.
- Test wiring and connectors, refer to applicable - Check fuse, refer to the appropriate POSITION
WIRING DIAGRAM. LIGHTS in this subsection.
6. Defective flasher module. 2. Power or ground circuit wiring.
- Replace flasher module, refer to the appropriate - Check wiring continuity, refer to WIRING DIA-
TURN SIGNAL/HAZARD in this subsection. GRAM.
HAZARD LIGHTS COME ON WITHOUT 3. Defective light bulbs

BEING SELECTED (CE MODELS ONLY) - Test/replace light bulbs.
1. Hazard lights switch or wiring short circuit.

- Check for water in LH multifunction switch.
- Test hazard light switch and wiring, refer to appli-
cable WIRING DIAGRAM.
2. Flasher module parallel Resistor is open.
- Test resistor (between hazard switch output and
ground), refer to applicable WIRING DIAGRAM.
2 vmr2017-109
PROCEDURES LIGHT SWITCH

FUNCTION PIN COLOR
ACTIVATING THE ELECTRICAL
12 volt input from MG1-4
SYSTEM headlights relay MG2-4
RD/BU
NOTICE Activating the electrical system re- 12 volt output to high

MG2-5 BU
beam headlights
peatedly or using electrical equipment will
discharge the battery and you may not be able 12 volt output to low
MG2-2 GN
to start the engine. beam headlights
Models with a RF D.E.S.S. key

Headlights Circuit Protection
Press and release the START button for less than
half a second and the electrical system will turn CONDITION CIRCUIT PROTECTION
ON: Unswitched Fuse 11
– For 30 seconds, without powering any equip-
ment, if the D.E.S.S. key is NOT installed on the Testing the Headlights
D.E.S.S. post OR if the Emergency Engine Stop
switch is set to the STOP position; 1. Disconnect LOW beam and HIGH beam head-
light bulb connectors. Refer to REPLACING
– For 10 minutes, powering equipment, if the
THE HEADLIGHT BULB in this subsection.
RF D.E.S.S. key is installed on the D.E.S.S.
post AND Emergency Engine Stop is set to 2. Activate the electrical system, refer to ACTIVAT-
the RUN position. The electrical system will ING THE ELECTRICAL SYSTEM in this subsec-
be shutdown after 30 seconds if either the tion.
D.E.S.S. key is removed OR the Emergency 3. Measure the voltage on headlight connector as
Engine Stop is set to the STOP position. follows.
NOTE: If the vehicle is connected to B.U.D.S. and REQUIRED TOOL
the RF D.E.S.S. key is installed on its post, the
electrical system will not shut down.
Models with a conventional ignition key FLUKE 115
MULTIMETER
Turn the ignition key to the ON position (P/N 529 035 868)
HEADLIGHTS (MODELS WITH 4

HEADLIGHTS) LIGHT
SWITCH WIRE COLOR VOLTAGE
Headlight Wire Identification POSITION
HEADLIGHTS RELAY (R5) LO beam
HI beam GN
FUNCTION PIN COLOR (Low beam
(Models
12 volt input from fuse with a connector) Battery
C6 YE/BK BK
F11 (headlights power) DPS) voltage
12 volt input from fuse F4 BU
D6 OR/GN
(relay winding input) HI beam (Hi beam
connector)
12 volt output to light
D7 RD/BU
switch
Relay winding ground
Replacing the Headlight Bulb
C7 OR/BK
(from ECM K2) NOTICE Never touch glass portion of a halo-
gen bulb with bare fingers, it shortens its oper-
ating life. If glass is touched, clean it with iso-
propyl alcohol which will not leave a film on
the bulb.
1. Unplug connector from bulb.
vmr2017-109 3
2. Rotate bulb. Headlights Circuit Protection

Supplied when relay Fuse 12 of fuse block 1
R3 is activated (from accessory relay R3)
Testing the Headlight

1. Disconnect headlight bulb connectors. Refer
to REPLACING THE HEADLIGHT BULB in this
subsection.
2. Activate the electrical system, refer to ACTIVAT-
ING THE ELECTRICAL SYSTEM in this subsec-
tion.
3. Measure the voltage on headlight connector as
follows.
vmo2012-012-060_b
REQUIRED TOOL
TYPICAL
3. Pull bulb out.

FLUKE 115
4. Properly reinstall removed parts in the reverse MULTIMETER
order of their removal. (P/N 529 035 868)
5. Validate headlight operation.
HEADLIGHTS (MODELS WITH 2 4. Measure the voltage on headlight connector as

HEADLIGHTS) follows.
LIGHT
Headlight Wire Identification SWITCH WIRE COLOR VOLTAGE
ACCESSORY RELAY (R3) POSITION
FUNCTION PIN COLOR Battery

LO beam GN
voltage
12 volt input from fusible (Low beam
E12 RD/GN connector)
link FL-2 HI beam
BK No voltage
12 volt input from F4 Lo beam
E10 OR/GN BU
(relay winding input)
(Hi beam Battery
RD/YE before HI beam connector)
12 volt output to light voltage
D10 F12 and RD/BK
switch (through F12)
after F12
Replacing the Headlight Bulb
D12 OR/BK NOTICE Never touch glass portion of a halo-
(from ECM K2)
gen bulb with bare fingers, it shortens its oper-
LIGHT SWITCH ating life. If glass is touched, clean it with iso-
FUNCTION PIN COLOR propyl alcohol which will not leave a film on
the bulb.
12 volt input from relay
MG2-4 RD/BU 1. Remove cover.
R3 (through fuse F12)
12 volt output to high 2. Unplug connector.
MG2-5 BU
beam headlights 3. Remove bulb.
12 volt output to low
MG2-2 GN
beam headlights
4 vmr2017-109
90°
A
B
vmr2006-020-002_a
TYPICAL
1. Light beam center
A. 5 m (16 ft)
B. Beam aiming specification
vmr2015-050_010_a
1. Cover
2. Connector 90°
4. Properly reinstall removed parts in the reverse
order of their removal.
5. Validate headlight operation. 1 2
HEADLAMP BEAM AIMING (ALL

MODELS) 90°
NOTE: Load vehicle as per normal use.
vmr2006-020-001_a
1. Position vehicle on a level surface 5 m (16 ft) in TYPICAL
front of a test surface ( wall or screen) as in first 1. Headlight center lines
2. Light beam center
illustration.
2. Measure the distance from the center of each Adjusting Beam Aiming (Models with
headlight to the ground (high beam and low 4 Headlights)
beam).
Turn adjustment knobs to adjust beam height and
3. Trace a line on the test surface parallel to the side orientation to specification.
ground at each measured height (one for high
beam and one for low beam).
Low beam aiming is correct when the crest of the
low beam is below the applicable horizontal cen-
ter line traced on the test surface as per specifi-
cation.
High beam aiming is correct when the center of
the high beam (focus point) is below the applica-
ble horizontal center line traced on the test sur-
face as per specification.
SPECIFICATION
Low beam crest (top vmo2012-012-059_b
of low beam) 25 mm to 125 mm
OUTLANDER LOW BEAM
(1 in to 5 in) below 1. Adjustment knobs
High beam center applicable line
(focus point)
vmr2017-109 5
BRAKE LIGHT RELAY (R8)

FUNCTION PIN COLOR
12 volt input from F4 (relay
D8 OR/GN
winding input)
12 volt output to LH and
D9 WH/OR
RH brake lights
(from brake light C9 RD/OR
switch(es))
Brake Light Circuit Protection

CIRCUIT
CONDITION
vmo2012-012-060_a PROTECTION
OUTLANDER HIGH BEAM AND RENEGADE LOW BEAM/HIGH
BEAM Supplied when:
1. Adjustment knobs Accessories relay Fuse 14 (from
R3 activated Accessories relay R3)
Adjusting Beam Aiming (Models with Brake relay R8 activated
2 Headlights)
Turn adjustment knobs to adjust beam height and Taillight Wire Identification
side orientation to specification.
CIRCUIT
FUNCTION PIN
PROTECTION
Supplied when
Accessories relay R3 3 RD/VI
activated
Ground from BK2 2 BK
Taillight Circuit Protection

Supplied when
Fuse 14 (from
Accessories relay R3
Accessories relay R3)
activated
vmr2015-050_008_a
1. Adjustment knobs
Taillight/Brake Light Bulb Replacement
TAILLIGHTS/BRAKE LIGHTS
(MODELS WITH 2 TAILLIGHTS) 2. Rotate light bulb counterclockwise to remove it
from taillight.
Brake Light Switch
For brake light switch location and testing, refer to
BRAKES subsection.
Brake Light Wire Identification
BRAKE LIGHT RELAY (R8)
FUNCTION PIN COLOR
12 volt input from fuse
C8 RD/VI
F14 (brake light power)
6 vmr2017-109
Taillight Wire Identification

FUNCTION PIN COLOR
Supplied when main relay
2 OR/GN
R2 activated
Ground from BN1 3 BK
Taillight Circuit Protection

Supplied when main Fuse 4 of fuse block 1
relay R2 activated (from main relay R2)
vmo2012-012-062_a Replacing the Taillight/Brake Light

ROTATE BULB COUNTERCLOCKWISE Bulb
3. Remove bulb socket from taillight. 1. Disconnect the taillight connector.
Installation is the reverse of the removal proce- 2. Rotate the socket counterclockwise to remove
dure. it from taillight.
TAILLIGHT/BRAKE LIGHT
(MODELS WITH A SINGLE
TAILLIGHT)
Brake Light Switch
For brake light switch location and testing, refer to
BRAKES subsection.
Brake Light Wire Identification vmr2015-050_014_a
BRAKE LIGHT RELAY (R8) 3. Remove the bulb from the socket.
FUNCTION PIN COLOR Installation is the reverse of the removal proce-
12 volt input from fuse F4 dure.
C8 OR/GN
(brake light power)
12 volt input from F4 (relay
D8 OR/GN
winding input)
12 volt output to brake
D9 WH/OR
light
(from brake light C9 RD/OR
switch(es))
Brake Light Circuit Protection

CIRCUIT
CONDITION
PROTECTION
Supplied when:
Fuse 4 of fuse block 1
Main relay R2 activated
(from main relay R2)
Brake relay R8 activated
vmr2017-109 7
POSITION LIGHTS (CE MODELS CONDITION CIRCUIT PROTECTION

WITH 4 HEADLIGHTS) Fuse 12 of fuse block
Supplied when relay R3
1 (from accessories
Headlight Wire Identification is activated
relay R3)
NOTE: The position lights and licence plate light
are supplied whenever the accessory relay R3 is
activated. TURN SIGNALS/HAZARD
ACCESSORY RELAY (R3)
(CE MODELS WITH 4
HEADLIGHTS)
FUNCTION PIN COLOR
12 volt input from fusible
Turn Signal/Hazard Lights Wire
link FL-2
E12 RD/GN Identification
12 volt input from F4 FLASHER MODULE
E10 OR/GN
(relay winding input) FUNCTION PIN COLOR
RD/YE before 12 volt input from
12 volt output to lights MC2-1 RD/WH
D10 F12 and RD/BK fuse F10 (unswitched)
(through F7)
after F7
12 volt input from
Relay winding ground MC1-5 RD/BK
D12 OR/BK fuse F7 (switched)
(from ECM K2)
RH turn 12 volt input
MC1-1 BE/BROWN
from turn signal switch
Position Light Circuit Protection
LH turn 12 volt input
CONDITION CIRCUIT PROTECTION MC1-2 BE/GY
Supplied when relay R3 Fuse 7 (from accessories Output to RH turn
is activated relay R3) MC2-2 BR
signal lights
Output to LH turn signal
MC2-3 GY
POSITION LIGHTS (CE MODELS lights
WITH 2 HEADLIGHTS) Output to multifunction
gauge (turn signal MC2-4 OR
Headlight Wire Identification indicator)
Ground MC1-4 BK
activated. Hazard 12 volt input
MC1-6 BE/RD
from hazard switch
ACCESSORY RELAY (R3)
FUNCTION PIN COLOR TURN SIGNAL SWITCH
(IN MULTIFUNCTION SWITCH)
12 volt input from fusible
E12 RD/GN FUNCTION PIN COLOR
link FL-2
12 volt input from F4 12 volt input from
E10 OR/GN MG3-3 RD/BK
(relay winding input) fuse F10 (unswitched)
RD/YE before RH turn 12 volt output
12 volt output to position MG3-1 BE/BR
D10 F12 and RD/BK to flasher module
lights (through F12)
after F12 LH turn 12 volt output
MG3-2 BE/GY
Relay winding ground to flasher module
D12 OR/BK
(from ECM K2)
Position Light Circuit Protection

activated.
8 vmr2017-109
HAZARD SWITCH TURN SIGNALS/HAZARD

FUNCTION PIN COLOR (CE MODELS WITH 2
12 volt input
HEADLIGHTS)
from fuse F10 MG3-3 RD/BK Turn Signal/Hazard Lights Wire
(unswitched)
Identification
12 volt output to
flasher module FLASHER MODULE
MG3-5 BE/RD FUNCTION PIN COLOR
12 volt output to
wake up gauge 12 volt input from
MC2-1 BE
fuse F8 (unswitched)
Turn Signal/Hazard Circuit Protection 12 volt input from
MC1-5 RD/BK
accessory relay R3
TURN SIGNAL CIRCUIT
RH turn 12 volt input
CONDITION CIRCUIT PROTECTION MC1-1 BE/BR
Supplied with
Fuse 7 (from Accessories LH turn 12 volt input
Accessories relay MC1-2 BE/GY
relay R3) from turn signal switch
(R3) activated
Output to RH turn
Battery power MC2-2 BR
Fuse 10 signal lights
(continuous)
Output to LH turn signal
MC2-3 GY
HAZARD CIRCUIT lights
CONDITION CIRCUIT PROTECTION Output to multifunction
gauge (turn signal MC2-4 OR
Battery power indicator)
Fuse 10
(continuous)
Ground MC1-4 BK
Flasher Module Access Hazard 12 volt input
MC1-6 BE/RD
Remove multifunction gauge. from hazard switch
TURN SIGNAL SWITCH

(IN MULTIFUNCTION SWITCH)
FUNCTION PIN COLOR
12 volt input from
MG3-3 BE
fuse F8 (unswitched)
RH turn 12 volt output
MG3-1 BE/BR
to flasher module
LH turn 12 volt output
MG3-2 BE/GY
to flasher module
HAZARD SWITCH
vmr2012-035-012_a FUNCTION PIN COLOR
TYPICAL
1. Flasher module location 12 volt input
from fuse F8 MG3-3 BE
(unswitched)
12 volt output to
flasher module
MG3-5 BE/RD
12 volt output to
hazard pilot lamp
vmr2017-109 9
Turn Signal/Hazard Circuit Protection

TURN SIGNAL CIRCUIT
Supplied when R3 is Fuse 12 of fuse block 1
activated (from accessory relay R3)
Battery power
(continuous)
HAZARD CIRCUIT
Battery power
(continuous)
Flasher Module Access

Remove multifunction gauge.
vmr2012-035-012_a
1. Flasher module location
10 vmr2017-109
Subsection XX (GAUGE)
GAUGE
SERVICE TOOLS
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ........................................... 10
GENERAL
NOTICE It is recommended to always discon-
nect the battery when replacing any electric
or electronic parts. Always disconnect battery
exactly in the specified order, BLACK (-) cable
first.
COMPACT DIGITAL
MULTIFUNCTION GAUGE vmr2007-050-002_d
1. Transmission position
Multifunction Gauge Description
DISPLAY FUNCTION
P Park
R Reverse
N Neutral
H High range
L Low range
3) Main Screen
The main screen is used to display numerous
functions of the multifunction gauge.
vmo2013-010-001_a
Refer to MULTIFUNCTION DISPLAY MODES for
1. Selector button the available display modes.
2. Transmission position display
3. Main screen 4) Fuel Level Display
4. Fuel level display
5. 4WD indicator lamp Bar gauge continuously indicates the level of fuel
6. Low fuel level indicator lamp in the fuel tank while riding.
7. Check engine indicator lamp
8. High beam indicator lamp
9. MPH, Km/h indicator lamp
10. Signal lights/hazard lights indicator lamp (CE models)
1) Selector Button
The selector button is used to navigate or change
settings in the multifunction gauge.
2) Transmission Position Display
This display will show transmission position.
vmr2017-110 1
10) Turn signal/Hazard lights Indicator Lamp
When this indicator is ON, it indicates:

– A turn signal is activated, or
– The hazard lights are activated.
Multifunction Display Modes

Speed Mode
In this mode, the display shows the speed of the
vmo2013-010-001_b
vehicle either in km/h or in MPH.
5) 4WD Indicator Lamp
When this indicator is ON, it indicates the 4WD

system is activated.
6) Low Fuel Level Indicator Lamp
vdd2008-001-084
RPM Mode
When this indicator is ON, it indicates that there is In this mode, the display shows the engine RPM.
approximately 5 L (1.3 U.S. gal.) of fuel left in fuel
tank.
7) Check Engine Indicator Lamp
When this indicator is ON, it indicates an engine

fault code, look for a message in the main screen
display.
When this indicator blinks, it indicates that LIMP vdd2008-001-089
HOME mode is activated.

Combined Mode
8) High Beam Indicator Lamp
In this mode, the display shows the speed of the
vehicle and the engine RPM.
When this indicator is ON, it indicates that high

beam is selected on the headlights switch and
that the ignition key is in the "ON with lights" po-
sition.
9) KM/H or MPH Indicator Lamp
vdd2008-001-085_a
The applicable lamp turns on to indicate the active 1. Vehicle speed
speedometer unit of display. 2. Engine RPM
2 vmr2017-110
Odometer (OD)
Odometer records the total distance travelled ei-
ther in miles or kilometers.
vsi2009-018-032
Press and HOLD the selector button for 2 seconds

to reset the hour meter.
vsi2009-018-030 Engine Hour Meter (EH)
Clock The engine hour meter records engine running
time.
Shows current time.
vsi2009-018-033
Message Display Mode

vmo2011-008-001
If an abnormal engine condition occurs, a mes-
Refer to PROCEDURES to set current time. sage may scroll across the main screen in con-
junction with a pilot lamp.
Trip Meter (TP) Refer to DIAGNOSTIC AND FAULT CODES sub-
The trip meter records the travelled distance since section.
it has been reset. Distance travelled is displayed
either in kilometers or miles. Navigating the LCD Gauge
WARNING
Never adjust or set functions on the multi-
function gauge while riding the vehicle.
Default Display Mode

After vehicle startup, the default display mode is
either:
– Vehicle speed
vsi2009-018-031
– Engine revolutions per minute (RPM)
Press and HOLD the selector button for 2 seconds – Both parameters simultaneously (combined
to reset the trip meter. mode).
To change from one display to the other, proceed
Trip Hour Meter (TH) as follows.
The trip hour meter records vehicle running time 1. Turn ignition key to ON to power-up the system.
when the electrical system is activated. It can be
used to establish traveling time between 2 places. 2. Wait until the “greeting message” has been
displayed.
vmr2017-110 3
3. Press and release selector button once to dis- FULL SIZE DIGITAL
play OD (odometer). MULTIFUNCTION GAUGE
4. Press the selector button again, this time for 2
seconds. Multifunction Gauge Description
This will change the Mode to either Speed, RPM The multifunction gauge is located in the middle
or Combined. of the handlebar.
vdd2008-001-083
5. To select another mode, repeat steps 3 and 4

until the desired mode is displayed.
Temporary Display Mode vmo2012-012-029_a
1. Display 1
In the temporary display mode, the following func- 2. Display 2
tions are available: 3. Display 3
4. Selector button
– Odometer 5. Transmission position display
– Clock 7. Indicator lamps
– Trip meter (resettable)
Speedometer
– Trip Hour meter (resettable)
– Engine hour meter. This display will show vehicle speed.
Press and release selector button to change the
default display mode to the temporary mode.
vmr2007-050-002_c
vmo2012-012-029_i
1. Selector button
1. Vehicle speed (Display 1)
The gauge will display the selected mode for 10 Tachometer
seconds then will return to the normal display
mode. Measures engine revolutions per minute (RPM).
Multiply by 1000 to obtain the actual revolutions.
While in a resettable mode, push and HOLD se-
lector button for 2 seconds to reset it. NOTE: RPM may also be displayed via Display 2
(mode) display.
4 vmr2017-110
vmo2012-012-029_k vmo2012-012-029_n
1. Tachometer 1. Fuel level display

2. Operating range
3. Tachometer via Display 2 (mode) Low fuel level Indicator Lamp
Transmission Position Display
This display will show transmission position.
When this indicator turns ON, it indicates that

there is approximately 5 L (1.3 U.S. gal.) of fuel
left in fuel tank.
4WD Indicator Lamp
When this indicator is ON, it indicates the 4WD

system is activated.
Brake Lock Indicator Lamp
vmo2012-012-029_j
DISPLAY FUNCTION
When this indicator is ON, it indicates the brake is
P Park
activated for more than 15 seconds (while riding).
R Reverse
High Beam Indicator Lamp
N Neutral
H High gear
L Low gear
When this indicator is ON, it indicates that high
NOTE: If the letter “E” is displayed in the trans- beam is selected.
mission position display, it means that there is a
electrical communication error. Contact an autho- Check Engine Indicator Lamp
rized Can-Am dealer.
Fuel Level Display
Bar gauge continuously indicates the fuel level in
the fuel tank. When this indicator is ON, it indicates an engine
fault code, look for a message at the LCD display.
Refer to DIAGNOSTIC AND FAULT CODES sub-
section.
vmr2017-110 5
Turn Signal/Hazard Lights Indicator Lamp E) Engine Hour Meter

CE Models Records engine running time.
F) Engine RPM
Measures engine revolutions per minute (RPM).
When this indicator is ON, it indicates:

– A turn signal is activated, or
– Hazard lights are activated.
Multifunction Display Modes

WARNING
Never adjust or set functions on the multi-
function gauge while riding the vehicle.
The available modes may be displayed by pressing

the selector button.
NOTE: An abbreviation of the mode selected will
also be displayed in Display 3.
vmo2012-012-029_m
1. Display 2 (mode)
2. Display 3 (mode/message)
A) Odometer
Records the total distance travelled.
B) Clock
Shows current time.
Press and HOLD selector button to set clock.
C) Trip Meter
Records the distance travelled since it has been
reset.
Press and HOLD display selection button to reset.
D) Hour Meter (Trip Time)
Records the vehicle running time when the elec-
trical system is activated since it has been reset.
Press and HOLD display selection button to reset.
6 vmr2017-110
ANALOG / DIGITAL MULTIFUNCTION GAUGE

Multifunction Gauge Description
The Multifunction Gauge (Analog/digital) is comprised of a digital gauge and two analog gauges
(speedometer and tachometer).
The engine temperature and fuel level bar graphs are comprised in the digital gauge.
The indicators lamps are comprised in both analog gauges.
1 11 2 6 3 7 4
M S
M S
5 10 12 13 9 8 5
vmo2013-007-001_c
TYPICAL
1. Analog speedometer
2. MODE (M) button
3. SET (S) button
4. Analog tachometer (RPM)
5. Indicator lamps
6. Main digital display
7. Multifunction display
8. Fuel level indicator
9. Gearbox position indicator
10. Engine temperature indicator
11. Numerical display
12. 2WD/4WD indicator
13. Secondary digital display
WARNING
Do not adjust the display while riding. You could lose control.
vmr2017-110 7
1) Analog Speedometer
Measures vehicle speed in km/h or mph.
2) MODE (M) Button
Pressing the MODE (M) button will scroll through the functions of the main digital display.
FUNCTION SEQUENCE OPTIONS
Air Suspension (LTD model only) Press ACS button to change setting (1 to 6)
Press SET (S) to scroll and select desired function
Numerical Display is flashing
and press MODE (M) to confirm
Press SET (S) to scroll and select desired function
Multifunction display is flashing
and press MODE (M) to confirm
3) SET (S) Button

Pressing the SET (S) button will scroll through the functions of the secondary digital display.
FUNCTION SEQUENCE INFORMATION DISPLAYED
XX:XX (24:00 time base)
Clock
XX:XX A or P (12:00 AM/PM time base)
Cumulative distance odometer XXXXX.X km or mi
Trip distance — odometer A (TRIP A) XXXXX.X km or mi
Trip distance — odometer B (TRIP B) XXXXX.X km or mi
Engine time chronometer (Hr) XXXXX.X
Trip time chronometer (HrTRIP) XXXXX.X
To reset any trip functions, push and hold the MODE (M) button for three seconds.
4) Analog Tachometer (RPM)
Measures engine revolutions per minute (RPM). Multiply by 1000 to obtain actual revolutions.
5) Indicator Lamps
Indicator lamps will inform you of various conditions or problems.
An indicator lamp can flash alone or in combination with another lamp.
INDICATOR LAMP(S) DESCRIPTION
All indicator lamps are activated when ignition switch is ON and
All indicator lamps On
the engine is not started
On Low Fuel
On Check Engine
On High Engine Temperature
On Headlights in the HIGH beam position
On Brake is pressed for more than 15 seconds while riding
8 vmr2017-110
6) Main Digital Display

Displays useful real-time information to the rider.
7) Multifunction Display
The vehicle speed or the engine revolutions (RPM) can be displayed. See MODE (M) BUTTON in this
section.
Important messages can also be displayed. Refer to table below.
MESSAGE DESCRIPTION
Message displayed when the brakes are applied continuously for 15
BRAKE
seconds.
NORMAL KEY Displayed at power up when a the normal key is used.
PERFORMANCE KEY Displayed at power up when a the performance key is used.
Override is displayed when the override switch is pressed and the shift
OVERRIDE
lever is set to reverse gear.
Displayed in the gauge when a periodic maintenance will soon be
MAINTENANCE REQUIRED required. To erase this message, refer to PROCEDURES in this
subsection.
If an abnormal engine condition occurs, a message can be combined with a pilot lamp. Refer to DIAG-
NOSTIC AND FAULT CODES subsection.
8) Fuel Level Indicator
Bar graph that continuously indicates the level of fuel left in the fuel tank.
9) Gearbox Position Indicator
Displays the selected gearbox position.
LTD Models
As a second function, will indicate the current ACS position setting.
10) Engine Temperature Indicator
Bar graph that continuously indicates the engine coolant temperature.
11) Numerical Display
The vehicle speed or the engine revolutions (RPM) can be displayed. See MODE (M) BUTTON in this
section.
12) 2WD/4WD Indicator
When this indicator is ON, the 4WD system is activated.
13) Secondary Digital Display
Displays useful real time information to the rider. For display function informations, refer to SET (S) BUT-
TON.
Gauge Setup
Setting Metric/Imperial Units
Use B.U.D.S. software to select metric or imperial units.
Setting Clock
Use B.U.D.S. software or do the following:
1. Press SET (S) button to select clock display.
2. Push and hold SET (S) button for three seconds.
vmr2017-110 9
3. Press SET (S) button to select 12:00 AM PM or 24:00 time base.

4. If 12:00 AM PM time base is selected, A or P flashes. Press SET (S) button to select A (AM) or P (PM).
5. Press SET (S) to select the first digit of the hour.
6. Press SET (S) to select the second digit of the hour.
7. Press SET (S) to select first digit of the minutes.
8. Press SET (S) to select second digit of the minutes.
Setting Language
The gauge display language can be changed using B.U.D.S. software.
TROUBLESHOOTING DIAGNOSTIC GUIDELINES

MULTIFUNCTION GAUGE WILL NOT
DIAGNOSTIC TIPS COME ON
NOTE: It is a good practice to check for fault 1. Multifunction gauge not powered up.
codes using B.U.D.S. software as a first trou-
- Check fuse(s), refer to CIRCUIT PROTECTION in
bleshooting step. Refer to COMMUNICATION this subsection.
- Test multifunction gauge 12 Vdc input and ground
IMPORTANT: When troubleshooting an electrical circuits as per WIRING IDENTIFICATION in this
system fault, check battery condition, cables and subsection. Refer to applicable WIRING DIA-
connections first. GRAM.
2. Defective Multifunction Gauge.
Testing a Circuit - Replace multifunction gauge.
Check the related-circuit fuse condition with a
fuse tester or test lamp (a visual inspection could MULTIFUNCTION GAUGE
lead to a wrong conclusion). COMMUNICATION ERROR
NOTE: If the ignition switch is left ON for a certain 1. Multifunction gauge CAN circuit open.
period of time, the accessory relay will shut down. - Ensure multifunction gauge is properly connected
and powered up.
Inspecting an Electrical Connection - Check for applicable fault code using B.U.D.S., re-
When replacing an electric or electronic compo- fer to DIAGNOSTIC AND FAULT CODES subsec-
nent, always check electrical connections. Make tion.
sure they are tight, make good contact, and are - Carry out TESTING THE CAN RESISTOR in this
corrosion-free. Dirty, loose or corroded contacts subsection.
are poor conductors and are often the source of a - Carry out a continuity test of the multifunction
system or component malfunction. gauge CAN wires, refer to applicable WIRING
DIAGRAM.
Pay particular attention to ensure that pins are not
bent or pushed out of their connectors. NO FUEL QUANTITY INDICATION
Ensure all wire terminals are properly crimped on 1. Defective fuel level sender or wiring.
wires, and connector housings are properly fas- - Refer to FUEL TANK AND FUEL PUMP subsec-
tened. tion.
Check for signs of moisture, corrosion or dullness. 2. Defective Multifunction Gauge.
Clean pins properly and coat them with DIELEC-
- Replace multifunction gauge, refer to PROCE-
TRIC GREASE (P/N 293 550 004) or other appropriate DURES in this subsection.
lubricant when reassembling them, except if oth-
erwise specified such as for the ECM connector.
Pay attention to ground wires.
For wiring harness connector locations, refer to
tion.
10 vmr2017-110
PROCEDURES Wiring Identification

FUNCTION PIN COLOR
MULTIFUNCTION GAUGE 12 volt input from fuse F4 17 ORANGE/YELLOW
Resetting the "Maintenance Required" 12 volt input from fuse F8 16 RED/WHITE
Message Using B.U.D.S.
Ground 20 BLACK
Connect to the latest applicable B.U.D.S. software
version. Refer to COMMUNICATION TOOLS CAN LO 18 WHITE/BLACK
AND B.U.D.S. subsection. CAN HI 19 WHITE/BEIGE
Select Vehicle tab. 4
Fuel level gauge supply BROWN/PINK
Click on the Reset Service button.
Fuel level gauge ground 21 VIOLET/PINK
2WD/4WD switch
7 BLACK/BEIGE
signal (-)
HI beam signal (+) 5 BLUE
Vehicle speed sensor
9 PINK
signal (VSS)
Circuit Protection
Supplied at all times
(from fusible link 1)
tmr2011-030-014_a Fuse 4 of fuse block
Supplied with main relay
TYPICAL 1 (from main relay R2
activated
1. Reset Service button in fuse block 1)
Resetting the "Maintenance Required" Setting the Clock Using the Gauge
Message Using the Gauge Button Selector Button
1. Select display and hold button as per following
table: Compact and Full Size Digital Multifunction
Gauges
BUTTON
GAUGE TYPE DISPLAY To set current time, proceed as follows:
(HOLD)
1. Select the clock display.
Analog / digital
multifunction Odometer SET (S)
gauge
Full size digital
multifunction Odometer Selector button
gauge
Compact digital
multifunction Default Selector button
gauge
2. While holding the button, alternate between

LOW beam and HIGH beam 3 times.
NOTE: Step 2 must be started on high beam and vmo2011-008-001
completed within 2 seconds. COMPACT DIGITAL MULTIFUNCTION GAUGE
3. Release SET button.
vmr2017-110 11
9. Press SET (S) button.
Setting Using B.U.D.S.

Connect to the applicable B.U.D.S. software. Re-
fer to COMMUNICATION TOOLS AND B.U.D.S.
subsection.
Language Selection
In B.U.D.S., select the:
– Setting page tab
– Cluster page tab.
Scroll and select the desired display language in
vmo2012-012-029_o
the Cluster Language box.
FULL SIZE DIGITAL MULTIFUNCTION GAUGE
1. Time (Display 2)
2. Message (Display 3)
2. Press and HOLD selector button.

NOTE: On the full size gauge, "SET TIME" will ap-
pear on display 3.
3. Choose the 12-hour (12H) or 24-hour (24H) for-
vmr2016-137-001_a
mat by pressing button.
4. If the 12-hour format was selected, choose Am Selecting Units
(A) or Pm (P) by pressing button. In B.U.D.S., select the:
5. Choose hour first digit by pressing button. – Setting page tab
6. Choose hour second digit by pressing button. – Cluster page tab.
7. Choose minutes first digit by pressing button. Select Imperial or Metric in the Cluster Units
box.
8. Choose minutes second digit by pressing but-
ton.
9. Press button to enter settings (CLOCK will ap-
pear on display).
NOTE: The gauge will display the current time for
10 seconds then will return to the normal display
mode.
vmr2016-137-001_b
Analog / Digital Multifunction Gauge

Setting the Clock
1. Press SET (S) button to select clock display.
2. Push and hold SET (S) button for three seconds.
– Setting page tab
3. Press SET (S) button to select 12:00 AM PM or – Cluster page tab.
24:00 time base.
To set clock to the 24-hour format, check the 24 H
4. If 12:00 AM PM time base is selected, A or P box. To set it to the 12-hour format, leave the box
flashes. Press SET (S) button to select A (AM) empty.
or P (PM).
If 12-hour format was selected, check the PM box
5. Choose hour first digit by pressing SET (S) but- if required.
ton.
Set hour and minutes using the up or down ar-
6. Choose hour second digit by pressing SET (S) rows.
button.
7. Choose minutes first digit by pressing SET (S)
button.
8. Choose minutes second digit by pressing SET
(S) button.
12 vmr2017-110
Indicator Lights Monitoring

– Monitoring page
– Cluster tab.
Use the Cluster Lamp Active box to monitor dif-
ferent indicator lights outputs.
vmr2016-137-002_a
TYPICAL
1. 24 H box
2. PM box
3. Arrows
Selecting Tire Size vmr2016-137-003
Select Setting and ECM tabs. TYPICAL - CLUSTER LAMP ACTIVE BOX
Scroll and select the appropriate tire diameter (see This function confirms that the signals are broad-
inscriptions on the tires) in the Tire Size box. casting and the indicator lights should be ON in
the multifunction gauge.
Switch Input Monitoring
– Monitoring page
– Cluster tab.
Use the Switch Inputs box to monitor different
switch inputs as you activates the switches.
tmr2016-136-306_a
1. Tire Size box
Testing Using B.U.D.S.

Connect to the latest applicable B.U.D.S. software
version. Refer to COMMUNICATION TOOLS vmr2016-137-004
AND B.U.D.S. subsection. TYPICAL - SWITCH INPUTS BOX
Wow Test This function confirms that the multifunction

This function is used to check if the indicator gauge receives the inputs.
lights, display and analog indicators (if applicable)
Vehicle Parameters Monitoring
are functional.
NOTE: This function does not test the signals or
external circuits. – Monitoring page
– Cluster tab.
– Activation page In the upper area of the B.U.D.S. cluster page, the
following indications are displayed.
– Cluster tab.
– Engine speed (RPM)
Click on the WOW Test button.
– Vehicle speed
– Fuel level.
vmr2017-110 13
These indications confirm that the applicable sig- NOTE: This tests both the ECM and the Cluster
nals are transmitted and the information should be CAN resistors and wires.
displayed in the multifunction gauge.
TEST RESULT
Testing the CAN Resistor READING POSSIBLE CAUSE
Models with a 1 connector DPS Approximately ECM and CLUSTER CAN wires and
60 resistors good
Disconnect DPS connector. Refer to the appropri-
ate DYNAMIC POWER STEERING (DPS) subsec- CAN wire to CLUSTER open
Approximately CAN wire to ECM open
tion. 120 CLUSTER CAN resistor open
Models with a 3 connectors DPS ECM CAN resistor open
Disconnect DPS1 (control) connector. Refer to Infinite CAN wire to DB connector open
the appropriate DYNAMIC POWER STEERING (open circuit) circuit
(DPS) subsection.
All Models Removing the Multifunction Gauge
(Outlander 450 / 570)
1. Remove seat to access diagnostic link connec-
tor (DB). 1. Remove the gauge support by pulling it up.
2. Remove diagnostic link connector from its
holder.
vmr2015-050_011_a
2. Disconnect the gauge connector.

3. From the back of the gauge support, release
the gauge retaining tabs and remove the gauge
vmr2012-023-003_a
from its support.
1. Diagnostic link connector (DB)
3. Measure the resistance of the CAN resistors as

follows.
REQUIRED TOOL
FLUKE 115
MULTIMETER
(P/N 529 035 868)
CAN RESISTOR TEST

vmr2012-035-003_a
DIAGNOSTIC LINK GAUGE RELEASE TABS (4)

RESISTANCE
CONNECTOR
14 vmr2017-110
Removing the Multifunction Gauge Tilt gauge rearward.

(Outlander 650 / 850 / 1000R)
Remove gauge outer support.
– Push in on both sides of its leading edge to dis-
engage it.
– Lift up and pull forward to remove.
NOTE: There are a total of 6 tabs that retain the
gauge support.
vmr2017-109-002_a
Disconnect the gauge connector.

Remove gauge from the inner support by pulling
it up.
Removing the Multifunction Gauge

(Renegade)
1. Remove console panel, refer to BODY subsec-
vmr2012-035-001_a tion.
OUTER GAUGE SUPPORT REMOVAL 2. Remove the gauge support as shown.
1. Push in and lift up here (both sides)
Full Size digital Multifunction gauge

Disconnect the gauge connector.
From the back of the outer gauge support, release
the bezel retaining tabs and remove the bezel.
vmr2016-410-004_a
EXCEPT X MR MODEL
vmr2012-035-002_a
BEZEL RETAINING TABS
From the back of gauge support, rotate the gauge

clockwise to release it from its support.
Analog / Digital Multifunction Gauge
Release tabs.
vmr2017-110 15
vmr2016-410-005_a
X MR MODEL
3. From the back of the gauge support, release

the gauge retaining tabs and remove the gauge
from its support.
vmr2012-035-003_a
GAUGE RELEASE TABS (4)
Installing the Multifunction Gauge

dure.
New Multifunction Gauge Registration
(coding)
Whenever the multifunction gauge is replaced,
B.U.D.S. must be used to register it in the ECM.
Simply click Yes when the following message
appears.
vmr2006-020-058_a
16 vmr2017-110
Subsection XX (ACCESSORIES)
ACCESSORIES
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ............................................. 1
GENERAL PROCEDURES
NOTICE It is recommended to always discon-
nect the battery when replacing any electric ACTIVATING THE ELECTRICAL
or electronic parts. Always disconnect battery SYSTEM
exactly in the specified order, BLACK (-) cable
first. NOTICE Activating the electrical system re-
peatedly or using electrical equipment will
TROUBLESHOOTING discharge the battery and you may not be able
to start the engine.
DIAGNOSTIC TIPS Models with a RF D.E.S.S. key
Testing a Circuit Press and release the START button for less than
Check the related-circuit fuse condition with a half a second and the electrical system will turn
fuse tester or test lamp (a visual inspection could ON:
lead to a wrong conclusion). – For 30 seconds, without powering any equip-
ment, if the D.E.S.S. key is NOT installed on the
NOTE: If the electrical system is left activated for D.E.S.S. post OR if the Emergency Engine Stop
a certain period of time, the accessory relay will switch is set to the STOP position;
shut down. See ACTIVATING THE ELECTRICAL
SYSTEM in this subsection for details. – For 10 minutes, powering equipment, if the
RF D.E.S.S. key is installed on the D.E.S.S.
Inspecting an Electrical Connection post AND Emergency Engine Stop is set to
the RUN position. The electrical system will
When replacing an electric or electronic compo- be shutdown after 30 seconds if either the
nent, always check electrical connections. Make D.E.S.S. key is removed OR the Emergency
sure they are tight, make good contact, and are Engine Stop is set to the STOP position.
corrosion-free. Dirty, loose or corroded contacts
are poor conductors and are often the source of a NOTE: If the vehicle is connected to B.U.D.S. and
system or component malfunction. the RF D.E.S.S. key is installed on its post, the
electrical system will not shut down.
Pay particular attention to ensure that pins are not
bent or pushed out of their connectors. Models with a Conventional Ignition Key
Ensure all wire terminals are properly crimped on Turn the ignition key to the ON position
wires, and connector housings are properly fas-
tened. 12 VOLT POWER OUTLET
Check for signs of moisture, corrosion or dullness.
Clean pins properly and coat them with DIELEC-
Removing and Installing a 12 Volt
TRIC GREASE (P/N 293 550 004) or other appropriate
Power Outlet
lubricant when reassembling them, except if oth- Refer to BODY and remove the LH side panel.
erwise specified such as for the ECM connector. Unplug the connectors of the power outlet.
Pay attention to ground wires. Unscrew the retaining nut.
For wiring harness connector locations, refer to Reverse procedure for installation.
tion.
219100883-010 1
12 Volt Power Outlet Wire

Identification
FUNCTION PIN COLOR
12 volt power supply from
2 RD/BR
fuse F12
Ground
1 BK
(to ground terminal BK3)
12 Volt Power Outlet Circuit Protection

Accessories relay Fuse 12 219100883-010-003
(R3) activated (from relay R3)
cedure, however, pay attention to the following.
HEATED VISOR CONNECTORS Install the negative wire eyelet between the con-
Removing and Installing the Front sole and the connector body.
Heated Visor Connector
Unscrew the cap from the connector.
219100883-010-002_a
UNDERNEATH THE CONSOLE

219100883-010-001 1. Negative eyelet
2. Connector body
Refer to GAUGE and remove the gauge support.
Refer to BODY and remove: Removing and Installing the Rear
– Windshield Heated Visor Connector
– Console Remove the rear seat.
Disconnect the other end of the harness from the Underneath, disconnect the seat harness connec-
accessory connector. tor.
Separate the seat cushion from the base.
219100883-010-011
2 219100883-010
Remove the heated visor connector cap.
219100883-010-002_a
TYPICAL - UNDERNEATH THE SEAT BASE

1. Negative eyelet
219100883-010-004
2. Connector body
Cut the black wire near the eyelet. TIGHTENING TORQUE

Remove the heated visor connector from the Seat cushion retaining 5 N•m ± 1 N•m
handhold, then pass it through the openings. screws (44 lbf•in ± 9 lbf•in)
Disconnect the wires from the seat harness. Handhold retaining 25 N•m ± 3 N•m
Heated Visor Connectors Wire

Identification
The heated visor connectors are connected to the
DC3 accessory connector through an extension
harness.
To verify the extension Harness, refer to TEST-
ING THE REAR EXTENSION HARNESS OUTPUT
VOLTAGE in HEATED PASSENGER GRIPS.
FUNCTION PIN COLOR
12 volt power supply from
219100883-010-005_a
Welded RD/BN
fuse F12
The installation is the reverse of the removal pro- Ground
cedure, however, pay attention to the following. (to ground terminal Eyelet BK
Pass the wires through the openings, then crimp BK3)
the new eyelet to the black wire.
Install the eyelet between the seat base and the Heated Visor Connectors Circuit
connector body. Protection
Accessories relay Fuse 12
HEATED THROTTLE LEVER

Removing and Installing the Heated
Throttle Lever
Refer to GAUGE and remove the gauge support.
219100883-010 3
Refer to BODY and remove: FUNCTION PIN COLOR

– Windshield
12 volt power supply to
– Console B WH
switch from fuse F14
Remove the air intake tube retaining screw. Switch ground
A BK
Positive power supply to 2
heating element (variable Throttle OR
voltage) lever side
1
Heating element ground Throttle BK
lever side
Heated Throttle Lever Circuit

Protection
219100883-010-006 CONDITION CIRCUIT PROTECTION
Move the air intake tube aside, and disconnect the Accessories relay Fuse 14
throttle lever wires from the accessories connec- (R3) activated (from relay R3)
tor.
Testing the Throttle Lever Heating
Element
Refer to REMOVING AND INSTALLING THE
HEATED THROTTLE LEVER for connector ac-
cess.
Disconnect the heating element connector.
Measure the heating element resistance as per
following table.
THROTTLE LEVER HEATING ELEMENT TEST
RESISTANCE
HEATER WIRE
219100883-010-009
@ 20°C (68°F)
OR BK 21 to 26
Note the wire routing and cable ties position.
Cut the cable ties. If the resistance is out of specification, replace the
Refer to STEERING SYSTEM and remove the throttle lever.
throttle lever. If resistance is good, carry out TESTING THE
The installation is the reverse of the removal pro- THROTTLE LEVER HEATING ELEMENT INPUT
cedure, however, pay attention to the following. VOLTAGE.
TIGHTENING TORQUE Testing the Throttle Lever Heating
Air intake tube retaining 1.6 N•m ± 0.4 N•m Element Input Voltage
screw (14 lbf•in ± 4 lbf•in) IMPORTANT: Make sure the switch power supply
and ground are good before carrying out this test.
Heated Throttle Lever Wire Refer to REMOVING AND INSTALLING THE
Identification HEATED THROTTLE LEVER for connector ac-
The throttle lever heated element is connected to cess.
a switch which is to connected to connector DC5. Activate the electrical system or start engine.
Backprobe the heating element connector and
measure voltage as per following table.
4 219100883-010
HEATING SELECTED Loosen the grip clamping screw.

VOLTAGE
ELEMENT HEAT
(APPROXIMATE)
CONNECTOR LEVEL
1 3 to 3.5 Vdc
2 6 to 7 Vdc
OR BK
wire wire 3 9 to 10.5 Vdc
4 12 to 14 Vdc
If voltage is out of specifications, replace the

switch.
219100883-010-008_a
HEATED HANDLEBAR GRIPS
Remove the grip.
Handlebar Grips NOTE: If the grip does not come off, cut it length-
wise.
Refer to BODY and remove:
– Windshield
cedure, however, pay attention to the following.
– Console
– Gauge support TIGHTENING TORQUE
Disconnect the heated grip wires from the switch 4.5 N•m ± 0.5 N•m
Clamping screw
harness. (40 lbf•in ± 4 lbf•in)
0.4 N•m ± 0.1 N•m
Handlebar tip screw
Heated Handlebar Grips Wire

Identification
The heated handlebar grips switch is connected to
connector DC5.
FUNCTION PIN COLOR
12 volt power supply to
B WH
switch from fuse F14
Switch ground
219100883-010-009 A BK
RH CONNECTOR SHOWN (to ground terminal BK3)
Positive power supply to
Note the wire routing and cable ties position. 2
heating element (variable RD
Switch side
Cut the cable ties. voltage)
On the LH side, split the multifunction switch. 1
Heating element ground BK
Remove the handlebar tip. Switch side
Heated Handlebar Grips Circuit

Protection
219100883-010-007
219100883-010 5
Testing the Handlebar Grips Heating HEATED PASSENGER GRIPS

Element
If only one element is heating up, carry out this Passenger Grips
test.
Remove the rear seat.
If no element is heating up, carry out TESTING
THE HEATED HANDLEBAR GRIPS INPUT VOLT- Underneath, disconnect the seat harness connec-
AGE. tor.
Refer to REMOVING AND INSTALLING THE Separate the seat cushion from the base.
HEATED HANDLEBAR GRIPS for connector ac-
cess.
Measure resistance as per following table.
GRIPS HEATING ELEMENT TEST
RESISTANCE
HEATER WIRE
@ 20°C (68°F)
RD BK 8.5 to 10.5
If the resistance is out of specification, replace the

grip. 219100883-010-011
If resistance is good, verify the accessory harness Note the wire routing.
wiring continuity. Disconnect the wires from the seat harness.
Testing the Heated Handlebar Grips Cut the heating element wires (on the handhold
Input Voltage side).
If no element is heating up, carry out this test. Remove the handhold retaining screw.
If only one element is heating up, verify the ac- Remove the handhold from the seat base.
cessory harness wiring continuity and carry out
TESTING THE HANDLEBAR GRIPS HEATING EL-
EMENT.
IMPORTANT: Make sure the switch power supply
and ground are good before carrying out this test.
Refer to REMOVING AND INSTALLING THE
HEATED HANDLEBAR GRIPS for connector ac-
cess.
Activate the electrical system or start engine.
Backprobe the heating element connector and
measure voltage as per following table.
HEATING SELECTED
VOLTAGE 219100883-010-010
ELEMENT HEAT
(APPROXIMATE)
CONNECTOR LEVEL The installation is the reverse of the removal pro-
1 3 to 3.5 Vdc cedure, however, pay attention to the following.
2 6 to 7 Vdc Once the wires are passed through the opening,
BK insert and lock the terminals in the connector
OR wire
wire 3 9 to 10.5 Vdc housing as per following table.
4 12 to 14 Vdc

switch.
6 219100883-010
WIRE CONNECTOR HOUSING PIN
GY 1
GN 2
RD 3
TIGHTENING TORQUE
Seat cushion retaining 5 N•m ± 1 N•m
Handhold retaining 25 N•m ± 3 N•m 219100883-010-012

Testing the Passenger Grips Switch
Heated Passenger Grips Wire Output
Identification If no element is heating up, carry out this test.
The heated passenger grips connector is con- If only one element is heating up, verify the ac-
nected to the DC3 accessory connector through cessory harness wiring continuity and carry out
an extension harness. TESTING THE PASSENGER GRIPS HEATING EL-
EMENT.
FUNCTION COLOR
IMPORTANT: Make sure the switch power supply
12 volt power supply to switch is good before carrying out this test.
RD/BK
from fuse F12
Backprobe the switch connector and measure
12 volt power supply to heating voltage as per following table.
RD
element (HI)
HEAT HEATED ELEMENT VOLTAGE
12 volt power supply to heating LEVEL CONNECTOR (APPROXIMATE)
GN
element (LO)
HI RD wire 12 Vdc
Heating element ground GY wire
GY LO GN wire 12 Vdc

Heated Passenger Grips Circuit switch.
Protection
If voltage is good, verify seat harness wiring con-
CONDITION CIRCUIT PROTECTION tinuity.
(R3) activated (from relay R3) Testing the Passenger Grips Heating
Element
Testing the Rear Extension Harness If only one element is heating up, carry out this
Output Voltage test.
Remove the rear seat. If no element is heating up, verify the accessory
harness wiring continuity and carry out TESTING
Underneath, disconnect the seat harness connec- THE PASSENGER GRIPS SWITCH OUTPUT.
tor.
Remove the rear seat.
REAR EXTENSION VOLTAGE
HARNESS CONNECTOR (APPROXIMATE)
Underneath, disconnect the seat harness connec-
tor.
RD/BR wire BK wire 12 Vdc
Separate the seat cushion from the base.
219100883-010 7
HORN (OUTLANDER 450 / 570 CE

MODELS)
Horn Wire Identification
HORN SWITCH (IN MULTIFUNCTION SWITCH)
FUNCTION PIN COLOR
12 volt input from
MG3-3 BE
fuse F8
12 volt output to horn MG3-4 BE/BK
219100883-010-011
HORN
Measure resistance as per following table. FUNCTION PIN COLOR
12 volt input from
GRIPS HEATING ELEMENT TEST 2 BE/BK
horn switch
RESISTANCE
HEATER WIRE Ground 1 BK
@ 20°C (68°F)
GN 13 to 17
GY Horn Circuit Protection
RD 6 to 8
If the resistance is out of specification, replace the Unswitched
handhold. from fusible link FL-1
HORN (OUTLANDER 650 / 850 WINCH

/ 1000R AND RENEGADE CE
MODELS) Winch Wire Identification
WINCH RELAY
Horn Wire Identification
FUNCTION PIN COLOR
HORN SWITCH (IN MULTIFUNCTION SWITCH)
12 volt input from battery
FUNCTION PIN COLOR BP4 RD
(winch power)
12 volt input Ground (Wire) SW4 BK
from fuse F10 MG3-3 RD/WH
(unswitched) Ground (Cable) BN4 BK
12 volt output to horn MG3-4 BE/BK 12 volt input from
SW1 GN/BU
switch (IN)
HORN 12 volt input from
SW2 LT BU
FUNCTION PIN COLOR switch (OUT)
12 volt input from Motor power (switches

2 BE/BK RD (with blue
horn switch polarity depending on SW3
sleeve)
rotation direction)
Ground 1 BK
Motor power (switches
RD (with
polarity depending on SW5
Horn Circuit Protection yellow sleeve)
rotation direction)
NOTE: The small black wire at terminal SW4 con-
Battery power nected to the diodes is used to prevent electric
Fuse 10
(unswitched) arcs in the switch. It can also be connected to
BN4.
8 219100883-010
Removing the Winch

1. Disconnect, the battery BLACK (-) cable first,
then the RED (+) cable.
WARNING
Always respect this order for disassembly;
disconnect BLACK (-) cable first.
2. Remove the hook.

2.1 Remove and discard the cotter pin.
2.2 Remove the hook pin.
vmr2017-111-001_a
WINCH RELAY
1. To GN / BU wire
2. To LT BU wire
3. To winch motor cable with BLUE sleeve
4. To BK ground cable
5. To winch motor cable with YELLOW sleeve
6. To RD positive cable
7. BK ground wire (can also be connected with the ground cable)
WINCH SWITCH (OUTLANDER 650 / 850

/ 1000R AND RENEGADE)
FUNCTION PIN COLOR
12 volt input from fuse 7 A RD/BK
12 volt output to relay
C GN/BU
winding (IN)
B LT BU
winding (OUT) tsi2011-004-009_a
1. Hook
2. Hook pin
WINCH SWITCH (OUTLANDER 450 / 570) 3. Cotter pin
FUNCTION PIN COLOR 3. Remove the winch cable fairlead.
12 volt input from fuse 12 A RD/BK
C GN/BU
winding (IN)
B BU/GN
winding (OUT)
NOTICE Before testing, make sure the winch

is in FREESPOOL mode (Freespool clutch dis-
engaged).
Winch Relay Access

Refer to BODY and remove the RH inner fender
panel. vmr2012-035-008_a
TYPICAL
Winch Switch Circuit Protection 1. Winch fairlead
2. Fairlead retaining screws
650 / 850 / 1000R Models
Outlander 450 / 570
Supplied when Fuse 12 4. Remove the front skid plate.
accessories relay NOTE: On CE models, disconnect the turn signal
R3 is activated All models except 450 / 570
Fuse 7 lights and front marker lights.
219100883-010 9
vmr2012-035-009_a
1. Front skid plate

vmr2012-035-011_a
2. Retaining screws
TYPICAL
All Models 1. Front bumper support
2. Winch retaining screws
5. Disconnect both winch power cables.
7. Remove winch.
NOTE: Note the position of the power cables for
reinstallation. Installing the Winch
dure, however pay attention to the following.
Connect winch power cables as noted at removal.
NOTE: If the winch power cables are not con-
nected correctly, the winch motor will operate in
the reverse direction of selection.
TIGHTENING TORQUE
16 N•m ± 2 N•m
Winch retaining screws
7 N•m ± .5 N•m
Winch power cables
Winch fairlead elastic 16 N•m ± 2 N•m
vmr2012-035-010_a
nuts (142 lbf•in ± 18 lbf•in)
TYPICAL
1. Winch power cables
Install a new cotter pin on the hook pin.
6. Remove the four winch retaining screws from
the front bumper support.
10 219100883-010
Section 06 DRIVE SYSTEM
Subsection 01 (FRONT DRIVE)
FRONT DRIVE
SERVICE TOOLS
BACKLASH MEASUREMENT TOOL............................................. 529 035 665 ......................................... 469
CV BOOT CLAMP PLIER .............................................................. 529 036 120 ......................................... 467
CV JOINT EXTRACTOR................................................................. 529 036 005 ......................................... 467
SPANNER SOCKET ....................................................................... 529 035 649 ......................................... 471
SERVICE PRODUCTS
LOCTITE 277 ................................................................................. 293 800 073 ......................................... 473
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ......................................... 475
XPS SYNTHETIC GREASE............................................................. 293 550 010 ......................... 467, 473, 475
vmr2015-138 463
FRONT DRIVE SHAFTS AND FRONT PROPELLER SHAFT
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
(M8)
NEW
NEW
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
(M10) See
STEERING
SYSTEM
Loctite
648
NEW
XPS Synthetic XPS
grease Synthetic
grease
75 ± 5 N•m 205 ± 15 N•m

(55 ± 4 lbf•ft) (151 ± 11 lbf•ft)
Loctite
648
NEW
75 ± 5 N•m
(55 ± 4 lbf•ft)

vmr2015-051-100_a
464 vmr2015-138
FRONT DIFFERENTIAL
NEW XPS synthetic NEW

grease 37 ± 3 N•m
(27 ± 2 lbf•ft)
33 ± 3 N•m
(24 ± 2 lbf•ft)
22.5 ± 2.5 N•m

(17 ± 2 lbf•ft)
NEW
NEW
For backlash
adjustment
NEW
180 ± 15 N•m
(133 ± 11 lbf•ft)
Loctite 277 NEW NEW
XPS synthetic
grease
7.5 ± 0.5 N•m

NEW
XPS synthetic grease

vmr2015-051-101_a
vmr2015-138 465
GENERAL
The procedure explained below is the same for
the RH and LH sides unless otherwise instructed.
SYSTEM DESCRIPTION
The Visco-Lok® system constantly monitors front
wheel speed and, if it detects one wheel spinning
faster than its mate, it progressively sends more
power to the wheel with the better traction.
The Visco-Lok system is comprised of two princi-
pal components, a shear pump and the controlled
multi-plate clutch. tmr2011-032-003_a
TYPICAL
A unique feature of the shear pump is that it 1. Cotter pin
2. Castellated nut
is self-contained and independent. It does not 3. Belleville washer
require an external source of hydraulic fluid. The
self-contained viscous shear pump generates a Remove wheel hub.
pressure proportional to wheel speed differential
- meaning the difference in rotational speed be- Wheel Hub Inspection
tween the two wheels. This pressure engages Check wheel hub for cracks or other damages.
the friction clutch via a piston to transmit the
Check inner splines for wear or other damages.
torque.
If any damage is detected on wheel hub, replace
In the event of a failure, the Visco-Lok carrier/ring
it with a new one.
gear and pinion gear will have to be replaced.
NOTE: The Visco-Lok shear pump is not service- Wheel Hub Installation
able. If the pump is disassembled, the viscous The installation is the reverse of the removal pro-
fluid contained inside will be lost and it cannot be cedure. However, pay attention to the following.
replaced.
Install Belleville washer with its convex side out-
wards.
PROCEDURES
Tighten castellated nut to specification.
WHEEL HUB TIGHTENING TORQUE
Wheel Hub Removal Castellated nut
205 N•m ± 15 N•m
Lift and support vehicle.
Select the 4WD position and place the transmis- NOTE: Tighten further castellated nut if required
sion lever on "P". to align grooves with drive shaft hole.
Remove caliper from knuckle. Refer to BRAKES Install a NEW cotter pin.
subsection.
Remove the following parts:
– Wheel cap
– Cotter pin
– Castellated nut
– Belleville washer.
tmr2011-032-005
466 vmr2015-138
FRONT DRIVE SHAFT 1

Front Drive Shaft Removal
Remove inner fender panel(s). Refer to BODY
subsection.
Remove the KNUCKLE. Refer to STEERING SYS-
TEM subsection.
Remove shock absorber lower bolt.
Lift and attach the following parts to make room. V07H0AA
– Shock absorber TYPICAL

– Upper suspension arm. 1. Stop ring
Strongly pull drive shaft out of differential. Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on
the splines.
Ensure that wear ring is close to the differential.
DRIVE SHAFT BOOT

Drive Shaft Boot Removal
Remove FRONT DRIVE SHAFT. See procedure in
this subsection.
Remove drive shaft boot clamps.
REQUIRED TOOL
CV BOOT CLAMP PLIER (P/N 529 036 120)
vmr2012-036-002_a
PULL DRIVE SHAFT
Discard the stop ring at the end of the shaft.
Front Drive Shaft Inspection 529036120
Inspect the condition of boots. If there is any dam- Dislodge the large end of the boot.
age or evidence of leaking lubricant, replace them. Separate the joint from the shaft. Two procedures
Refer to DRIVE SHAFT BOOT in this subsection. can be done.
Check splines for excessive wear. Replace if nec-
Without the Special Tool
essary.
Clamp joint housing in a vise.
NOTE: If the splines on plunging joint are worn, a
check of differential inner splines should be done. Align shaft with joint.
Pull hard on shaft to remove from joint.
Front Drive Shaft Installation
Remove boot from drive shaft.
cedure. However, pay attention to the following. Remove and discard the circlip. A new one is in-
cluded in the boot kit.
Install a NEW stop ring.
With the Special Tool
Place drive shaft in vice with the joint downward.
Install the tool on bearing.
REQUIRED TOOL
CV JOINT EXTRACTOR (P/N 529 036 005)
vmr2015-138 467
529036005
vmr2012-036-003_a
FROM LH SIDE
1. Vent hose
4. Remove bolts securing front differential to

vmr2007-053-010_a frame.
TYPICAL — CV JOINT SHOWN
1. Joint extractor tool
With an hammer, hit on the tool to separate joint

from shaft.
When joint and shaft are separated, remove boot
from drive shaft.
Remove and discard the circlip. A new one is in-
cluded in the boot kit.
Drive Shaft Boot Installation

Install the NEW circlip.
vmr2012-036-004_a
Pack bearing area with grease (included with the 1. Bolts securing front differential to frame
new boot kit).
NOTE: Do not use or add other grease. 5. Remove the following Oetiker clamps from
Install NEW drive shaft boot clamps.
FRONT DIFFERENTIAL
Front Differential Removal
1. Drain front differential. Refer to PERIODIC
2. Remove both front drive shafts. Refer to
FRONT DRIVE SHAFT in this subsection.
3. Detach vent hose from front differential.
vmr2012-009-020_a
1. Oetiker clamps
6. Detach front propeller shaft from front differen-

tial by moving it rearward.
468 vmr2015-138
vmr2012-036-005_a
vmr2006-023-015_a
FRONT PROPELLER SHAFT MOVED REARWARD
1. Tab of backlash measurement tool
2. Mark on tab
7. Remove front differential by pulling it from RH
A. 25.4 mm (1 in)
side.
NOTICE Be careful not to knock or to bend Position the dial indicator tip against the tab at a
90° angle and right on the previously scribed mark.
vent hose fitting while removing front differen-
tial. Gently, move the tool tab back and forth. Note the
backlash result.
Front Differential Inspection
(Assembled)
Manually turn the pinion gear; it should turn
smoothly. Repair if necessary.
Check if oil seals are brittle, hard or damaged. Re-
place if necessary.
Backlash Inspection
When measuring backlash, the differential cover
should be upside down to pull the ring gear out of
mesh.
Using a dial indicator and the BACKLASH MEA-
SUREMENT TOOL (P/N 529 035 665), measure the
backlash.
vmr2006-023-016
Place the backlash measurement tool at the end
of pinion gear. Rotate pinion gear 1/2 turn and recheck backlash.
From center of tool bolt, measure 25.4 mm (1 in) Note the result.
and scribe a mark on the tab. Rotate pinion gear 1 turn and recheck backlash.
BACKLASH SPECIFICATION
0.1 mm (.004 in) to 0.25 mm (.01 in)
If backlash is out of specification, split final drive

housing and adjust shim thickness as per follow-
ing guideline.
vmr2015-138 469
BACKLASH ADJUSTMENT GUIDELINE

BACKLASH
WHAT TO DO
MEASUREMENT
Remove shim(s) and
Below 0.1 mm (.004 in)
recheck backlash
Add shim(s) and recheck
Above 0.25 mm (.01 in)
backlash
vmr2015-051-006_a
PRELOAD SPECIFICATION
Maximum 0.50 N•m (4 lbf•in)
If preload is out of specification, split front differ-

ential housing and check all bearings conditions.
Front Differential Disassembly

Differential Housing
Remove front differential housing screws.
vmr2015-051-008
1. Backlash shim
Preload Inspection
Screw the propeller shaft screw in pinion gear.
vmr2012-036-008_a
Separate half housings.

Remove oil seals.
vmr2015-051-005_a
Using a needle torque wrench, measure the

preload.
vmr2015-051-001_a
470 vmr2015-138
Visco-Lok Carrier/Ring Gear

Remove Visco-Lok carrier/ring gear out of half
housing.
vmr2015-051-010_a
1. Visco-Lok unit
2. Ring gear
Pinion Gear
vmr2015-051-002_a
Remove screw retaining front propeller shaft
adapter.
Remove screws securing ring gear to Visco-Lok
unit.
vmr2012-036-009_a
1. Retaining screw
Remove and discard oil seal.
vmr2015-051-009
Separate ring gear from Visco-Lok unit.
vmr2012-036-010_a
1. Oil seal
Unscrew the pinion nut.

REQUIRED TOOL
SPANNER SOCKET (P/N 529 035 649)
vmr2015-138 471
529035649
vmr2008-142-010_a
1. O-ring
2. Pinion gear
3. Bearing
Remove and discard the needle bearing.
vmr2012-036-011_a
Front Differential Assembly
1. Pinion nut Adjustment is required when any of the following
part is changed.
Remove bearing and pinion gear together.
– Pinion gear
RECOMMENDED TOOLS QTY – Ring gear
Pipe: 78 mm (3-1/16 in) diameter x 127 mm – Viscolok unit
1
(5 in) in length – Housing.
Threaded rod: M10 x 1.25, 178 mm (7 in)
1
As a preliminary setup, install shim according to
length the following table.
M10 x 1.25 nut 3 RECOMMENDED SHIM THICKNESS
Flat bar 1 0.5 mm (.02 in)
BACKLASH
(as a preliminary adjustment)
vmr2012-036-012_a
1. Bearing
2. Pinion gear
Remove and discard O-ring. vmr2015-051-008
Remove bearing from pinion gear. 1. Backlash shim
Prior to finalizing assembly, proceed in this order:

– Temporarily assemble final drive using recom-
mended torques.
– Do not apply thread locker product.
– Do not install a new pinion nut.
– Check backlash.
– Check preload.
472 vmr2015-138
Visco-Lok Carrier/Ring Gear

Tighten Visco-Lok / ring gear screws to specifica-
tion.
TIGHTENING TORQUE
Visco-Lok / ring gear 37 N•m ± 3 N•m
Check condition of seal. Replace if damaged.

vmr2015-051-001_a
Tighten differential housing screws to specifica-

tion.
TIGHTENING TORQUE
Differential housing 23.5 N•m ± 3.5 N•m
Pinion Gear
Install a NEW ball bearing.
Install a NEW O-ring.
Install a NEW needle bearing.
Apply LOCTITE 277 (P/N 293 800 073) to pinion nut.
vmr2015-051-003_a
Install and tighten the pinion nut to specification.
TIGHTENING TORQUE
Check bearings. Replace with NEW bearings if
necessary. 180 N•m ± 15 N•m
Pinion nut
+
800 073)
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on

NEW oil seal and install.
Tighten front propeller shaft adapter retaining
screw to specification.
TIGHTENING TORQUE
Front propeller shaft 75 N•m ± 5 N•m
adapter retaining screw (55 lbf•ft ± 4 lbf•ft)
Front Differential Installation

vmr2015-051-004_a The installation is the reverse of the removal pro-
NEW oil seals and install. When inserting the small portion of propeller shaft
into propeller shaft boot, make sure both parts of
propeller shaft are well indexed.
vmr2015-138 473
TIGHTENING TORQUE
M8 nut securing front 24.5 N•m ± 3.5 N•m
differential to frame (18 lbf•ft ± 3 lbf•ft)
M10 nuts securing front 61 N•m ± 9 N•m
differential to frame (45 lbf•ft ± 7 lbf•ft)
Install NEW Oetiker clamps.

Refill front differential with recommended oil. Re-
fer to PERIODIC MAINTENANCE PROCEDURES
subsection.
vmr2012-009-020_a
FRONT PROPELLER SHAFT 1. Oetiker clamps
Front Propeller Shaft Removal 6. Detach front propeller shaft from front differen-
1. Lift and support vehicle. tial by moving it rearward.
2. Remove front wheel. Refer to WHEELS AND
TIRES subsection.
3. Remove inner fender panel(s). Refer to BODY
subsection.
4. Remove bolts securing front differential to
frame.
vmr2012-036-005_a
FRONT PROPELLER SHAFT MOVED REARWARD
7. Pry front differential upwards to make room.
vmr2012-036-004_a
1. Bolts securing front differential to frame
5. Remove the following Oetiker clamps from

vmr2012-036-007_a
1. Pry bar
8. Remove front propeller shaft by pulling it for-

ward.
474 vmr2015-138
9. Remove front propeller shaft adapters from en-

gine and from front differential.
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

The installation is the reverse of removal proce-
splines.
Tighten propeller shaft adapter screw to specifica-
tion.
TIGHTENING TORQUE
75 N•m ± 5 N•m
Propeller shaft
adapter screw
+
(differential side:
LOCTITE 648 (GREEN)
M10x16)
(P/N 413 711 400)
75 N•m ± 5 N•m
Propeller shaft (55 lbf•ft ± 4 lbf•ft)
adapter screw +
(engine side: M12x20) LOCTITE 648 (GREEN)
(P/N 413 711 400)
vmr2015-138 475
Subsection XX (REAR DRIVE (570/650 / 850 /
1000R))
REAR DRIVE (570 / 650 / 850 / 1000R)

SERVICE TOOLS
BACKLASH MEASUREMENT TOOL............................................. 529 035 665 ........................................... 10
CV BOOT CLAMP PLIER .............................................................. 529 036 120 ............................................. 5
CV JOINT EXTRACTOR................................................................. 529 036 005 ............................................. 5
SPANNER SOCKET ....................................................................... 529 035 649 ........................................... 12
SERVICE PRODUCTS
LOCTITE 277 ................................................................................. 293 800 073 ..................................... 14–15
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ............................................. 8
XPS SYNTHETIC GREASE............................................................. 293 550 010 ......................................... 4, 8
vmr2017-129 1
Subsection XX (REAR DRIVE (570 / 650 / 850 / 1000R))
DRIVE SHAFTS AND PROPELLER SHAFT

XPS Synthetic
grease
Max models
NEW
XPS Synthetic
Short models grease
NEW
NEW
XPS Synthetic
205 ± 15 N•m grease
(151 ± 11 lbf•ft)
90 ± 5 N•m
(66 ± 4 lbf•ft)
NEW XPS Synthetic
XPS grease
Synthetic NEW
22.5 ± 2.5 N•m
grease (17 ± 2 lbf•ft)
NEW
Loctite
648
Hi-temp bearing grease NEW
XPS Synthetic NLGI-2 or equivalent
grease
75 ± 5 N•m
(55 ± 4 lbf•ft)
Loctite NEW
648
NEW
XPS Synthetic
grease NEW
205 ± 15 N•m
(151 ± 11 lbf•ft)
vmr2013-037-002_a
2 vmr2017-129
Subsection XX (REAR DRIVE (570 / 650 / 850 /
1000R))
REAR FINAL DRIVE
NEW XPS synthetic

grease
For preload
adjustment
32 ± 3 N•m
(24 ± 2 lbf•ft)
NEW For backlash

adjustment
22.5 ± 2.5 N•m
(17 ± 2 lbf•ft)
NEW
NEW
180 ± 15 N•m
(133 ± 11 lbf•ft) NEW NEW
LH threads
5 ± 1 N•m
(44 ± 9 lbf•in)
Loctite 277
XPS synthetic
grease
NEW NEW

vmr2015-052-102_a
vmr2017-129 3
PROCEDURES
WHEEL HUB
Removing the Wheel Hub
Remove the wheel.
Remove the following parts:
– Caliper mounting bolts (if applicable), refer to
BRAKES subsection
– Hub cap
– Cotter pin
– Wheel hub nut vmr2012-037-004
– Belleville washer.
Installing the Wheel Hub
dure. Pay attention to the following.
drive shaft splines.
Install Belleville washer with its convex side out-
ward.
vmr2012-037-003_a
1. Caliper
2. Remove bolts
Remove wheel hub.
Inspecting the Wheel Hub

Remove disk from RH wheel hub as necessary. vmr2012-037-005_a
Check wheel hub for cracks or other damages. 1. Wheel hub

2. Washer — Convex side here
Check inner splines for wear or other damages. 3. Nut
If any damage is detected on wheel hub, replace TIGHTENING TORQUE
it with a new one.
205 N•m ± 15 N•m
Wheel hub nut
NOTE: If required, tighten castle nut further to

align grooves with drive shaft hole.
Install a NEW cotter pin, bend as shown.
4 vmr2017-129
1000R))
Installing the Drive Shaft

Install a NEW stop ring.
tmr2017-108-001_a
1. Cotter pin correctly bent

2. Domed (convex) side here
DRIVE SHAFT
Removing the Drive Shaft
V01H0FA 1
TYPICAL
1. NEW stop ring
After drive shaft insertion in rear final drive, vali-

date if properly locked.
DRIVE SHAFT BOOT

Removing the Drive Shaft Boot
Remove the drive shaft from vehicle. See proce-
dure in this subsection.
Remove drive shaft boot clamps using the follow-
ing tool:
REQUIRED TOOL
vmr2012-037-014_a
CV BOOT CLAMP PLIER
TYPICAL
1. Drive shafts (P/N 529 036 120)
Lift and support vehicle. Dislodge the large boot end.

Remove the wheel hub. See procedure in this Separate the joint from the shaft. Two procedures
subsection. can be done.
Remove trailing arm. Refer to REAR SUSPEN- Without the Special Tool
SION.
Clamp joint housing in a vise.
Strongly pull drive shaft out of final drive.
Align shaft with joint.
Inspecting the Drive Shaft Pull hard on shaft to remove from joint.
Inspect the condition of boots. If there is any dam- Remove boot from drive shaft.
age or evidence of leaking lubricant, replace them. Remove and discard the circlip. A new one is in-
Refer to DRIVE SHAFT BOOT. cluded in the boot kit.
Check shaft splines. Replace drive shaft if neces-
With the Special Tool
sary.
Place drive shaft in vice with the joint downward.
Check dust shield on drive shaft end. Replace if
necessary. Install the CV JOINT EXTRACTOR (P/N 529 036 005)
on bearing.
vmr2017-129 5
PROPELLER SHAFT
Removing the Propeller Shaft
529036005
vmr2007-053-010_b
TYPICAL — CV JOINT SHOWN vmr2012-037-014_b

1. Joint extractor tool
TYPICAL
1. Propeller shaft
With an hammer, hit on the tool to separate joint
from shaft. 1. Remove wheels. Refer to WHEELS AND
When joint and shaft are separated, remove boot TIRES subsection.
from drive shaft. 2. Drain oil from rear final drive. Refer to PERI-
Remove and discard the circlip. A new one is in- ODIC MAINTENANCE PROCEDURES.
cluded in the boot kit. 3. Detach brake master cylinder from frame (Out-
Remove drive shaft boot. lander only). Refer to BRAKES subsection.
Installing the Drive Shaft Boot

Pay attention to the following.
Pack bearing area with grease (included with the
new boot kit).
NOTE: Do not use any other grease.
vmr2012-037-006_a
1. Remove retaining screws
6 vmr2017-129
1000R))
vmr2012-037-009_a
vmr2012-037-007_a
TYPICAL — LH SIDE OF VEHICLE
1. Master cylinder moved apart 1. Remove screw
4. Lift and support vehicle. 7. Remove rear final drive retaining bolts. Refer to
5. From RH side of vehicle, remove propeller shaft REAR FINAL DRIVE in this subsection.
screw from gearbox output shaft. 8. Remove bolts from rear retaining plate. Refer
NOTE: Heat screw to break the threadlocker to REAR FINAL DRIVE in this subsection.
bond prior to removal. 9. Move the rear final drive rearward to allow dis-
lodging the propeller shaft.
10. Dislodge the propeller shaft from the gearbox.
11. Remove the propeller shaft.
vmr2012-037-008_a
TYPICAL — RH SIDE OF VEHICLE

1. Remove screw
6. From LH side of vehicle, remove propeller shaft

screw from rear final drive yoke. vmr2012-037-012_a
1. Pull out propeller shaft
Inspecting the Propeller Shaft

Inspect if propeller shaft is not bent or twisted.
Check propeller shaft splines for wear or damage.
Check if propeller shaft bellow is cracked, pierced
or brittle.
Installing the Propeller Shaft

Installation is essentially the reverse of removal
procedure. Pay attention to the following details.
vmr2017-129 7
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) to

splines.
On the engine side, Install the Belleville with the
notches towards the screw head.
V01H0ZA
Support U-joint in vice and drive inner yoke down

to remove remaining bearing caps.
tmr2017-109-001
TYPICAL
Remove U-joint cross.
TIGHTENING TORQUE Installing the Propeller Shaft U-Joint

Propeller shaft screw 75 N•m ± 5 N•m Install new U-joint in inner yoke.
(rear final drive side) (55 lbf•ft ± 4 lbf•ft) NOTE: Position propeller shaft U-joint as shown
75 N•m ± 5 N•m for proper grease fitting location.
Propeller shaft screw
+
(gearbox side)
LOCTITE 648 (GREEN)
(P/N 413 711 400)
Refill rear final drive. Refer to PERIODIC MAINTE-

PROPELLER SHAFT U-JOINTS

Removing the Propeller Shaft U-Joint
Remove internal snap ring from bearing caps.
V01H10A
Install bearing caps. Use a vise to push bearing

caps.
V01H0YA 1
1. Snap ring
Support inner yoke in vice and drive other yoke V01H11A

down with a soft hammer.
8 vmr2017-129
1000R))
Using a suitable pusher, fully seat bearing cap on

one side.
V01H12A vmr2012-037-010_a
1. Remove bolts
Install snap ring.
Remove bolts from rear retaining plate.
Complete installation for the other bearing caps.
Grease U-joint. Refer to PERIODIC MAINTE-
REAR FINAL DRIVE

Removing the Rear Final Drive
Drain oil. Refer to PERIODIC MAINTENANCE
Support rear bottom end of frame.
Remove drive shafts. See procedure in this sub-
section.
Remove rear propeller shaft screw from the rear
final drive yoke. Refer to PROPELLER SHAFT in vmr2012-037-011_a
this subsection. 1. Remove bolts
Remove rear final drive bolts. Unplug the vent hose from final drive.
vmr2012-037-015_a
1. Pull out
vmr2017-129 9
Remove the final drive.
Inspecting the Rear Final Drive

(Assembled)
Manually turn rear final drive gear; it should turn
smoothly. Repair if necessary.
Check if oil seals are brittle, hard or damaged. Re-
place if necessary.
Measuring the Backlash
Using a dial indicator and the BACKLASH MEA-
SUREMENT TOOL (P/N 529 035 665), measure the
backlash.
Place the backlash measurement tool at the end vmr2006-023-016
of pinion gear.
Rotate pinion gear 1/2 turn and recheck backlash.
From center of tool bolt, measure 25.4 mm (1 in) Note the result.
and scribe a mark on the tab.
Rotate pinion gear 1 turn and recheck backlash.
BACKLASH SPECIFICATION
0.05 mm (.002 in) to 0.36 mm (.014 in)
If backlash is out of specification, split final drive

housing and adjust shim thickness as per follow-
ing guideline.
BACKLASH ADJUSTMENT GUIDELINE
BACKLASH
WHAT TO DO
MEASUREMENT
Add shim(s) and recheck
Below 0.05 mm (.002 in)
backlash
Remove shim(s) and
Above 0.36 mm (.014 in)
recheck backlash
vmr2006-023-015_a
1. Tab of backlash measurement tool

2. Mark on tab
A. 25.4 mm (1 in)
Position the dial indicator tip against the tab at a

90° angle and right on the previously scribed mark.
Gently, move the tool tab back and forth. Note the
backlash result.
vmr2012-037-016_b
1. Backlash shim
Measuring the Preload

Screw the propeller shaft screw in pinion gear.
10 vmr2017-129
1000R))
vmr2012-037-016_a
1. Preload shim
vmr2015-052-005_a
Disassembling the Rear Final Drive

Ring Gear
Remove the final drive housing screws.
vmr2015-052-006_a
PRELOAD SPECIFICATION
0.06 N•m (.5 lbf•in) to 0.50 N•m (4 lbf•in)
If preload is out of specification, split final drive

housing and adjust shim thickness as per follow- vmr2015-052-007_a
ing guideline.
Split final drive housings.
PRELOAD GUIDELINE NOTE: Be careful to keep track of shims on ring
PRELOAD gear.
WHAT TO DO
MEASUREMENT
Below 0.06 N•m Add shim(s) and recheck
(.5 lbf•in) preload
Above 0.50 N•m Remove shim(s) and
(4 lbf•in) recheck preload
vmr2017-129 11
vmr2015-052-009_a
vmr2015-052-004_c
1. Backlash shim
2. Preload shim NOTE: The pinion nut is left hand threaded. Un-
3. Ring gear screw by turning clockwise.
Extract ring gear out of half housing. Remove the bearing along with the pinion gear.
Be careful to keep track of shims. Discard bear-
Pinion Gear ing.
Remove and discard oil seal.
vmr2015-052-008_a
vmr2015-052-010_a
Unscrew the pinion nut. Use the SPANNER
SOCKET (P/N 529 035 649).
529035649
vmr2015-052-011_a
1. O-ring
2. Ball bearing
3. Pinion gear shim
4. Pinion gear
12 vmr2017-129
1000R))
The pinion gear and bearing can be easily removed 3. Measure the distance "B" between outside sur-
using the following suggested tool: face of the gear case and the bearing shoulder
of the gear case.
PART QTY
4. The shim thickness will be "A-B-0.53 mm
Pipe: 83 mm (3-1/4 in) diameter x 127 mm (.021 in)".
1
(5 in)
5. Select the good combination of shim to match
Threaded rod: M10 x 1.25 x 178 mm (7 in) 1 the thickness calculated on step 4.
M10 x 1.25 nut 3
Flat bar 1
Remove and discard the needle bearing.
vmr2015-052-016_a
vmr2015-052-012_a
Assembling the Rear Final Drive

Adjustment is required when any of the following
part is changed.
– Pinion gear
– Ring gear
– Housing.
As a preliminary setup, install shims according to
the following table.
vmr2015-052-015_a
RECOMMENDED SHIM THICKNESS 1. Backlash side
2. Preload side
See procedure for pinion gear
PINION GEAR
shim thickness
BACKLASH 0.5 mm (.02 in)
PRELOAD (as a preliminary adjustment)
Procedure for pinion gear shim thickness:

1. Remove the old pinion gear and install the new
one without the ball bearing. The new pinion
will be located at the "zero" location.
2. Measure the distance "A" between outside sur-
face of the gear case and the shim surface of
pinion.
vmr2017-129 13
vmr2015-052-004_a
1. Backlash shim
vmr2015-052-013_a
Install NEW bearings.
vmr2015-052-004_b
1. Preload shim
Prior to finalizing assembly, proceed in this order:

– Temporarily assemble final drive using recom-
mended torques. vmr2015-052-014_a
– Do not apply thread locker product.

Tighten final drive housing screws as per specifi-
– Do not install a new pinion nut.
cation.
– Check backlash.
– Check preload. TIGHTENING TORQUE
Final drive housing 32 N•m ± 3 N•m
Ring Gear
cedure. However, pay attention to the following: Pinion Gear
Check condition of seal. Replace if damaged. The installation is the reverse of the removal pro-
cedure. However, pay attention to the following:
Install a NEW needle bearing.
Install the shim(s) then a NEW ball bearing.
install a NEW O-ring.
Apply LOCTITE 277 (P/N 293 800 073) to pinion nut.
Install and tighten the pinion nut as per specifica-
tion.
14 vmr2017-129
1000R))
TIGHTENING TORQUE
180 N•m ± 15 N•m
Pinion nut
+
(LH THREADS)
800 073)
Lubricate and install a NEW oil seal.
Installing the Rear Final Drive

cedure. However, pay attention to the following:
Install the lowest rear final drive retaining screws
first.
Install all screws and nuts prior to tighten.
Tighten nuts to specification.
TIGHTENING TORQUE
90 N•m ± 5 N•m
Final drive retaining nuts
Refill the final drive with recommended oil. Re-

fer to PERIODIC MAINTENANCE PROCEDURES
subsection.
vmr2017-129 15
Section 08 CHASSIS
Subsection 01 (WHEELS AND TIRES)
WHEELS AND TIRES

SERVICE PRODUCTS
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ......................................... 627
PROCEDURES
TIRES
WARNING
Do not rotate tires. The front and rear tires
have a different size. Respect direction of ro-
tation when applicable.
Tire Pressure
WARNING tmr2011-033-002_a
TYPICAL
Tire pressure greatly affects vehicle handling 1. Direction of rotation
and stability. Insufficient pressure may cause
tire to deflate and rotate on wheel. Excessive
pressure may burst the tire. Always follow WHEELS
recommended pressure. Wheel Removal
Loosen nuts just enough to be able to unscrew
Check pressure when tires are cold before us- them once the vehicle will be off the ground.
ing the vehicle. Tire pressure changes with tem-
perature and altitude. Recheck pressure if one of Lift and support the vehicle.
these conditions has changed. Remove nuts, then remove wheel.
TIRE PRESSURE FRONT REAR
Wheel Inspection
41.4 kPa 41.4 kPa Inspect wheel for wear or damage especially at
MIN.
(6 PSI) (6 PSI)
the mounting holes.
MAX.
Use when total 48.3 kPa 68.9 kPa Wheel Installation
load is greater than (7 PSI) (10 PSI)
At installation, it is recommended to apply LOC-
131.5 kg (290 lb)
TITE 767 (ANTISEIZE LUBRICANT) (P/N 293 800 070)
on threads.
Tire Inspection Check if tires are unidirectional.
Check tire for presence of slits, bulges, wear or
other damage. Replace if necessary.
Tire Replacement
Use an automotive tire changer to replace tires.
WARNING
– Replace tires only with the same type and
size as original tires.
– For unidirectional tread pattern, ensure
that the tires are installed in the correct
direction of rotation.
vmr2015-053 627
Section 08 CHASSIS
Subsection 01 (WHEELS AND TIRES)
tmr2011-033-002_a
TYPICAL
1. Direction of rotation
Install wheel with the tire in the right direction of

rotation.
Install lug nuts with the taper towards the wheel.
Tighten wheel lug nuts to the specified torque us-
ing the illustrated sequence.
WHEEL LUG NUTS
100 N•m ± 10 N•m
TORQUE
vmr2012-038-004_a
TYPICAL - 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.
628 vmr2015-053
Subsection XX (STEERING SYSTEM)
STEERING SYSTEM
(OUTLANDER 570 / 650 / 850 /
1000R AND RENEGADE)
SERVICE TOOLS
STEERING ALIGNMENT TOOL..................................................... 529 036 059 ........................................... 5

SMOOTHFLOW™ TAPERED TIP.................................................. 16 ga ........................................... 6
#511 rtt-b
SERVICE PRODUCTS
LOCTITE 406 (GLUE)..................................................................... 293 800 100 ........................................... 6
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ........................................... 6
vmr2017-126 1
Subsection XX (STEERING SYSTEM
Outlander and Renegade Without DPS
Outlander
Renegade
Europe
Loctite
406
24.5 ± 3.5 N•m

XPS (18 ± 3 lbf•ft)
Synthetic
grease NEW Loctite
NEW 406
NEW
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
Loctite
243
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft) NEW
NEW
72.5 ± 7.5 N•m NEW
(53 ± 6 lbf•ft)
XPS
Synthetic
NEW grease
72.5 ± 7.5 N•m 72.5 ± 7.5 N•m

NEW (53 ± 6 lbf•ft) (53 ± 6 lbf•ft)
72.5 ± 7.5 N•m

(53 ± 6 lbf•ft)
NEW = Component must be replaced when removed. NEW
vmr2016-140-001_a
2 vmr2017-126
Outlander with DPS
Europe
Loctite
406
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
XPS
Synthetic NEW
grease NEW Loctite
NEW 406
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW
24.5 ± 3.5 N•m
Loctite 767 (18 ± 3 lbf•ft)
Antiseize
NEW
72.5 ± 7.5 N•m
(53 ± 6 lbf•ft)
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW
72.5 ± 7.5 N•m NEW
72.5 ± 7.5 N•m (53 ± 6 lbf•ft)
NEW (53 ± 6 lbf•ft)
NEW NEW
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft) XPS
Synthetic
grease
72.5 ± 7.5 N•m

NEW = Component must be replaced when removed. NEW (53 ± 6 lbf•ft)
vmr2012-039-002_a
vmr2017-126 3
Subsection XX (STEERING SYSTEM )
Renegade with DPS
31.5 ± 3.5 N•m

(23 ± 3 lbf•ft)
Europe Loctite Loctite

406 406
24.5 ± 3.5 N•m

XPS (18 ± 3 lbf•ft)
Synthetic NEW
grease NEW
NEW
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
NEW
Loctite 767
Antiseize
NEW 24.5 ± 3.5 N•m
72.5 ± 7.5 N•m (18 ± 3 lbf•ft)
(53 ± 6 lbf•ft)
NEW 24.5 ± 3.5 N•m

72.5 ± 7.5 N•m
NEW (53 ± 6 lbf•ft) 72.5 ± 7.5 N•m (18 ± 3 lbf•ft)
NEW
(53 ± 6 lbf•ft)
72.5 ± 7.5 N•m
(53 ± 6 lbf•ft)
24.5 ± 3.5 N•m
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
XPS
Synthetic
grease
72.5 ± 7.5 N•m
NEW = Component must be replaced when removed. NEW (53 ± 6 lbf•ft)
vmr2012-039-003_a
4 vmr2017-126
GENERAL 9. Rotate the front wheel to position the align-

ment tool level with the rope. Ensure rope
The procedures described below are the same for passes over the spacer blocks on the align-
the RH and LH sides, unless otherwise instructed. ment tool.
ADJUSTMENT
ALIGNING THE WHEELS
1. Place vehicle on a level surface.
2. Check pressure in each tire. Adjust to recom-
mended pressure.
3. Lift and secure vehicle off the ground so that
the suspension is fully extended.
4. Remove both inner fenders to have easy ac- vmr2008-068-006_a
1. Steering adjustment tool

cess to pitman arm. 2. Angle gauge or level
5. Center pitman arm by measuring equal dis-
tances, ±1mm, between the edges as per 10. At the LH front of wheel, near the front of the
the following illustration, on both sides of the rim, pull on the rope so that it does not touch
pitman arm. the first spacer block on the alignment tool.
vmr2016-059-001_a
A. Equal distance ± 1 mm (1/32 in) on both sides

1. Steering column lower attach
vmr2008-068-005_a
2. Pitman arm
TYPICAL
6. Secure handlebar without moving steering col-
umn. 11. Slowly move rope back until it just makes con-
tact with both spacers.
7. Remove two wheel nuts on the LH rear wheel
and install the steering alignment tool. NOTE: Ensure rope remains in this position as
you carry out the following steps.
REQUIRED TOOL
STEERING ALIGNMENT
TOOL (P/N 529 036 059)
8. Place a rope around all four tires using an elas-

tic, link both ends together.
NOTE: The rope must be placed at the center of
the wheels.
vmr2008-068-007
TYPICAL
vmr2017-126 5
12. Measure the distance between the rope and

the rim, at the front and at the rear of the
wheel rim.
tmr2011-034-107_a
A. Maximum tie-rod end length
14.3 Tighten tie-rod end lock nuts to specifica-

tion.
TIGHTENING TORQUE
Tie-rod end locking 34 N•m ± 2 N•m
nut (25 lbf•ft ± 1 lbf•ft)
vmr2008-068-008
TYPICAL — FRONT OF WHEEL

15. Repeat procedure for other front wheel.
16. Put the vehicle back on the ground.
17. Remove the handlebar securing device.
18. Place the front wheels in straight ahead posi-
tion and adjust the handlebar in its center posi-
tion by loosening the 4 bolts clamping the han-
dlebar on the steering column.
PROCEDURES
HANDLEBAR GRIP
vmr2008-068-009
TYPICAL — REAR OF WHEEL Removing the Handlebar Grip

1. Loosen the screw at the end of handlebar grip.
13. Calculate the difference between the front
and rear measurements and compare with 2. Remove the handlebar grip cap.
following specifications. 3. Cut and remove the handlebar grip.
MODELS SPECIFICATION
Installing the Handlebar Grip
0 mm to 3 mm 1. Remove all rubber residues of the old grip be-
All Outlanders
(0 in to .118 in) toe-in
fore installing the new.
3 mm to 5.6 mm 2. Clean the handlebar with PULLEY FLANGE
All Renegades
(.118 in to .22 in) toe-in
CLEANER (P/N 413 711 809) or alcohol to remove
any greasy matter on it.
14. If the wheel toe measurement is out of spec-
ification, carry out the following: 3. Install handlebar grip by blowing compressed
air between handle grip and handlebar.
14.1 Loosen tie-rod end lock nuts.
4. Install a SMOOTHFLOW™ TAPERED TIP
14.2 Adjust tie-rod length.
(P/N 16 GA #511 RTT-B) from EFD Inc on a
NOTE: For a toe-in adjustment, the dis- bottle of LOCTITE 406 (GLUE) (P/N 293 800 100).
tance must be longer at the front of the
5. Lift a part of the grip using a small screwdriver
wheel. Lengthen tie-rod to increase toe-in,
and inject glue (about 4 spots per side).
and vise-versa.
NOTE: The glue dries quickly. Do not apply it be-
WARNING fore installing grip.
The maximum unengaged tie-rod 6. Apply pressure on the grip for approximately
length must not exceed 32 mm (1.26 in) 30 seconds to set the glue.
Tie rod unengaged length must be the 7. Install the handlebar grip cap and tighten
same at both ends of the tie-rod. screws to specification.
6 vmr2017-126
TIGHTENING TORQUE HANDLEBAR

Handlebar grip cap screw 0.4 N•m (3.5 lbf•in) Removing the Handlebar
All Outlander Models
HANDLEBAR COVER 1. Remove handlebar cover.
Removing the Handlebar Cover NOTE: Remove handlebar grips, throttle handle,
brake handle and multifunction switch only if the
Outlander handlebar is defective and requires replacement.
Pull on plastic handlebar cover to remove it from 2. Remove handlebar mounting bolts, stiffener
the handlebar. and handlebar clamps.
Outlander XT
Unscrew both plastic U-clamps that attach handle-
bar cover to the handlebar.
vmr2012-039-004_a
vmr2006-025-005_a
TYPICAL
1. Stiffeners
TYPICAL 2. Handlebar clamps
1. Plastic U-clamp
3. Remove the handlebar.
Renegade
Remove the 4 screws that secure the steering Renegade Model
cover and handlebar to the steering head. NOTE: Handlebar grips, throttle and brake levers
as well as the multifunction switch should be re-
Renegade X xc moved only if the handlebar is defective and re-
Remove the fabric steering cover, then pull the quires replacement.
protective foam from the handlebar. 1. Unscrew the four socket screws securing the
moulded handlebar support.
Inspecting the Handlebar Cover
Check covers for cracks or other damages. Re-
place if necessary.
Installing the Handlebar Cover

dure.
Renegade X xc 800R/1000
NOTE: Ensure handlebar "U" clamps in handlebar
cover are tightened equally (equal distance on
each side of clamps).
vmr2007-055-003_a
TYPICAL
1. Moulded handlebar support
2. Socket screws
2. Remove handlebar.
vmr2017-126 7
Renegade Models (X xc Model)

1. Remove fabric steering cover.
2. Pull foam protector from handlebar.
3. Remove the four socket screws, then remove
the handlebar clamps.
vmo2012-012-033_a
1. Gauge support
2. Remove front body module, refer to body sub-

section.
3. Remove dash board support.
vmr2012-039-005_a
1. Socket screws
2. Handlebar clamps
Inspecting the Handlebar

Inspect the handlebar for damage, cracks or bend-
ing. Replace if any of these problems is detected.
Installing the Handlebar

dure.
NOTE: Ensure handlebar "U" clamps are tightened
equally (equal distance on each side of clamps). vmr2012-033-001_a
1. Dash board support

STEERING CONNECTORS
Steering Connector Access
1. Remove gauge support, refer to GAUGE sub-
section.
8 vmr2017-126
Steering Connector Identification 4. Take note of the positions of the locking ties
securing the steering harness, then cut them
and remove the multifunction switch steering
harness from the vehicle.
Installing the Multifunction Switch

NOTICE Be sure to route and secure the mul-
tifunction switch steering harness as noted
prior to removal.
THROTTLE LEVER
Removing the Throttle Lever
vmr2012-039-007_a 1. Disconnect the HIC1 connector (2/4WD
STEERING CONNECTOR IDENTIFICATION switch), refer to STEERING CONNECTORS
1. MG1 (LH multifunction switch)
2. MG2 (LH multifunction switch) in this subsection.
3. MG3 (LH multifunction switch)
4. DC3 (DC power connector) 2. Remove throttle lever housing retaining
5. HIC1 (Engine interconnect) screws.
6. HICA (Accessory interconnect)
7. SWW 2 (Switch winch)
8. SWW 1 (Switch winch) 1
MULTIFUNCTION SWITCH
Removing the Multifunction Switch
(From the Vehicle)
Remove gauge support. Refer to GAUGE subsec-
tion.
Carry out steps in REMOVING THE MULTIFUNC-
TION SWITCH (AT HANDLEBAR).
Removing the Multifunction Switch (At
Handlebar)
1. Remove multifunction switch screws.
V07I0FA
TYPICAL - THROTTLE LEVER HOUSING

1. Remove retaining screws
3. Separate throttle lever housing from handlebar.

4. Slide rubber protector back to expose throttle
cable adjuster.
vmr2012-039-006_a
TYPICAL - MULTIFUNCTION SWITCH
2. Separate multifunction switch from handlebar.

3. Disconnect multifunction switch steering con-
nectors, refer to STEERING CONNECTOR
IDENTIFICATION in this subsection:
– MG1
– MG2
– MG3.
vmr2017-126 9
V07I0GA 1 2 3 4
1. Cable protector
3. Lock nut
4. Throttle lever housing V07I0IA
5. Loosen lock nut and screw in the throttle cable

adjuster. 8. Remove throttle cable from housing.
6. Remove inner housing protector. Installing the Throttle Lever
Adjust throttle cable. Refer to THROTTLE CABLE
ADJUSTMENT in ELECTRONIC FUEL INJECTION
(EFI) subsection.
BRAKE LEVER
Removing the Brake Lever From the
Vehicle
1. Carry out steps in REMOVING THE BRAKE
LEVER (AT HANDLEBAR).
NOTICE Avoid spilling brake fluid on plastic,
rubber or painted parts.
V07I0HA 1 2. Disconnect brake hose, refer to BRAKES sub-

section.
7. Slide cable in clip slot and remove the end of Removing the Brake Lever (At
the cable from clip. Handlebar)
1. Remove brake lever retaining screws.
10 vmr2017-126
vmr2008-068-004_a
TYPICAL
1. Remove these retaining screws
2. Separate brake lever from handlebar. vmr2012-033-001_a
TYPICAL - OUTLANDER MODELS

Installing the Brake Lever 1. Dash board support
For installation, reverse the removal procedure
All Models
however, pay attention to the following.
4. Remove the air intake silencer. Refer to AIR IN-
TIGHTENING TORQUE TAKE SYSTEM subsection.
Brake lever mounting 9 N•m ± 1 N•m 5. Remove handlebar, refer to REMOVING THE
screw (80 lbf•in ± 9 lbf•in) HANDLEBAR in this subsection. Also remove
locking ties and separate wiring harnesses and
WARNING hoses from the steering column.
If brake hose was disconnected, bleed brake 6. Disconnect the tie-rods from the pitman arm at
system. Refer to BRAKES subsection. the bottom of the steering column. Refer to
TIE-ROD, in this subsection.
STEERING COLUMN BEARING
The steering column bearing(s) used on these ve-
hicles are half bushings.
For inspection and replacement of steering col-
umn half bushings, refer to STEERING COLUMN
in this subsection.
STEERING COLUMN
Removing the Steering Column
(Without DPS)
section. vmr2012-039-008_a
2. Remove the front body module, refer to BODY TYPICAL

1. Steering column
subsection. 2. Pitman arm
3. Tie-rod end
Outlander Models 4. Cotter pin
5. Tie-rod retaining nut
NOTE: When removing tie-rods from pitman arm,
take note of positions of flat washers for installa-
tion.
7. Remove lower half bushing retaining bolts and
pull retainer off of half bushings.
vmr2017-126 11
vmr2012-039-009_a vmr2012-033-001_a
TYPICAL TYPICAL - OUTLANDER MODELS

1. Lower retainer mounting screws (2) 1. Dash board support
2. Lower half bushing retainer
3. Steering column
4. Pitman arm
All Models
4. Remove the air intake silencer. Refer to AIR IN-
8. Remove upper half bushing retaining bolts and TAKE SYSTEM subsection.
pull retainer off of half bushings.
5. Remove handlebar, refer to REMOVING THE
HANDLEBAR in this subsection. Also remove
locking ties and separate wiring harnesses and
hoses from the steering column.
6. Cut the locking ties securing the boot at the bot-
tom of the steering column.
vmr2012-039-010_a
TYPICAL
1. Upper steering column support
2. Half bushings
3. Half bushing retainer
4. Retainer mounting screws (2)
9. Pull steering column from vehicle. vmr2010-003-016_a
Removing the Steering Column (With 7. Roll up the boot to access the steering column
pinch bolt.
DPS)
8. Remove sthe pinch bolt.
section. NOTE: Some parts in following illustration not
shown for clarity of illustration.
2. Remove the front body module, refer to BODY
subsection.
Outlander Models
12 vmr2017-126
PRODUCT
O-rings and half XPS SYNTHETIC GREASE
bushings (P/N 293 550 010)
DPS input and
LOCTITE 767 (ANTISEIZE
output shaft
LUBRICANT) (P/N 293 800 070)
splines
Install NEW cotter pins (as applicable per model).

Both ends of cotter pins must be folded.
Install NEW elastic nuts where used.
Torque all fasteners as specified in the applicable
vmr2012-039-011_a exploded view.
1. Steering column
2. Steering column lower pinch bolt Carry out a steering alignment, refer to ALIGNING
3. DPS unit THE WHEELS in this subsection.
9. Remove upper half bushing retaining bolts and Reset the torque sensor offset, refer to RESET-
pull retainer off of half bushings. TING THE TORQUE OFFSET in the appropriate
DYNAMIC POWER STEERING (DPS) subsection.
TIE-ROD
NOTE: Use the same procedure for RH and LH
side.
Removing the Tie-Rod

1. Place vehicle on jack stands and remove the ap-
plicable wheel.
2. Remove tie-rod end from steering knuckle by
removing:
– Cotter pin (discard)
– Retaining nut
vmr2012-039-010_a
– Hardened washers (note position).
TYPICAL
1. Upper steering column support
2. Half bushings
3. Half bushing retainer
4. Retainer mounting screws (2)
10. Pull steering column from vehicle.
Inspecting the Steering Column

1. Inspect steering column for wear, cracks or
bending. Replace if any of these problems is
detected.
2. Check steering column O-rings for brittleness,
hardness, wear or other damage. Replace if
necessary.
3. Clean and check steering column half bushings.
If they show signs of wear or cracking, replace vmr2012-039-012_a
them. TYPICAL - TIE ROD AT STEERING KNUCKLE

1. Cotter pin
2. Elastic nut
Installing the Steering Column 3. Hardened washers
For the installation, reverse the removal proce- 3. If completely removing tie-rod from vehicle, re-
dure however, pay attention to the following. peat previous step at pitman arm.
vmr2017-126 13
tmr2011-034-107_a
MAXIMUM TIE-ROD UNENGAGED LENGTH

A. 32 mm (1.26 in)
Install NEW cotter pins. Both ends of cotter pins

must be folded.
Check the steering alignment, refer to ALIGNING
vmr2012-039-008_b THE WHEELS in this subsection.
TYPICAL
1. Steering column Apply specified torques.
2. Pitman arm
3. Tie-rod end TIGHTENING TORQUE
34 N•m ± 2 N•m
Inspecting the Tie-Rod Tie-rod lock nut
Inspect tie-rod for straightness, cracks and other
72 N•m ± 7 N•m
damages. Replace as required. Tie rod end retaining nut
Inspect tie-rod ends for wear or excessive play. If
excessive, replace the tie-rod end.
KNUCKLE
Installing the Tie-Rod Removing the Knuckle
1. Safely lift and support the front of vehicle.
dure. Pay attention to the following details.
2. Remove front wheel.
When installing a new tie-rod or tie-rod end, adjust
tie-rod to nominal length. 3. Detach tie-rod end from knuckle, refer to TIE-
ROD in this subsection.
TIE-ROD NOMINAL LENGTH
4. Remove brake caliper, refer to BRAKES subsec-
Dimension "A" - 416.4 mm tion.
center to center (16.394 in)
5. Remove wheel hub, refer to the appropriate
FRONT DRIVE subsection.
rmr2008-028-015_a
NOMINAL LENGTH
1. Pitman arm side
2. Knuckle side
A. 416.4 mm (16.394 in)
TIE-ROD MAXIMUM UNENGAGED LENGTH

Dimension "A" - Shoulder
32 mm (1.26 in)
to tie rod end face
WARNING
vmr2015-141-003
Maximum tie-rod unengaged length must
not exceed specification. Both tie-rod ends 6. Detach upper suspension arm from knuckle, re-
must be engaged equally. fer to FRONT SUSPENSION.
7. Detach lower suspension arm from knuckle, re-
fer to FRONT SUSPENSION.
14 vmr2017-126
8. Remove knuckle from vehicle.
Inspecting the Knuckle

Check knuckle for cracks or other damages. Re-
place if necessary.
Check if wheel bearing turns freely and smoothly.
See WHEEL BEARINGS in this subsection.
Installing the Knuckle

dure.
WHEEL BEARINGS tmr2011-034-109
TYPICAL
Inspecting the Wheel Bearing
(Maintenance) NOTE: It may be necessary to heat the knuckle to
Refer to PERIODIC MAINTENANCE PROCE- remove bearing.
DURES subsection.
WARNING
Inspecting the Wheel Bearing (During Clean all grease from outside and inside of
Component Removal) knuckle before heating it.
Whenever the drive axle or knuckle is removed,
check wheel bearing as follows: Installing the Wheel Bearing
– Check if wheel bearing turns freely and The installation is the reverse of the removal pro-
smoothly. cedure. However, pay attention to the following.
– Check seal condition. To ease wheel bearing installation:
Replace if necessary. – Place bearing in a freezer for 10 minutes.
– Place knuckle in oven to 100°C (212°F) for
Removing the Wheel Bearing 30 minutes maximum.
1. Remove knuckle from vehicle, refer to REMOV- When knuckle is cooled down, install NEW circlip
ING THE KNUCKLE in this subsection. and NEW seal.
2. Remove the circlip.
PITMAN ARM (WITHOUT DPS)
The pitman arm is replaced with the steering col-
umn. Refer to STEERING COLUMN in this sub-
section.
PITMAN ARM (WITH DPS)

Refer to the appropriate DYNAMIC POWER
STEERING (DPS) subsection.
vmr2017-112-001_a
1. Circlip
3. Install knuckle on a press.

4. Remove bearing from knuckle using an appro-
priate bearing remover.
vmr2017-126 15
Subsection XX (DYNAMIC POWER STEERING (DPS) - 3-CONNECTOR TYPE)
DYNAMIC POWER STEERING (DPS) -

3-CONNECTOR TYPE
SERVICE TOOLS
PITMAN ARM JIG ......................................................................... 529 036 225 ..................................... 22, 24
PITMAN ARM PULLER ................................................................. 529 036 227 ........................................... 23
POSITIONING ADAPTOR .............................................................. 529 036 230 ........................................... 23
SERVICE PRODUCTS
NEW
NEW NEW
Loctite 767
Antiseize
NEW
72.5 ± 7.5 N•m
(53 ± 6 lbf•ft)
NEW
NEW
NEW
XPS
Synthetic
grease
vmr2017-114-101_a
vmr2017-114 1
GENERAL When the electrical system is under high load

(battery not at full charge, operating the vehicle
SYSTEM DESCRIPTION for prolonged periods of time at slow speed and
low RPM which, requires higher power steering
(FEATURES) assist), the battery power reserve will gradually
The Dynamic Power Steering (DPS) provides decrease. This further increases the load on the
a computer controlled, variable power assist, charging system and the electrical system volt-
achieved by an electric motor to optimize the age will drop. As system voltage drops, so does
amount of steering input required by the rider. power steering assist.
NOTE: It is important to maintain the battery at
a full state of charge to ensure proper DPS oper-
ation. The magneto output is 650 watts to mini-
mize battery drain and system voltage drop.
DPS Assist Mode

The DPS system provides three rider selectable
modes of operation.
NOTE: The system automatically adjusts to the
speed of the vehicle and driving conditions. the
modes are designed to meet the preference of
the rider.
The following DPS modes are preset in the vehi-
cle.
vmr2010-003-014_a
DPS MODE
1. Dynamic power steering unit (DPS)
DPS MAX. Maximum steering assist
The DPS system uses the following parameters to
DPS MED. Medium steering assist
determine how much steering assist it provides:
– Engine RPM DPS MIN. Minimum steering assist
– Battery/electrical system voltage
A fourth mode of operation is available as an ac-
– Vehicle speed cessory to adjust the steering assist level for op-
– DPS shaft torque sensor input. eration with an approved BRP track kit.
– DPS temperature.
The amount of steering assist provided is depen- Derating Explanation
dent on the handlebar effort (steering torque), Derating is an internal protection system inte-
electrical power available, and vehicle speed. grated in the DPS electronic module.
The greater the handlebar effort (torque), the This system protects the electronic components
greater the assist will be. when DPS works too hard and the internal tem-
The slower the vehicle speed, the greater the as- perature reaches a critical level.
sist will be. It also protects electronics when current ripples in
If the electrical system is activated but the engine the system are too high. These current ripples can
is not running, there is no power assist provided. be caused by:
– Loose battery connections
When the handlebar is in the straight ahead posi-
tion, there is no steering assist. – Low battery voltage
– Bad grounds
Steering torque may also come from the wheels
due to rough terrain. Steering kickback is reduced – Defective stator or bad stator output wires con-
while providing feedback to the driver. nection
– Failed regulator
The greater the power steering assist, the greater
the load on the electrical system. – High electrical loads.
The internal protection system decreases the
assistance level available to protect its electronic
board. The normal assistance level will return
2 vmr2017-114
when riding conditions are back to normal and CONDITION DPS BEHAVIOR
the internal temperature decrease and/or when
the ripples in the electric circuit decreases. When motor internal
temperature reaches a certain
NOTE: This reaction is a normal protective behav- temperature (DPS continuously Steering assist
ior of the unit and it does not necessarily raise a estimates it) will gradually
fault in the cluster. decrease
DPS internal board
temperature is above
DPS SYSTEM DESCRIPTION 85°C (185°F)
(COMPONENTS) DPS internal board
Steering assist
temperature is above
DPS Unit 100°C (212°F)
is stopped
The DPS unit is a self contained unit that includes
the steering gear, the DPS module, the DPS mo- When the DPS unit temperature is back within
tor, and the torque sensor. normal operating range, normal steering assist
will resume.
Steering Torque Sensor
vmr2010-003-003
TYPICAL - DPS UNIT
The DPS module provides DC power to the mo-

tor. The amount and duration of that DC power is
determined by the inputs to the DPS module. The
direction in which the motor turns is changed by
reversing the polarity of the circuit current.
The DPS motor does not "spin", but rather turns in
very small increments based on the amount, du- rmr2008-019-017
ration, and direction of DC power delivered by the
DPS module. The steering column is connected to the shaft on
NOTE: Should the DPS unit fail, vehicle steering the DPS unit. A small area of the DPS shaft is
is still available with increased steering effort. magnetized. Inside the DPS unit, a torque sensor
surrounds the magnetized area of the DPS shaft.
DPS Unit Protection When the handlebar is turned, torque is applied to
To protect the DPS electronic components, the the shaft which tends to twist the shaft slightly,
steering assist behavior will change as follows. deforming the magnetic field in the shaft. The
sensor detects the torque by measuring the devi-
ation of the magnetic field.
The torque sensor is very sensitive and can de-
tect very small changes in the magnetic field.
The harder the handlebar is turned, the greater
the magnetic deviation, the greater the power
steering assist.
vmr2017-114 3
ADJUSTMENT
RESETTING THE TORQUE
OFFSET
When replacing the following parts or adjust-
ing steering alignment, the sensor torque offset
MUST be reset to zero) for proper system oper-
ation.
PART ADJUSTED OR
WHAT TO DO
REPLACED
vmr2010-003-002_a
– DPS unit DPS TORQUE OFFSET RESET
– Steering column 1. Setting page tab
2. DPS tab
half bushings 3. Reset Torque Offset button
– Steering column
– Tie rod DPS ASSIST MODE
– Tie rod end
Reset Torque Offset 1. To view the active DPS ASSIST mode, momen-
– Knuckle in Setting, DPS
– Wheel bearing tarily press and release the OVERRIDE/DPS
– Ball joint button on the LH multifunction switch assem-
bly.
– Front suspension arm
(lower/upper)
– Pitman arm
– Steering alignment
1. Ensure the wheels are correctly aligned, refer

to ALIGNING THE WHEELS in the appropriate
STEERING SYSTEM subsection.
3. In B.U.D.S., select Read Data.
4. Choose the Setting page tab.
5. At the bottom LH corner of the Setting page,
choose the DPS tab.
NOTICE Ensure handlebar is free and cen- vmo2012-012-014_b
tered within ±10 degrees of center position. 1. OVERRIDE/DPS/ACS button

There MUST NOT be any effort applied to the
steering column. The active DPS mode will be displayed in the
lower portion of multifunction gauge.
6. Press Reset Torque Offset button.
4 vmr2017-114
– Flow chart C: Derating or Limited Assistance

– Flow chart D: Free Play Felt in Steering System
– Flow chart E: Steering Turn Easier on One Side
than the Other.
LCD gauge
1. DPS mode indication
ANALOG/DIGITAL GAUGE
1. DPS mode display
2. To change DPS ASSIST mode, press and hold

the OVERRIDE/DPS button for approximately 2
seconds to go to the next setting.
The DPS system will toggle to the following avail-
able mode. The newly activated DPS mode will
be briefly displayed in the multifunction gauge.
3. Repeat previous step to toggle through the
available mode.
NOTE: The DPS mode of operation cannot
be changed if the vehicle is in reverse. The
DPS/Override switch must be released between
each DPS mode selection.
TROUBLESHOOTING
TROUBLESHOOTING FLOW
CHARTS
Use the troubleshooting flow charts to diagnose a
problem. If a problem cannot be solved, contact
a service representative for support before replac-
ing a DPS.
Here is the list of provided flow charts:
– Flow chart A: No Assistance From DPS
– Flow chart B: DPS Intermittent Assistance
vmr2017-114 5
6
No Assistance from DPS
vbs2014-009-001_aen
Flow Chart A
• Install latest calibration file
(FC file).
YES Is it a replacement
NOTE: New DPS comes without DPS?
calibration. Therefore, B.U.D.S.
must be used to install one. • Check DPS fuses F-4 (7.5A) - Push
NO • on ‘‘OVERRRIDE/DPS’’ button to
• validate if DPS communicates with
• cluster.
• Check fuse F-3 (40A) - Check
••voltage at PWR connector
Is there voltage going • Check battery voltage (min. 12V)
to both wires of the DPS NO
• and ground connections.
NO (power and control • Check ground going to DPS.
connector)? • Check all connector pins.
NOTE: Refer to appropriate Shop

YES Manual for proper validation.
In B.U.D.S., clic on Module, • Check connection from ECM to DPS

DPS, Information and validate YES In B.U.D.S., click on Module (upper left in NO unit.
if the Calibration Checksum screen), and validate if the DPS tab • Check for proper B.U.D.S. version.
is VALID. is visible. • Power down unit, reboot B.U.D.S.
then repower up.
• Check if torque sensor values

• are varying in the B.U.D.S. Consult B.U.D.S. screen for re-occurring
• monitoring screen while turn- active or occured faults and perform
• ing the handlebars . required service action.
• Check if DPS motor is drawing
• amps in the B.U.D.S. monitoring
• screen (engine must be running). Still no assistance? DPS tab still
invisible?
If problem not solved:

contact the Service Department
and have the B.U.D.S. report
ready to be sent.
vmr2017-114
DPS
vmr2017-114
Intermittent
Assistance
vbs2014-009-002_aen
Flow Chart B
Tire pressure good? NO • Test again once pressure is

34 to 48 kPa (5 to 7 PSI) corrected.
YES
• Perform the required service Any active or

actions as per B.U.D.S. and/or YES
occured faults in B.U.D.S.
appropriate Shop Manual. screen?
NO
• Check battery voltage and ground connections.

• Check DPS fuses F-4 (7.5 Amp) & F-3 (40 Amp).
• Check power source and ground going to DPS.
• Check all connector pins.
• Check stator connector and charging system.
• Inspect all relevant wiring harnesses.
NOTE: Refer to appropriate Shop Manual for

proper validation.
If problem not solved,

contact the Service Department Possibly related to derating.
and have the B.U.D.S. report Refer to
ready to be sent. Flow Chart C.
7
8
Derating or Limited
Assistance
vbs2014-009-003_aen
Flow Chart C
Make sure that no DPS file

updates are proposed in
B.U.D.S.
Tire pressure good? NO • Test again once pressure is

34 to 48 kPa (5 to 7 PSI) corrected.
• Check battery voltage and ground

connections. If any doubt, install YES
a new fully charged battery.
• Verify charging system.
• Check stator connection. • Verify steering components
Is there a voltage for any interference or dam-
• Check all connections related to drop a the battery when NO
the DPS and charging system. YES aged parts.
the DPS is activated while • Insure nothing limits the mov-
• Consult B.U.D.S. screen for the engine is
active or occured faults and ement of steering components.
running?*
perform required service action.
• Inspect steering column, pitman arm,
NOTE: Refer to appropriate Shop bushings, tie-rod ends and ball joints
Manual for proper validation. for free normal movement (no
obstructions).
• Inspect front brake pads for sticking.
• Inspect drive shafts and Visco-Lok
functionnality.
If mechanical components are in good
condition, let the DPS unit cool down
before trying the vehicle again.
If problem not solved:
Contact service department if additional After the test, if the DPS unit works
information is required and have B.U.D.S. properly, the problem is caused by the
file saved and ready to be sent. activation of the integrated protection
system. This situation is probably due to
severe riding conditions, the activation
*Refer to appropriate shop manual for procedure. of the integrated protection system is
**Refer to derating explanation o n first page. normal.**
vmr2017-114
vmr2017-114
vbs2014-009-004_aen
Flow Chart D
Free Play Felt in

Steering System
• Verify if the pinch bolt at the Is there any Contact the service
YES backlash or play in NO department and have the
bottom of the steering column
is tight. the steering system? B.U.D.S. report ready to
be sent.
Bolt tight
• Verify that tie-rods, pitman arm,

ball joints, ,all steering All OK and problem
components and fasteners are still present
tight...........
• Ensure the upper steering
bushing is greased.
9
10
Steering Turns
Easier on One than
the Other Side
vbs2014-009-006_aen
Flow Chart E
• Check tire pressure and • Test again once pressure and
steering alignment. alignment are corrected.
• Connect to B.U.D.S. and go to

the DPS monitoring screen.
Is torque offset value

• Check for faults and perform
YES more than 3 N•m when the NO required actions.
• Re-set the torque sensor. handlebars are free, untouched • Ensure the latest calibration file
and are positioned straight is installed.
ahead?
Can’t reset the torque Re-occurring

sensor or a re-occurring NO faults or
torque sensor fault? symptoms?
YES YES
• Make sure nothing touches

the steering column. Contact the service
Any of the previous YES department and have the
• Verify steering column align- issues still
ment as per appropriate Shop B.U.D.S. report ready to
exist? be sent.
Manual.
vmr2017-114
PROCEDURES MULTIMETER PROBE POSITIONS VOLTAGE

DPS2 power
DPS UNIT connector pin A
Battery ground
DPS Unit Fuse Location DPS2 power
connector pin B
Battery
voltage
rmr2008-028-091_a
If NO voltage is measured, test the 40 A DPS fuse

in the rear fuse holder (F2). If good, check wires
and connector pins. Replace or repair defective
vmr2017-113-002_a
parts and reset fault codes.
1. DPS (F2) fuse
If battery voltage is measured, carry out the fol-
Testing the DPS Unit Input Voltage lowing TESTING THE DPS UNIT INPUT VOLTAGE
(Power Side) (CONTROL SIDE).
1. Disconnect the DPS PWR (power) connector. NOTE: This test may also be carried out by con-
necting a 12 Vdc test light between each DPS
PWR connector pins (A and B), and the battery (-)
negative terminal. The test light must come on
bright.
Testing the DPS Unit Input Voltage

(Control Side)
1. Disconnect DPS CTRL (control) connector.
vmr2010-003-013_d
TYPICAL
1. DPS PWR connector (motor power)
2. Test for 12 Vdc DPS motor power at DPS2-A

and DPS2-B as per following table.
vmr2010-003-013_b
TYPICAL
1. DPS CTRL (control) connector
2. Set the ignition switch to ON.

3. Set the engine RUN/STOP switch to RUN.
4. Test for 12 Vdc power to the DPS module at
DPS1-A as per following table.
vmr2017-114 11
MULTIMETER PROBE If there is NO continuity or a high resistance is

VOLTAGE measured, check wires and connector pins from
POSITIONS
DPS unit to chassis ground post. Replace or re-
DPS control connector (pin A)
pair defective parts and reset fault codes.
and battery ground
If there is good continuity, carry out the follow-
ing TESTING THE DPS UNIT COMMUNICATION
Battery voltage LINK (CAN) CONTINUITY.
NOTE: This test may also be carried out by con-
necting a 12 Vdc test light between each GDN
connector pin and the battery (+) positive termi-
nal. The test light must come on bright.
rmr2008-028-093_a
Testing the DPS Unit Communication
If NO voltage is measured, check wires and con- Link (CAN) Continuity
nector pins from DPS unit to the Relays/Speedo NOTE: DPS unit must receive an RPM signal to
fuse in front fuse box (PF1-F4). Replace or repair provide power steering assist.
defective parts and reset fault codes.
1. Disconnect the DPS control connector and the
If battery voltage is measured, carry out the fol- diagnostic connector.
lowing TESTING THE DPS UNIT GROUND CIR-
CUIT. 2. Test continuity of CAN Bus Wires at DPS1-C
and DPS1-D.
NOTE: This test may also be carried out by con-
necting a 12 Vdc test light between the DPS con- MULTIMETER PROBE RESISTANCE @
trol connector (pin A), and the battery (-) negative POSITIONS 20°C (68°F)
terminal. The test light must come on bright. DPS control connector (pin C)
and diagnostic connector (pin 1)
Testing the DPS Ground Circuit
1. Disconnect the DPS ground connector (GDN).
rmr2008-028-094_a
Below 1
DPS control connector (pin D)
and diagnostic connector (pin 2)
vmr2010-003-013_c
TYPICAL
1. DPS ground connector (GDN)
rmr2008-028-094_b
2. Test for continuity between DPS3-A and

DPS3-B to battery ground. If resistance measured is out of specification,
check wires and connector pins. Carry out re-
MULTIMETER PROBE pairs as required and reset fault codes using
READING
POSITIONS B.U.D.S software.
DPS GDN If resistance measured is good, replace the DPS
connector pin A Continuity unit and reset fault codes using B.U.D.S software.
Battery ground
DPS GDN (close to 0 )
connector pin B
12 vmr2017-114
Testing the DPS System Load

If the charging system cannot sustain normal volt-
age when the DPS is operating, DPS ASSIST may
be greatly reduced or nonexistent. Carry out the
following steps.
1. Measure the battery voltage.
NOTE: If battery voltage is low, recharge battery.
2. Ensure the vehicle transmission is set to PARK.
3. Start the engine.
4. Note the voltage on the multimeter with the en-
gine running (charging system voltage).
5. Press the RANGE button repeatedly to select
Manual Range 6 0.
mmr2009-023-027_e
1. MIN function selected
7. Turn the handlebar momentarily against the

steering frame stops to each side.
NOTE: Do not hold steering against frame stops
for an extended period of time.
8. Read the MIN charging system voltage
recorded while the handlebar was turned
against each stop.
DPS SYSTEM LOAD TEST
STEERING VOLTAGE
PROBE POSITIONS
POSITION READING
Battery (-) DPS fuse LH stop At least

terminal holder pin B RH stop 12 Vdc
mmr2009-023-027_a
VDC SELECTED TO MANUAL RANGE 6 0 NOTE: Turning the handlebar momentarily

6. Press the MIN MAX button on the multimeter against the frame stops generates maximum
to engage the MIN function. DPS load (maximum current draw on electrical
system). Electrical system must sustain at least
12 Vdc for proper DPS operation.
vmr2017-114 13
5. With the vehicle engine running in PARK, turn

the handlebar side to side, momentarily against
each stop and observe the indications on the
B.U.D.S. DPS Monitoring page.
The DPS Torque Sensor Nm increase with torque
applied to handlebar.
The DPS Current ammeter should increase pro-
portionately to the torque applied, and decrease
with the torque as steering assist is provided.
vmr2010-003-007
If the electrical system cannot sustain at least

12 Vdc, check the following:
– Battery
– Battery connections
– DPS unit power and ground connections
– Charging system vmr2010-003-009_a
TYPICAL - LH TURN
– Frame and engine ground studs. 1. Torque sensor indication (negative)
2. DPS current indication (positive)
If the previously listed items, carry out the follow-
ing TESTING THE DPS UNIT CURRENT.
Testing the DPS Unit Current

3. Choose the Monitoring page tab.
4. At the bottom of the Monitoring page, choose
the DPS tab.
vmr2010-003-010_a
TYPICAL - RH TURN
1. Torque sensor indication (positive)
2. DPS current indication (negative)
NOTE: Increase and decrease in torque and cur-

rent readings is very brief as steering assist is
quickly provided. Current draw should remain
within green scale but may momentarily peak to
60 amps, then drop off close to 0 amps as torque
applied is nulled out by steering assist. A residual
torque of 2 N•m (18 lbf•in) with a corresponding
current draw is acceptable.
vmr2010-003-008_a
If current draw tends to remain high, carry out the
Step 1: Press Data button following:
Step 2: Select Monitoring page tab – Steering alignment check.
Step 3: Select DPS tab
14 vmr2017-114
– Steering column shim adjustment at half bush- 6. Remove the steering column pinch bolt and re-
ings as described in the INSTALLING THE DPS taining nut. Discard the retaining nut.
UNIT procedure detailed in this section.
– RESETTING THE TORQUE OFFSET RESET pro-
cedure detailed in this section.
– Replace DPS unit.
Removing the DPS Unit

1. Remove the front body module, refer to BODY
subsection.
2. Remove both inner fender panels
3. Remove the CVT air inlet duct assembly, refer
to AIR INTAKE SYSTEM subsection.
4. Disconnect the 3 electrical connectors from the
DPS unit. vmr2010-003-017_a
TYPICAL
1. Steering column pinch bolt
7. Remove the hardware that secures both tie-rod

ends to the pitman arm (steering lever). Discard
cotter pins.
vmr2010-003-013_a
TYPICAL
1. DPS connectors (3x)
5. Cut the locking tie securing the bellows at the

bottom of steering column near the DPS unit,
and pull the bellows upwards sufficiently to ac- vmr2010-003-022_a
cess the steering column pinch bolt. TYPICAL

1. Pitman arm
2. Tie rod ends
8. Turn the steering to each side and disengage

each tie-rod end from the pitman arm.
vmr2010-003-016_a
TYPICAL
1. Cut this locking tie
2. Steering column bellows
vmr2017-114 15
vmr2012-039-014_a
DPS REMOVAL - RH SIDE

vmr2010-003-023
1. DPS
TYPICAL - TIE ROD ENDS (HARDWARE REMOVED) 2. RH DPS support bracket
3. Remove these screws (2)
9. Pull up on the steering column to partly disen-
gage it from the DPS unit. NOTE: Discard the conical spring washers on the
DPS retaining screws.
NOTE: A mechanical stop on the steering column
will prevent you from fully disengaging the steer- 12. On the LH side of the DPS unit, remove the
ing column. DPS support bracket from the frame in the fol-
lowing manner:
10. Remove the lower half bushing retainer that
secures the steering shaft to the frame. 12.1 Remove the top retaining screw.
12.2 Loosen the lower retaining screw suffi-
ciently for the bracket to become loose
on the frame.
vmr2012-039-013_a

2. Bolts to remove (2)
vmr2012-039-015_a
11. Remove the 2 hexagonal flanged screws se- DPS REMOVAL - LEFT SIDE
curing the DPS unit to the RH support bracket. Step 1: Remove DPS retaining screws (2 each side)
Step 2: Discard conical washers under screw head
13. Pull up on DPS unit to remove the DPS unit

and support bracket from the frame.
16 vmr2017-114
vmr2012-039-035_a
vmr2012-039-016_a 1. DPS heat shield

TYPICAL - LH DPS SUPPORT BRACKET 2. Retaining screws to hold steady (2 not visible)
1. DPS unit 3. Retaining nuts to remove
2. DPS support bracket
3. Vehicle frame Installing the DPS Unit
4. Slotted hole in DPS support bracket
IMPORTANT: The following hardware must all
14. If replacing DPS unit, remove the following be replaced with new ones:
from the DPS unit:
– Hexagonal forming screws with threadlocker
– LH DPS support bracket
– Conical spring washers
– DPS heat shield.
– Elastic nuts.
1. If the DPS unit is being replaced, install heat
shield from old DPS unit onto new DPS unit.
vmr2012-039-034_a
1. LH DPS support bracket

2. Retaining screws
vmr2012-039-035_a
NOTE: When removing the DPS heat shield, hold
1. DPS heat shield
the DPS housing screws steady using a wrench 2. Retaining screws to hold steady (2 not visible)
to as you remove the 2 heat shield retaining nuts. 3. Retaining nuts to remove (2)
NOTE: Important: Hold DPS housing screws

steady using a wrench as you apply specified
torque to heat shield retaining nuts.
TIGHTENING TORQUE
Retaining nuts, DPS 24.5 N•m ± 3.5 N•m
heat shield (18 lbf•ft ± 3 lbf•ft)
2. Install LH DPS support bracket loosely using

NEW fasteners.
vmr2017-114 17
NOTE: Important: Install the retaining screws to

the DPS support bracket loosely at this time. This
is required to ensure proper DPS alignment at a
later step when all steering and DPS fasteners are
tightened to specified torque.
vmr2012-039-018_a
A. XPS synthetic grease (P/N 293 550 010) here
5. Insert the steering column onto the DPS input

shaft
6. Position the LH DPS support bracket onto the
hexagonal forming screw that was left on the
vmr2012-039-034_a
frame DPS mount.
1. LH DPS support bracket
2. Retaining screws
3. Ensure "O" rings on steering shaft are in good

condition.
4. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
to:
– The inside of both steering shaft half bush-
ings
– The steering shaft and "O" rings.
vmr2012-039-019_a
1. Steering column onto the DPS input shaft here

2. LH DPS support bracket onto the hexagonal forming screw here
NOTE: The DPS shaft splines have a key which

must be aligned with the keyway in the steering
column.
vmr2012-039-017_a
A. XPS synthetic grease (P/N 293 550 010) here
18 vmr2017-114
vmr2010-003-031
vmr2010-003-023_a
TYPICAL - STEERING COLUMN INDEXED TO DPS SHAFT
SPLINES TYPICAL
1. Pitman arm
2. Tie rod ends inserted in pitman arm
7. Ensure the following are properly positioned 3. Hardened steel washer on tie rod end
on the lower steering shaft and lower steering
shaft mount. 9. Install the lower half bushing retainer loosely
– O-rings using NEW fasteners.
– Steering shaft half bushings.
vmr2012-039-021_a
vmr2012-039-020_a
2. Hexagonal forming screws installed loosely
1. Lower steering shaft mount
2. O-rings
3. Steering shaft half bushings 10. Install steering column pinch bolt and a NEW
elastic nut loosely.
8. Install the 3 remaining hexagonal forming
11. Tighten the steering and DPS fasteners to
screws that secure the DPS unit loosely using
specified torque using the torque sequence
NEW fasteners.
specified in the following 3 illustrations.
NOTE: Ensure the support bracket retaining
screws have a NEW conical spring washer be- TIGHTENING TORQUE
tween the screw head and the DPS frame sup- DPS retaining screws
port.
DPS bracket retaining
Ensure both tie rod ends have a hardened steel screws 24.5 N•m ± 3.5 N•m
washer on them, then insert the tie-rod ends onto (18 lbf•ft ± 3 lbf•ft)
the pitman arm. Steering column retainer
Steering column pinch bolt
vmr2017-114 19
4 5
1 11
6 7
13
8
9
2 3 vmr2012-039-102_a
DPS AND STEERING TORQUE SEQUENCE (3 OF 3)
12. Install the second hardened steel washer and

vmr2012-039-100_a nut on each tie-rod end. Tighten retaining nuts
DPS AND STEERING TORQUE SEQUENCE (1 OF 3) as specified.
TIGHTENING TORQUE
72.5 N•m ± 7.5 N•m
Tie-rod end to pitman arm
13. Install NEW cotter pins on the tie-rod ends.
10
12
vmr2012-039-101_a vmr2010-003-022_b
DPS AND STEERING TORQUE SEQUENCE (2 OF 3) TYPICAL

1. Hardened steel washers (one each side of pitman arm)
2. Tie rod end retaining nut (torque applied)
3. NEW cotter pin installed
14. Pull bellows down over steering column pinch

bolt and edge of DPS unit housing extension.
Secure bellows using the appropriate locking
tie.
20 vmr2017-114
NOTE: Ensure the locking tie is on the tube part of

the steering column, not on the forged end. Bel-
lows should cover end of ring flange on DPS unit
but not cover the drainage hole at the bottom of
the ring flange. Do not install a locking tie on the
DPS end of the bellows. Lower portion of bellows
MUST remain floating over the DPS housing.
vmr2010-003-039_a
TYPICAL - LH ILLUSTRATED
1. Pitman arm
2. Contact point with frame stop
NOTE: Contact between pitman arm and pitman

arm stops must be checked with vehicle weight
on wheels.
vmr2010-003-016_a
TYPICAL
16. Reconnect DPS electrical connectors.
1. Locking tie location 17. Perform a steering alignment as described in
2. Steering column bellows
the applicable STEERING SYSTEM subsec-
tion.
18. If installing a replacement DPS unit, refer to
UPDATING THE ELECTRONIC MODULE in
this subsection.
19. Perform the torque offset reset. Refer to RE-
SETTING THE TORQUE OFFSET in this sub-
section.
20. Install all other removed parts in the reverse
order of removal.
21. Carry out a test ride of the ATV to ensure
proper operation of the DPS unit.
Updating the Electronic Module

vmr2010-003-033_a
New DPS units do not come with the required
TYPICAL
software programmed into the unit. A DPS unit
1. Drainage hole in DPS ring flange fault will be generated when the vehicle is pow-
2. Steering column bellows ered up. The check engine light will come on and
15. Turn handlebar fully to each side and check for a DPS FAULT message will appear in the multi-
proper contact between pitman arm and pit- function gauge.
man arm frame stops (both sides). To update the software, proceed as follows:
1. Connect the ATV to the latest applicable
2. Select the Read Data button.
3. In the Module menu, choose the DPS sub-
menu and install the latest DPS software
Update file as applicable to the type ATV (Out-
lander or Renegade).
vmr2017-114 21
REQUIRED TOOLS
PITMAN ARM JIG

(P/N 529 036 225)
4. Insert the DPS input shaft in the Pitman arm jig

receptacle with the Pitman arm facing up.
vmr2010-003-040
DPS SOFTWARE UPDATE
4. Once the correct DPS software file is installed,

go to the Faults page and clear the fault codes.
5. Carry out the RESETTING THE TORQUE OFF-
SET procedure as described in this subsection.
6. Test drive the ATV to ensure proper DPS oper-
ation.
PITMAN ARM
Removing the Pitman Arm
1. Remove DPS unit from vehicle, refer to RE- vmr2012-039-025_a
MOVING THE DPS in this subsection. 1. DPS input shaft

2. Shaft receptacle in Pitman arm jig
2. Remove Pitman arm retaining nut and washer.
vmr2012-039-022_a
vmr2012-039-023_a
1. DPS 1. Pitman arm jig in vice
2. Pitman arm 2. Pitman arm up
3. Pitman arm nut and washer 3. DPS input shaft inserted in jig
3. Install the pitman arm jig in a vise with the po- 5. Insert the positioning adapter in the Pitman arm
sitioning screw upward. so its point rests in the DPS output shaft.
NOTE: A countersunk hole is machined in tip of
the DPS output shaft to accept and center the po-
sitioning adapter point.
22 vmr2017-114
REQUIRED TOOL
POSITIONING
ADAPTOR
(P/N 529 036 230)
vmr2012-039-026_b
1. Extractor nut
2. No space here
8. Install the universal Pitman arm puller over the

Pitman arm and the extractor thrust bearing.
REQUIRED TOOL
vmr2012-039-024_a
1. Pitman arm
2. Positioning adapter PITMAN ARM PULLER
(P/N 529 036 227)
6. Turn the jig positioning screw until the screw tip
rests snugly in the positioning adapter.
vmr2012-039-026_a
1. Jig screw tip vmr2012-039-028_a

2. Positioning adapter
1. Extractor thrust bearing
2. Pitman arm puller
7. Turn the extractor nut down until their is no 3. Pitman arm
space between the extractor and the position-
ing tip. 9. Lock the positioning screw by screwing the
lock nut tightly against jig upper bar.
NOTE: Be sure to hold the position screw steady
to prevent its tip from backing off the positioning
adapter.
vmr2017-114 23
REQUIRED TOOL
PITMAN ARM JIG

(P/N 529 036 225)
2. Apply antiseize lubricant on DPS output shaft

splines; completely cover all the splines with a
light coat.
SERVICE PRODUCT
LOCTITE 767 (ANTISEIZE
vbs2011-015-008_a DPS output shaft
LUBRICANT) (P/N 293
1. Jig upper bar splines
2. Positioning screw
800 070)
3. Lock nut
3. Place Pitman arm on DPS shaft as per following
10. As you hold the positioning screw steady, turn illustration.
the extractor nut up to pull the Pitman arm off
NOTE: Be sure to correctly align the Pitman arm
the DPS output shaft.
shaft key with the keyway (ground off splines) on
the DPS output shaft.
4. Insert the DPS input shaft in the Pitman arm jig
receptacle with the Pitman arm facing up.
vmr2012-039-029_a
1. Positioning screw (held steady)

2. Extractor nut (turned up )
vmr2012-039-025_a
11. Remove Pitman arm puller. 1. DPS input shaft
2. Shaft receptacle in Pitman arm jig
12. Unscrew positioning screw.
13. Remove Pitman arm from the DPS shaft.
Installing the Pitman Arm

1. Install Pitman arm jig in a vise with positioning
screw upward.
24 vmr2017-114
vmr2012-039-032_a
vmr2012-039-030_a
1. Spline keyway alignment here
5. Turn the jig positioning screw until the align-

ment point makes proper contact with the Pit-
man arm.
NOTE: Ensure positioning screw is centered in
Pitman arm tube.
vmr2012-039-033_a
1. Ensure proper contact here
7. Unscrew positioning screw and remove pusher

adapter and pull out DPS unit.
8. Install Pitman arm retaining washer and nut.
Tighten nut as specified.
vmr2012-039-031_a
1. Ensure proper contact here
6. Turn the positioning screw to push the Pitman

arm on the DPS output shaft until it bottoms out
on the DPS output shaft nut.
NOTE: Ensure specified torque is applied.
TIGHTENING TORQUE
Positioning screw torque 50 N•m (37 lbf•ft)
vmr2012-039-022_a
1. DPS
2. Pitman arm
3. Pitman arm nut and washer
TIGHTENING TORQUE
72.5 N•m ± 7.5 N•m
Pitman arm retaining nut
vmr2017-114 25
9. Carry out a steering alignment as described in

this subsection.
26 vmr2017-114
Subsection XX (FRONT SUSPENSION)
FRONT SUSPENSION
SERVICE TOOLS
BALL JOINT REMOVAL TOOL...................................................... 529 036 310 ........................................... 9
vmr2017-115 1
UPPER SUSPENSION ARMS AND COMPONENTS (OUTLANDER 450 /

570)
NEW
NEW
65 ± 5 N•m
NEW (48 ± 4 lbf•ft)
Suspension
3.0 ± 0.5 N•m Grease
(27 ± 4 lbf•in) 90° from arm axis
Suspension
Grease
3.0 ± 0.5 N•m

(27 ± 4 lbf•in)
65 ± 5 N•m
NEW
45 ± 5 N•m
(33 ± 4 lbf•ft)

vmr2017-115-102_a
2 vmr2017-115
UPPER SUSPENSION ARMS AND COMPONENTS (OUTLANDER 650 /

850 / 1000R AND RENEGADE)
65 ± 5 N•m
(48 ± 4 lbf•ft)
3.0 ± 0.5 N•m
Suspension (27 ± 4 lbf•in)
Grease
90° from arm axis
NEW
NEW
NEW
3.0 ± 0.5 N•m

(27 ± 4 lbf•in)
NEW
65 ± 5 N•m
(48 ± 4 lbf•ft)
Suspension
Grease
NEW
NEW 45 ± 5 N•m
(33 ± 4 lbf•ft)

vmr2017-115-101_a
vmr2017-115 3
LOWER SUSPENSION ARMS AND COMPONENTS (ALL MODELS)
NEW
NEW
4.5 ± 0.5 N•m
(40 ± 4 lbf•in)
NEW
3.0 ± 0.5 N•m

(27 ± 4 lbf•in)
Suspension
Grease
NEW
3.0 ± 0.5 N•m 65 ± 5 N•m

(27 ± 4 lbf•in) (48 ± 4 lbf•ft)
65 ± 5 N•m
(48 ± 4 lbf•ft) Suspension
Grease
90° from arm axis

vmr2017-115-103_a
4 vmr2017-115
GENERAL ACTION RESULT

The procedure explained below is the same for Increasing compression Firmer compression
the RH and LH sides unless otherwise noted. damping force damping
Decreasing compression Softer compression
ADJUSTMENT damping force damping
SHOCK DAMPING WARNING

ADJUSTMENTS (APPLICABLE Make sure compression damping setting is
MODELS) the same on both sides.
Compression damping controls how the shock ab- PROCEDURES

sorber reacts when riding.
POSITION SETTING
RESULT ON BIG SHOCK ABSORBER
BUMPS
Removing the Shock Absorber
Softer compression
1 Soft 1. Safely lift and support the vehicle off the
damping
ground.
Medium
Medium 2. Remove screws and nuts retaining the shock
2 compression
(Factory) absorber.
damping
Firmer
3 Hard compression
damping
219001682-007_a
1. Position 1
2. Position 2
3. Position 3
vmr2015-056-001_a
3. Remove shock absorber.
Inspecting the Shock Absorber

Remove spring from shock absorber. Refer to
SPRINGS in this subsection.
Secure the end of shock eyelet in a vise with its
rod upward.
219001727-010_a
COMPRESSION DAMPING
1. Increases damping (stiffer)
2. Decreases damping (softer)
Turn adjuster clockwise to increase shock damp-

ing action (stiffer).
Turn adjuster counterclockwise to decrease
shock damping action (softer). vsi2015-143-003_a
TYPICAL
vmr2017-115 5
NOTICE Do not clamp directly on shock

body.
Extend and compress the piston several times
over its entire stroke. Check that it moves
smoothly and with uniform resistance with its
rod upward.
Check the following conditions that will denote a
defective shock:
– A skip or a hang back when reversing stroke at
mid travel.
– Seizing or binding condition except at extreme
end of either stroke.
– Oil leakage. vmr2015-056-002_a
– A gurgling noise, after completing one full com-

pression and extension stroke. 4. Remove screws and nuts securing suspension
arm to frame.
Replace if any faults are present.
Installing the Shock Absorber

Install shock absorber screws from front towards
rear of vehicle.
Tighten shock absorber nuts to specification.
TIGHTENING TORQUE
Shock absorber nut 61 N•m ± 9 N•m
(450 / 570) (45 lbf•ft ± 7 lbf•ft)
Shock absorber nut (650 73 N•m ± 7 N•m
/ 850 / 1000R) (54 lbf•ft ± 5 lbf•ft)
vmr2012-040-003_a
1. Suspension arm screws

SHOCK ABSORBER BUSHINGS
5. Remove suspension arm.
Refer to SHOCK ABSORBER BUSHINGS in
REAR SUSPENSION subsection for complete
procedures.
SPRINGS
Refer to SPRINGS in REAR SUSPENSION subsec-
tion for complete procedures.
LOWER SUSPENSION ARM

Removing the Lower Suspension Arm
1. Safely lift and support the vehicle off the
ground.
2. Remove wheel, refer to WHEELS AND TIRES vmr2012-040-004_a
MOVE OUTWARDS
subsection.
3. Remove screw and nut securing lower ball joint
to knuckle.
6 vmr2017-115
Installing Lower Suspension Arm

Lubricate suspension arm. Refer to PERIODIC
Tighten ball joint nut to specification.
TIGHTENING TORQUE
Nut securing ball joint 45 N•m ± 5 N•m
to knuckle (33 lbf•ft ± 4 lbf•ft)
Perform steering alignment procedure. Refer to

STEERING ALIGNMENT subsection.
vmr2015-056-004_a
UPPER SUSPENSION ARM

5. Remove ball joint nut and washer.
Removing the Upper Suspension Arm
ground.
2. Remove wheel, refer to WHEELS AND TIRES
subsection.
3. Remove fasteners retaining brake hose to vehi-
cle.
vmr2015-056-005_a
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.
vmr2015-056-003_a NOTICE Never hit on suspension arm to
avoid damaging it permanently.
4. Remove and discard cotter pin retaining ball
joint.
vmr2017-115 7
Installing the Upper Suspension Arm

Install a NEW cotter pin to secure ball joint nut.
Both end of cotter pin must be folded.
Tighten shock absorber nut to specification.
TIGHTENING TORQUE
Shock absorber nut 61 N•m ± 9 N•m
(450 / 570) (45 lbf•ft ± 7 lbf•ft)
tmr2011-035-020
TYPICAL - CAREFULLY HIT ON KNUCKLE SIDE

Shock absorber nut (650 73 N•m ± 7 N•m
/ 850 / 1000R) (54 lbf•ft ± 5 lbf•ft)
8. Remove screw and nut securing suspension
arm to shock absorber. Tighten ball joint nut to specification.
TIGHTENING TORQUE
45 N•m ± 5 N•m
Ball joint nut
Perform steering alignment procedure. Refer to

STEERING ALIGNMENT subsection.
SUSPENSION ARM BUSHINGS

Removing the Suspension Arm
Bushings
1. Remove wear plates, bushings and sleeves
from suspension arm.
vmr2015-056-006_a
TYPICAL
9. Remove screws and nuts securing suspension

arm to frame.
vmr2015-056-009_a
LOWER SUSPENSION ARM

1. Wear plates
2. Bushings
3. Sleeves
vmr2015-056-007_a
TYPICAL
10. Remove suspension arm.
8 vmr2017-115
vmr2015-056-011
UPPER BALL JOINT

vmr2015-056-008_a
3. Install suspension arm on a press.
TYPICAL - UPPER SUSPENSION ARM
1. Wear plates
2. Bushings NOTICE Pressing on the center or on the lip
3. Sleeves of the ball joint will damage it.
Installing Suspension Arm Bushings
BALL JOINTS
Removing the Ball Joint
1. Remove suspension arm from vehicle. Refer to
REMOVING SUSPENSION ARM in this subsec-
tion.
2. Remove circlip from ball joint. vmr2015-056-012_a
DO NOT PRESS THERE
NOTE: The BALL JOINT REMOVAL TOOL (P/N 529

036 310) is design to apply force only on the out-
side edge of the ball joint.
vmr2015-056-010
LOWER BALL JOINT
529036310
vmr2017-115 9
vmr2015-056-013
vmr2015-056-014_a
CONTACT BETWEEN TOOL AND BALL JOINT ON THE OUTSIDE

EDGE ONLY
4. Remove ball joint from suspension arm.

NOTICE Make sure that suspension arm is
properly supported on the press during ball
joint removal.
Installing Ball Joint

Install a NEW circlip to secure ball joint.
10 vmr2017-115
Subsection XX (REAR SUSPENSION)
REAR SUSPENSION (OUTLANDER 570 /

650 / 850 / 1000R AND RENEGADE)
SERVICE TOOLS
SPRING COMPRESSOR ............................................................... 529 036 184 ........................................... 4
SERVICE PRODUCTS
SUSPENSION GREASE ................................................................. 293 550 033 ........................................... 8
53 ± 3 N•m
(39 ± 2 lbf•ft)
NEW
Suspension
grease
NEW NEW
Suspension
grease
NEW
255 ± 10 N•m 3.0 ± 0.5 N•m
(188 ± 7 lbf•ft) (27 ± 4 lbf•in)
Suspension
grease
Loctite 271
3.0 ± 0.5 N•m

Suspension
grease
vmr2017-117-101_a
vmr2017-117 1
GENERAL
The procedure described below is the same for
the RH and LH sides, unless otherwise instructed.
ADJUSTMENT
SHOCK DAMPING
ADJUSTMENTS (APPLICABLE
MODELS)
Compression damping controls how the shock ab-
sorber reacts when riding.
219001727-010_a
RESULT ON BIG COMPRESSION DAMPING
POSITION SETTING
BUMPS 1. Increases damping (stiffer)
Softer compression
1 Soft Turn adjuster clockwise to increase shock damp-
damping
ing action (stiffer).
Medium
Medium Turn adjuster counterclockwise to decrease
2 compression
(Factory) shock damping action (softer).
damping
Firmer ACTION RESULT
3 Hard compression
damping Increasing compression Firmer compression
damping force damping
Decreasing compression Softer compression
damping force damping
WARNING
Make sure compression damping setting is
the same on both sides.
PROCEDURES
SHOCK ABSORBERS
219001682-007_a
NOTE: For specific information on air shock ab-
1. Position 1
2. Position 2 sorber, refer to the AIR CONTROLLED SUSPEN-
3. Position 3 SION (ACS) subsection.
Removing the Shock Absorber
ground.
2. Remove shock absorber retaining bolts.
2 vmr2017-117
Tighten shock absorber nuts to specification.

TIGHTENING TORQUE
53 N•m ± 3 N•m
Shock absorber nuts
SHOCK ABSORBER BUSHINGS

NOTE: For specific information on air shocks, re-
fer to the AIR CONTROLLED SUSPENSION (ACS)
subsection.
Replacing the Shock Absorber Bushing

vmr2017-117-001 All Shock Absorbers Except HPG
1. Remove shock absorber from vehicle. Refer to
3. Remove shock absorber.
SHOCK ABSORBERS in this subsection.
Inspecting the Shock Absorber 2. Install shock absorber on a press.
Remove spring from shock absorber. Refer to 3. Use an appropriate socket to push bushing.
SPRINGS in this subsection.
Secure the end of shock body in a vise with its rod
upward.
A14F0BA
TYPICAL
1. Clamp here
NOTICE Do not clamp directly on shock tmr2011-036-021
body. TYPICAL
Extend and compress the piston several times 4. Remove bushing from shock absorber.
over its entire stroke. Check that it moves
rod upward.
Check the following conditions that will denote a
defective shock:
mid travel
end of either stroke
– Oil leakage
pression and extension stroke.
tmr2011-036-020
Replace if any faults are present. TYPICAL
Installing the Shock Absorber 5. Install a NEW bushing as the reverse of re-
moval.
cedure. However, pay attention to the following. 6. Install shock absorber on vehicle.
vmr2017-117 3
HPG Shock Absorber (without Remote Shock Absorber with a Cam Preload Adjuster
Reservoir) Remove spring cap and stopper.
1. Remove shock absorber from vehicle. Refer to
SHOCK ABSORBERS in this subsection.
2. Install shock absorber on a press.
3. Use an appropriate socket to push inner bush-
ing.
4. Remove outer bushings.
vmr2017-117-002_a
TOP - TYPICAL CAM PRELOAD ADJUSTER TYPE

1. Spring cap
2. Spring stopper
Shock Absorber with a Threaded

Preload Adjuster
Remove spring stopper.
vmr2012-041-020_a
TYPICAL
1. Inner bushing
2. Outer bushing
5. Install NEW bushings as the reverse of re-

moval.
6. Install shock absorber on vehicle.
SPRINGS
Removing the Spring
vmr2017-117-003_a
1. Remove shock absorber from vehicle. Refer to BOTTOM - TYPICAL THREADED RING PRELOAD ADJUSTER
SHOCK ABSORBERS in this subsection. TYPE
1. Spring stopper
2. Use SPRING COMPRESSOR (P/N 529 036 184).
7. Release spring remover screw.
8. Remove spring from shock absorber.
Inspecting the Spring

Inspect the spring for damage.
529036184
Installing the Spring

3. Place the tool in a vise.
4. Position the shock absorber in the tool. cedure. However, pay attention to the following.
5. Install the spring compressor pins.
Shock Absorber with a Cam Preload Adjuster
6. Tighten spring remover screw until the spring is
sufficiently compressed to remove spring stop- Install the spring stopper and cap underneath the
per (and cap if applicable). built-in washer.
4 vmr2017-117
STABILIZER BAR
Removing the Stabilizer Bar
ground.
2. Remove rear wheels, refer to WHEELS AND
TIRES subsection.
3. Refer to EXHAUST SYSTEM and remove:
– Muffler
– Y-Exhaust pipe.
4. Detach stabilizer bar from link arm (both sides).
vmr2017-117-004_a
TOP - TYPICAL CAM PRELOAD ADJUSTER TYPE

1. Built-in washer
2. Spring cap
3. Spring stopper
Orient the openings 180° apart.
vmr2012-041-004_a

1. Bolt securing stabilizer bar
5. Remove bolts and nuts securing stabilizer bar

to frame (both sides).
vmr2017-117-004_b
TOP - TYPICAL CAM PRELOAD ADJUSTER TYPE (OPENINGS

180° APART)
Shock Absorber with a Threaded

Preload Adjuster
Install the spring stopper underneath the built-in
washer.
vmr2012-041-005_a

1. Bolts securing stabilizer bar
6. Remove stabilizer bar bushing holders (both

sides).
vmr2017-117-003_b
BOTTOM - TYPICAL THREADED RING PRELOAD ADJUSTER

TYPE
1. Built-in washer
2. Spring stopper
vmr2017-117 5
TIGHTENING TORQUE
Bolts securing stabilizer 24.5 N•m ± 3.5 N•m
bar to frame (18 lbf•ft ± 3 lbf•ft)
Bolts securing stabilizer 48 N•m ± 6 N•m
bar to link arm (35 lbf•ft ± 4 lbf•ft)
Lubricate stabilizer bar. Refer to PERIODIC MAIN-

TRAILING ARM
Removing the Trailing Arm
vmr2012-041-006_a
ground.
1. Stabilizer bar bushing holder
2. Remove wheel hub, refer to REAR DRIVE sub-
7. Remove stabilizer bar. section.
3. Remove protective plate from trailing arm.
Inspecting the Stabilizer Bar
Check stabilizer bar for cracks, bending or other
damages.
Installing the Stabilizer Bar

Install all stabilizer bar retaining bolts loosely.
Position link arm bolts with their heads towards
the inside.
vmr2015-057-005
TYPICAL
4. Detach the brake hose P clamp from the trailing

arm.
5. Remove the nut and washer securing the trail-
ing arm pivot shaft.
vmr2015-057-006
TYPICAL
Tighten stabilizer bar retaining bolts to specifica-

tion.
vmr2017-117-005
6. Remove the stabilizer bar link arm lower bolt.
6 vmr2017-117
Disassembling the Trailing Arm

Removing Drive Shaft Bearing
1. Remove circlip securing bearing into trailing
arm.
vmr2017-117-006
7. Remove the shock absorber lower retaining

bolt.
vmr2015-057-012
2. Install trailing arm on a press.

3. Use an appropriate bearing remover.
4. Remove drive shaft bearing from trailing arm.
Removing the Link Arm Inner Bushing
Remove both bushings and the sleeve from the
trailing arm.
vmr2017-117-007
8. Firmly hold trailing arm, then:

– Remove shock absorber lower bolt
– Pull trailing arm pivot shaft from the opposite
side to free the trailing arm.
NOTE: If only one trailing arm is removed, pull
pivot shaft just enough to free the trailing arm.
vmr2017-117-009_a
1. Bushings
2. Sleeve
Removing the Trailing Arm Pivot Bearing

1. Remove both spacers and seals from trailing
arm pivot.
vmr2017-117-008_a
9. Remove trailing arm from the vehicle.
vmr2017-117 7
Use an appropriate shaft to center trailing arm in-

ner spacer during pivot bearings installation.
Install pivot bearings and inner spacer as per the
following sequence.
vmr2017-117-010_a
1. Spacers
2. Seals
vmr2017-117-012_a
2. Use an appropriate bearing remover.
LH SHOWN
3. Remove pivot bearings by pulling them out- Step 1: Insert inner bearing on RH side
Step 2: Insert outer bearing on RH side
wards. Step 3: Center inner sleeve with RH side bearings using a shaft
Step 4: Insert inner bearing on LH side
NOTE: Remove one bearing at a time. Step 5: Insert outer bearing on LH side
4. Remove inner sleeve from trailing arm.
Lubricate trailing arm pivot seals.
LUBRICATION
SUSPENSION GREASE
Pivot seals
(P/N 293 550 033)
Install the trailing arm pivot seal with its cavity fac-
ing inwards.
vmr2017-117-011_a
1. Bearings
2. Inner sleeve
Inspecting the Trailing Arm

Check trailing arms for:
– Cracks
– Bending.
Check seals condition.
Check inner race of each pivot bearing with your vmr2015-057-017_a
finger: 1. Seal cavity
– Bearings should turn smoothly and quietly. 2. Trailing arm
Replace all damaged parts. Center trailing arm pivot shaft.

Assembling and Installing the Trailing Install the spacers.
Arm Tighten trailing arm pivot nuts as per the following
sequence.
Install the following NEW parts:
– Trailing arm pivot nuts
– Pivot bearings
– Pivot seals
– Circlip.
8 vmr2017-117
TIGHTENING SEQUENCE
Tighten nut until
RH side nut it reaches end of
Trailing arm threads
pivot nuts
255 N•m ± 10 N•m
LH side nut
Position link arm bolts with their heads towards

the inside.
vmr2015-057-006
TYPICAL
Tighten trailing arm fasteners to specification.

TIGHTENING TORQUE
Bolts securing trailing 48 N•m ± 6 N•m
arm to link arm (35 lbf•ft ± 4 lbf•ft)
53 N•m ± 3 N•m
Shock absorber nuts
Protective plate retaining 10 N•m ± 2 N•m
nuts (89 lbf•in ± 18 lbf•in)
vmr2017-117 9
Subsection 06 (AIR CONTROLLED SUSPENSION (ACS))
AIR CONTROLLED SUSPENSION (ACS)

SERVICE TOOLS
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................... 8, 11–14, 17–18
OETIKER PLIERS........................................................................... 295 000 070 ........................................... 19
SPRING COMPRESSOR ............................................................... 529 036 184 ........................................... 20
SERVICE PRODUCTS
LOCTITE 592 (PIPE SEALANT) ..................................................... 293 800 018 ...........................9, 11, 16, 21
vmr2016-144 1
NEW
NEW
To Pressure
Transducer NEW
NEW
NEW
NEW
NEW
NEW
NEW
Loctite 592
(pipe sealant)
To ACS Compressor
vmr2016-144-003_a
2 vmr2016-144
GENERAL Changing ACS Setting

Be careful while manipulating nylon hoses, they To change the ACS setting proceed as follows:
must not be kinked. Press MODE (M) button to display AIR_SUSP.
CAUTION The ACS suspension system

may be under high pressure (up to 6 bar
(85 PSI)). Release air pressure prior to work-
ing on the system. Refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING.
1
SYSTEM DESCRIPTION
2
(FEATURES)
The ACS suspension automatically keeps air pres-
sure constant with changing rider weights or loads
applied. The system can be adjusted on the fly to tmo2013-003-001_b
1. AIR_SUSP displayed
suit rider's preferences. 2. Actual setting
The multifunction gauge indicates suspension set-
ting as follows. Press and release ACS button until the requested
setting is displayed.
tmo2013-003-001_b
2. Actual setting
Refer to the following table to know the ACS pres-

sure related to multifunction gauge setting. vmo2012-012-014_b
TYPICAL
ACS SUSPENSION SETTINGS 1. ACS button
RIDING RECOMMENDED
SETTING PRESSURE The requested setting is controlled by the ACS
COMFORT LOAD
electronic module. The module is equipped with
0.35 bar a pressure transducer to keep air pressure con-
ACS 1 Softest
(5 PSI) stant in the system. Depending on the rider ad-
Operator only
1.4 bar justment, the module will increase pressure using
ACS 2 Soft the compressor or release pressure using the so-
(20 PSI)
lenoid release valve.
ACS 3 2 bar (30 PSI) Semi-soft Transporting a
2.75 bar passenger OR ACS Setting Acknowledgement
ACS 4 Semi-firm a cargo
(40 PSI) If ACS suspension was set to ACS 5 or ACS 6 be-
4.5 bar Transporting a
fore shutting down the vehicle, the multifunction
ACS 5 Firm gauge will scroll an acknowledgement message
(65 PSI) passenger AND
a cargo at startup.
ACS 6 6 bar (85 PSI) Firmest
To acknowledge the ACS suspension setting,
press and release ACS button while message
appears.
vmr2016-144 3
NOTE: If the message is not acknowledged, the zones using check valves. With this layout, both
suspension will automatically return to setting pressure zones are independent to eliminate any
ACS 3. air pressure variation.
NOTE: If the MODE (M) button in the multi- NOTE: The auxiliary line output pressure will vary
function gauge is pressed while the acknowl- according to the ACS suspension setting. The
edgement message appears, the suspension will ACS 1 adjustment will provide less pressure than
directly return to setting ACS 3. the ACS 6 adjustment.
NOTE: If the vehicle transmission is set to RE- NOTICE Never inflate tires above the recom-
VERSE position at startup, the override message mended pressure.
will be displayed instead of acknowledgement
message. ACS SYSTEM
PRESSURE
Using the Auxiliary Line to Inflate Tires ZONE
LINK
TRANSDUCER
The ACS system is equipped with an auxiliary line WITH
LOCATION
specially designed to inflate tires. The air pressure
High-pressure Shock
in this auxiliary line is controlled by a second pres- zone absorbers
Inside ACS module
sure transducer connected to the ACS module.
In line between
Low-pressure Auxiliary
solenoid release valve
zone line
and compressor
Releasing Air Pressure in System for

Servicing
Put ACS setting to 1 before servicing ACS system.
Refer to CHANGING ACS SETTING subsection.
SYSTEM DESCRIPTION
(COMPONENTS)
Fuse and Relay
1. ACS fuse (F12) is located in the front fuse box.
vmo2013-007-018_a 2. ACS compressor relay (R15) is located above
1. Auxiliary line adaptor to inflate tire the ACS module.
To ensure that the use of the auxiliary line will
not change the pressure setting inside shock
absorber, the system has been divided in two
ACS Main Components

ACS COMPONENTS MAIN FUNCTION
Filter (air intake) To filter air intake of the compressor
Compressor To pressurize the system
Solenoid release valve To release air from the system
Electronic module To control the compressor or the solenoid release valve
To split the air hoses and allows to manually release air in the
Manifold
system
Pressure transducer (Low-pressure zone) To monitor the air pressure of the auxiliary line
Pressure transducer (High-pressure zone) To monitor the air pressure of the shock absorbers
Check valve (compressor) To protect the compressor
4 vmr2016-144
ACS COMPONENTS MAIN FUNCTION

To eliminate air pressure variation between low and high
Check valve (between both zones)
pressure zone
Auxiliary line To inflate tire
Cluster To monitor the air pressure setting
Low pressure High pressure

Pneumatic zone zone
Electric
Auxiliary
output
Release
valve
Check-valve Check-valve Shock 1
Filter Compressor Manifold
Pressure Shock 2
transducer
Pressure
transducer
Electronic
Cluster module
vdd2010-001-601_en
vmr2016-144 5
TROUBLESHOOTING Suspension Setting Can Not Be

Changed/Level Blinking in the Gauge
DIAGNOSTIC TIPS 1. Check the override/ACS button as detailed in
OVERRIDE SWITCH in the LIGHTS GAUGE
Error Code (AIR FAULT) Displayed in AND ACCESSORIES subsection.
Gauge
2. Check fuse (F12).
The error code AIR FAULT can appear on the mul-
tifunction gauge for different reasons that are not 3. Check ACS module signal continuity.
necessarily related to a failure of the ACS system. 4. Check ACS module input voltage.
If the error code appears on the multifunction 5. Check ACS module ground.
gauge, it indicates a disparity between the re- Refer to ACS MODULE to see the complete test-
quested and the actual suspension settings. ing procedures.
There might be an obstruction on the release
valve, or the release valve itself may be defec- Suspension Setting Can Be Reached to
tive. Decrease Pressure Only
Error Code Displayed and Suspension Setting 1. Check fuse (F3) and relay (R15).
Can Not Be Adjusted
2. Check ACS compressor operation.
If there is no leak, it is probably an electrical prob-
3. Check ACS compressor input voltage.
lem. In this case, an electrical failure of the com-
pressor or the solenoid valve will result the impos- Refer to ACS COMPRESSOR to see the complete
sibility to change the actual suspension setting. testing procedures.
After multiple attempts to change suspension Suspension Setting Can Be Reached
setting, the module will activate error code AIR
FAULT. Refer to TROUBLESHOOTING GUIDE-
To Increase Pressure Only
LINES for further troubleshooting procedure. 1. Check for unplug or kinked hoses.
ACS Level Blinking in the Gauge 2. Check ACS compressor connection.
The ACS level will blink in the gauge until the re- 3. Check ACS solenoid valve operation.
quested position is reached. If it blink for a long 4. Check ACS solenoid valve input voltage.
period during a request to inflate the suspension, Refer to ACS SOLENOID VALVE to see the com-
it may indicates a major leak in the system. plete testing procedures.
In this case, the module will automatically shut
down the compressor to prevent it from overheat- No Pressure Output from the Auxiliary
ing. Line
The shut down procedure will stay active until the 1. Ensure that ACS suspension setting is adjusted
next restart of the vehicle (Key OFF/key ON). to ACS 6 to provide the maximum air pressure
If there is a major leak in the system, refer to in the auxiliary line.
ACS SYSTEM LEAK TEST in TROUBLESHOOT- 2. Check pressure transducer for air leakage.
ING WITH B.U.D.S. further in this subsection. 3. Check signal continuity of the auxiliary line pres-
sure transducer.
TROUBLESHOOTING 4. Check input voltage of the auxiliary line pres-
GUIDELINES sure transducer.
Requested Setting Display Does Not 5. Check ground of the auxiliary line pressure
Change in Gauge transducer.
1. Check the override/ACS button as detailed in 6. Check compressor operation.
OVERRIDE SWITCH in the LIGHTS GAUGE
AND ACCESSORIES subsection. Multifunction Gauge Display Flickers
OFF and Back ON
1. Check diode (D7) of the solenoid valve.
6 vmr2016-144
NOTE: The diode (D7) is located on the main har-

ness near the ACS sub-harness junction. Refer to
the appropriate WIRING DIAGRAM for location.
TROUBLESHOOTING WITH
B.U.D.S.
ACS System Leak Test
1. Connect vehicle to B.U.D.S. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. subsection.
2. Select Activation page.
3. Select SCM folder.
vmr2013-043-016_a
4. Press Test START button to proceed. 1. Auxiliary line check valve
2. Compressor check valve
ACS Air Pressure Monitoring

To monitor air pressure in the system during trou-
bleshooting operation, proceed as follows:
2. Select Monitoring page.
vmr2016-144-001_a
Step 1: Activation page

Step 2: SCM folder
Step 3: Leak Test START button
After pressing Test START button, the com-

pressor will pressurize the air system at 6.5 bar
(90 PSI) for approximately 1 minutes and B.U.D.S.
will monitor the system for any leakage. The
result will be indicated in the TEST STATUS box.
If a leak is detected, pressurize the system again vmr2016-144-002_a
and inspect hoses and fittings with soapy water Step 1: Monitoring page
to locate the faulty component. Step 2: SCM folder
If no leak is detected from hoses or fittings, in-

spect the compressor check valve and the auxil- PROCEDURES
iary line check valve with soapy water.
ACS SOLENOID VALVE
ACS Solenoid Valve Operation Test
2. Select Activation page.
4. Press Relief Valve button to proceed.
vmr2016-144 7
ACS Solenoid Valve Removal

1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Disconnect the following hoses and connector
from solenoid valve air fittings.
– Manifold air inlet hose (from manifold)
– Module hose
– Rear suspension shocks hose
– Solenoid connector.
vmr2016-144-001_b

Step 2: SCM folder
Step 3: Solenoid valve operation test button
ACS Solenoid Valve Input Voltage Test

1. Remove seats and RH side panel.
2. Place ignition switch to ON position.
3. Press MODE (M) button to display AIR_SUSP.
4. Set suspension mode to ACS 2 using the ACS
button.
5. Wait until the actual setting shows 2. vmr2013-043-015_b
1. Manifold air inlet hose (from compressor)

2. Module hose
3. Rear suspension Shocks hose
4. Solenoid connector
3. To disconnect hoses, proceed as follows:

3.1 Push fitting ring toward manifold.
1
3.2 Hold ring in place.
2 3.3 Pull air hose.
tmo2013-003-001_b
2. Actual setting
NOTE: Make sure to wait enough time in order to

let the system adjust the air pressure.
6. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
7. Back probe solenoid connector (without discon-
necting). vmr2013-043-010_a
8. Set suspension mode to ACS 1 using the ACS 1. Fitting

2. Fitting ring
button.
9. Measure voltage between solenoid connector 4. Remove solenoid retaining screws.
terminals as per the following table.
TEST PROBES VOLTAGE
Pin 2 (YL/GN) Battery voltage
Pin 1 (BK) (± 12 Vdc)
8 vmr2016-144
vmr2013-043-017_c
Install air fittings and check valve as follows.

vmr2013-043-024_a
1. Retaining screws
5. Unscrew air fittings and check valve.
vmr2013-043-017_d
RETAINING SCREWS ARE OFFSET TOWARD MODULE FITTING

1. Manifold air inlet fitting (from manifold)
2. Auxiliary line check valve
3. Shocks fitting
vmr2013-043-017_d 4. Module fitting
1. Manifold air inlet fitting (from manifold)
2. Manifold inlet check valve Ensure that air hoses are properly inserted into fit-
3. Shocks fitting
4. Module fitting tings, refer to the following illustrations.
ACS Solenoid Valve Installation

The installation procedure is the reverse of re-
moval procedure, however pay attention to the
following.
If fitting is the one previously removed (old one),
apply LOCTITE 592 (PIPE SEALANT) (P/N 293 800 018)
on all male fittings.
vmo2010-011-102_a
If fitting is a new one, do not apply sealant, it
TYPICAL - PUSH HOSE UNTIL THE MARK IS COMPLETELY
should be already applied on male threads. INSERTED
1. Fitting
On check valve apply LOCTITE 592 (PIPE SEALANT) 2. Mark
(P/N 293 800 018) on male threads. A. Must be inserted into fitting
Install air fittings and check valve as follows with
arrows pointing toward solenoid.
vmo2010-011-103
TYPICAL - HOSE PROPERLY INSERTED INTO FITTING
vmr2016-144 9
ACS MANIFOLD
ACS Manifold Removal
subsection.
2. Disconnect pressure transducer connector.
vmr2013-043-026_a
1. Inlet hose (from compressor)

2. Solenoid valve hose
3. Auxiliary valve hose
4. Pressure transducer hose
5. Remove retaining screw securing manifold to

support.
vmr2013-043-007_b
1. Connector of auxiliary line pressure transducer
3. Disconnect the following hoses and connector

from solenoid valve air fittings.
– Air inlet hose (from compressor)
– Solenoid valve hose
– Auxiliary line hose
– Pressure transducer.
4. To disconnect hoses, proceed as follows:
4.3 Pull air hose.
vmr2013-043-027_a
1. ACS manifold retaining screw

2. ACS manifold
6. Unscrew air fittings and check valve.
10 vmr2016-144
TEST PROBES
RESISTANCE
GAUGE MODULE
Pin 18 (WH/BK) Pin 5 (WH/BK) Close to 0
Pin 19 (WH/BE) Pin 6 (WH/BE) Close to 0
ACS Module Input Voltage Test

1. Disconnect module connector.
vmr2013-043-028_a
1. Manifold air inlet fitting (from compressor)

2. Compressor line check valve
3. Auxiliary line fitting
4. Solenoid line fitting
5. Pressure transducer fitting
ACS Manifold Installation

following.
Apply LOCTITE 592 (PIPE SEALANT) (P/N 293 800
018) on male fittings.
vmr2013-043-004_a
1. Module connector
ACS MODULE
ACS Module Signal Circuit Continuity 868) to Vdc.
Test
4. Measure voltage as per the following table.
2. Disconnect multifunction gauge from vehicle.
Refer to LIGHTS, GAUGE AND ACCESSORIES TEST PROBES VOLTAGE
subsection. Pin 12 (OR/GN) Battery voltage
3. Disconnect ACS module connector. (± 12 Vdc)
Battery negative (-) post
ACS Module Ground Test

1. Verify if compressor is properly grounded to
frame before performing the ground test.
vmr2013-043-004_a
1. Module connector

868) to .
5. Measure resistance as per the following tables.
vmr2016-144 11
vmr2013-043-006_b
vmr2013-043-004_a
1. Module hose
1. Module connector
NOTICE Do not attempt to disconnect hose
3. Set the FLUKE 115 MULTIMETER (P/N 529 035 from module.
868) to Vdc.
4. Place ignition switch to ON position. 3. Disconnect module connector.
TEST PROBES VOLTAGE
Pin 7 (BK) Battery voltage
Battery negative (-) post (± 12 Vdc)
If compressor does not work:

TEST PROBES VOLTAGE
HIC8 (RD/PK) Battery voltage
If valves do not work:

TEST PROBES VOLTAGE vmr2013-043-004_a
1. Module connector
DB1-6 (RD/BR) Battery voltage
Battery positive (+) post (± 12 Vdc) 4. Remove module retaining bolts and nuts.
ACS Module Removal

subsection.
2. Disconnect module hose from solenoid valve
air fitting as follows:
2.3 Pull air hose.
vmr2013-043-006_c
1. Module retaining bolt
5. Remove module from vehicle.
12 vmr2016-144
ACS Module Installation TEST PROBES RESISTANCE

The installation procedure is the reverse of re- Terminal 30 (pin 12B)
moval procedure, however pay attention to the Close to 0
following. Terminal 87 (pin 11A)
If a new ACS module is installed, check diode (D7) If results are not as per the above tables, replace
of the solenoid valve to ensure that it is not de- relay.
fective as it can damage the ACS module. The
diode (D7) is located on the main harness near the ACS Relay Input Voltage Test
ACS sub-harness junction. Refer to the appropri-
ate WIRING DIAGRAM for diode location. 1. Remove relay (R15), located above the ACS
module.
Ensure that air hoses are properly inserted into fit-
tings, refer to the following illustrations. 2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
4. Measure voltage as per the following tables.
TEST PROBES
RESISTANCE
FUSE BOX BATTERY
Negative (-) Battery voltage
Pin E8 (RD/BR)
post (± 12 Vdc)
vmo2010-011-102_a Negative (-) Battery voltage
TYPICAL - PUSH HOSE UNTIL THE MARK IS COMPLETELY Pin E9 (RD/YL)
post (± 12 Vdc)
INSERTED
1. Fitting
2. Mark If voltage is not as specified, check wiring, con-
A. Must be inserted into fitting nector and terminal condition.
ACS Relay Ground Wire Continuity

Test
1. Remove relay (R15), located above the ACS
module.
vmo2010-011-103
TYPICAL - HOSE PROPERLY INSERTED INTO FITTING
ACS COMPRESSOR RELAY (R15)

ACS Relay Continuity Test
1. Remove relay (R15), located above the ACS
module.
868) to .
3. Measure resistance as per the following table.
Terminal 30 (pin 12B)
Open (OL)
Terminal 87 (pin 11A) vmr2013-043-004_a
1. Module connector
4. Apply 12 volts on terminals 86 (pin 11B) and 85
(pin 12A). 3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Measure resistance again as per the following
table. 4. Measure resistance as per the following table.
vmr2016-144 13
TEST PROBES RESISTANCE 3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
Module pin 8 (OR/PK)
Close to 0 4. Measure resistance as per the following table.
wire (OR/PK) TEST PROBES RESISTANCE
Compressor pin C
ACS COMPRESSOR (RD/WH)
Close to 0
ACS Compressor Operation Test Terminal 87 (RD/WH)
NICATION TOOLS AND B.U.D.S. subsection. ACS Compressor Input Voltage Test
2. Select Activation page. 1. Reinstall the ACS relay (R15).
3. Select SCM folder. 2. Release air pressure, refer to RELEASING AIR
4. Press Compressor button to proceed. PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
868) to Vdc.
4. Disconnect compressor connector.
vmr2016-144-001_c

Step 2: SCM folder
Step 3: Compressor operation test button
5. Verify if compressor works properly.
ACS Compressor Power Wire vmr2013-043-002_a
1. Compressor connector
Continuity Test (from Relay)
1. Remove relay (R15), located above the ACS 5. Place ignition switch to ON position.
module. 6. Probe compressor connector.
2. Disconnect compressor connector. 7. Press MODE (M) button to display AIR_SUSP.
8. Set suspension mode to ACS 2 using the ACS
button.
vmr2013-043-002_a
14 vmr2016-144
7. Disconnect compressor connector.
tmo2013-003-001_b
2. Actual setting
9. Measure voltage between compressor connec-

tor terminals as per the following table. vmr2013-043-002_a
TEST PROBES VOLTAGE
Pin C (RD/WH)
8. Disconnect the following hoses from compres-
Battery voltage sor air fittings.
Pin A (BK) (± 12 Vdc)
– Compressor air inlet hose
– Compressor air outlet hose.
ACS Compressor Removal
subsection.
2. Refer to the BODY section and remove the fol-
lowing:
– RH side panel
– RH footrest.
3. Remove solenoid valve. Refer to ACS SOLE-
NOID VALVE REMOVAL.
4. Remove manifold. Refer to ACS MANIFOLD vmr2013-043-001_a
REMOVAL. 1. Compressor air inlet hose
2. Compressor air outlet hose
5. Remove module. Refer to ACS MODULE RE-
MOVAL. 9. To disconnect hoses, proceed as follows:
6. Remove connector of auxiliary line pressure 9.1 Push fitting ring toward manifold.
transducer from support.
9.3 Pull air hose.
10. Remove compressor support rear retaining
bolts and nuts.
11. Remove compressor side retaining bolt and
nut.
vmr2013-043-007_b
1. Connector of auxiliary line pressure transducer
vmr2016-144 15
vmr2013-043-013_a
TYPICAL
1. Compressor front support mounting bolts
vmr2013-043-019_a
TYPICAL - PARTS REMOVED FOR CLARITY

1. Compressor support rear retaining bolts
2. Compressor support side retaining bolt
12. Remove compressor front retaining screw.
vmr2013-043-003_a
TYPICAL
1. Compressor rear support mounting nuts
NOTICE Do not remove front support from

compressor.
17. Remove the following fittings from compres-
sor.
– Compressor air inlet fitting
vmr2013-043-020_a
– Compressor air outlet fitting.
1. Front retaining screw
13. Remove compressor from vehicle by pulling it

upwards.
14. Detach compressor connector from compres-
sor support.
15. Remove mounting nuts from compressor sup-
port. vmr2013-043-018_a
16. Remove rear compressor support from com- TYPICAL

pressor. 1. Compressor air inlet fitting
2. Compressor air outlet fitting
ACS Compressor Installation

following.
If fitting or valve is the one previously removed
(old one), apply LOCTITE 592 (PIPE SEALANT)
(P/N 293 800 018) on all male threads.
16 vmr2016-144
If fitting or valve is a new one, do not apply

sealant, it should be already applied on male
threads.
Ensure that check valve is installed with arrows
pointing toward the manifold.
vmr2013-043-004_a
1. Module connector

vmr2013-043-021_a

tings, refer to the following illustrations.
vmo2010-011-102_a
PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED

1. Fitting vmr2013-043-007_b
2. Mark
1. Pressure transducer connector
A. Must be inserted into fitting
868) to .
5. Measure resistance as per the following table.
Pressure transducer
vmo2010-011-103 pin 2 (PK/BR) Close to 0
HOSE PROPERLY INSERTED INTO FITTING
Module pin 3 (PK/BR)
ACS AIR FILTER Refer to the following illustration for the pressure
transducer connector pinout.
ACS compressor picks up air from air box.
PRESSURE TRANSDUCER
Pressure Transducer Signal Circuit
Continuity Test
2. Disconnect module connector. vmr2010-004-108
vmr2016-144 17
Pressure Transducer Input Voltage Test

vmr2013-043-007_b
1. Pressure transducer connector

868) to Vdc.
vmr2013-043-007_b 4. Place ignition switch to ON position.
1. Pressure transducer connector 5. Measure voltage as per the following table.
3. Set the FLUKE 115 MULTIMETER (P/N 529 035 TEST PROBES VOLTAGE
868) to Vdc.
Pin 1 (BK) Battery voltage
4. Place ignition switch to ON position. (± 12 Vdc)
Battery positive (+) post
TEST PROBES VOLTAGE Refer to the following illustration for the pressure
Pin 3 (PK/OR) Battery voltage
Refer to the following illustration for the pressure

vmr2010-004-108
Pressure Transducer Replacement

vmr2010-004-108
subsection.
Pressure Transducer Ground Test 2. Disconnect pressure transducer connector.
1. Remove seats and RH side panel. 3. Remove Oetiker clamp.
2. Disconnect pressure transducer connector. 4. Remove pressure transducer from hose.
18 vmr2016-144
vmr2013-043-014_a
1. Auxiliary line adapter

2. Fitting ring
vmr2013-043-011_a
1. Auxiliary line pressure transducer 3. Install new adapter.

2. Connector
3. Oetiker clamp 4. Secure adapter support using rivets.
5. Connect auxiliary line hose into adapter.
5. Install a new pressure transducer on hose.
6. Install a new Oetiker clamp using OETIKER PLI-
tings, refer to the following illustrations.
ERS (P/N 295 000 070).
7. Connect pressure transducer connector.
8. Ensure that there is no air leaks from pressure
transducer hose. Refer to ACS SYSTEM LEAK
TEST (WITH B.U.D.S.).
ACS HOSES
ACS Hose and Fitting Replacement
vmo2010-011-102_a
1. Release air pressure, refer to RELEASING AIR TYPICAL - PUSH HOSE UNTIL THE MARK IS COMPLETELY
PRESSURE IN SYSTEM FOR SERVICING in this INSERTED
subsection. 1. Fitting
2. Mark
2. Locate hose or fitting to be replaced. A. Must be inserted into fitting
3. Remove it from vehicle.

4. Install the new hose or fitting.
5. Perform a ACS SYSTEM LEAK TEST (WITH
B.U.D.S.).
Auxiliary Line Adapter Replacement vmo2010-011-103
1. Release air pressure, refer to RELEASING AIR TYPICAL - HOSE PROPERLY INSERTED INTO FITTING
subsection. SHOCK ABSORBERS
2. Disconnect auxiliary line hose from adapter as
follows: Shock Absorber Removal
2.1 Push fitting ring toward adapter. 1. Lift rear of vehicle until rear shock absorbers are
fully extended.
2. Install jack stands or blocks under the frame to
2.3 Pull air hose. support the vehicle.
vmr2016-144 19
3. Unscrew air hose from shock absorber as fol-

lows:
3.1 Install an appropriate wrench on shock fit-
ting to hold it in place.
3.2 Unscrew air hose fitting using another
wrench.
vmr2013-043-022_b
1. Shock absorber upper bolt

2. Shock absorber upper nut
6. Remove shock absorber from vehicle.
Shock Absorber Disassembly

NOTICE Be careful while manipulating or
vmr2013-043-022_a installing the shock absorber in the spring
1. Shock absorber fitting remover tool. The shock absorber body must
2. Air hose fitting
not be scratched or damaged to avoid air leak-
NOTICE To avoid damaging the shock fitting age.
threads, install a wrench on the shock fitting to 1. Secure the SPRING COMPRESSOR (P/N 529 036
hold it in place while unscrewing the air hose 184) in a vise.
fitting.
4. Remove the shock absorber lower bolt and nut.
529036184
2. Position the shock absorber in the tool and in-

stall the spring compressor hooks.
3. Tighten the spring compressor tool screw until
the spring is sufficiently compressed to remove
spring locking devices.
4. Remove spring stopper and its cap then loosen
vmr2010-004-028_a
the spring compressor tool screw.
TYPICAL 5. Remove circlip and spring retainer.
1. Shock absorber lower bolt
6. Remove spring from shock.
5. Remove the shock absorber upper bolt and nut.
Shock Absorber Inspection
Inspect the spring for damage. Replace if neces-
sary.
Secure the end of shock body in a vise with its rod
upward.
20 vmr2016-144
A14F0BA
TYPICAL
1. Clamp here
NOTICE Do not clamp directly on shock

body.
Inspect shock absorber as following: vmr2010-004-702_a
1. Examine the shock absorber for leaks. TYPICAL

1. Sleeve
2. Extend and compress the shock absorber shaft 2. O-ring
several times over its entire stroke.
3. Check that the shock absorber shaft moves
rod upward.
Any of the following conditions will denote a de-
fective shock absorber:
mid travel.
end of either stroke.
pression and extension stroke.
Replace shock absorber if any faults are present.
Shock Absorber Assembly and

Installation vmr2013-043-023_a
TYPICAL
Assembly and installation are the reverse of dis- 1. Small sleeve
2. Lower cap
assembly and removal procedures, however pay 3. Upper cap
attention to the following. 4. Large sleeve
Assemble shock absorber as per the following il- Torque upper and lower shock absorber bolts.
lustrations.
TIGHTENING TORQUE
Shock absorber bolts 53 N•m (39 lbf•ft)
If the same shock absorber is reused, apply LOC-

TITE 592 (PIPE SEALANT) (P/N 293 800 018) on air
hose sleeve male threads.
While holding shock fitting with a wrench, tighten
air hose fitting.
NOTICE Never screw shock absorber air
hose by using the air hose fitting only. To
avoid damaging the shock fitting threads, in-
stall a wrench on the shock fitting to hold it in
vmr2010-004-701_a
place while screwing the air hose fitting.
TYPICAL
1. Sleeve
2. O-ring
vmr2016-144 21
TIGHTENING TORQUE
Air hose fitting 19 N•m (168 lbf•in)
vmr2013-043-022_a
1. Shock absorber fitting

2. Air hose fitting
Ensure that there is no air leaks from shock ab-

sorber fitting and air hose. Refer to ACS SYSTEM
LEAK TEST (WITH B.U.D.S.).
22 vmr2016-144
Subsection 07 (BRAKES)
BRAKES
SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 8
SERVICE PRODUCTS
XPS BRAKES AND PARTS CLEANER (USA) ................................. 219 701 705 ........................................... 12
XPS BRAKES AND PARTS CLEANER ........................................... 219 701 776 ........................................... 12
vmr2016-145 1
OUTLANDER (FRONT CIRCUIT)

All Except CE Models
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
To rear circuit
5.5 ± 1.5 N•m NEW

(49 ± 13 lbf•in)
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
NEW
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)

vmr2012-042-100_a
2 vmr2016-145
OUTLANDER (REAR CIRCUIT)

All Except CE Models
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
0.7 ± 0.1 N•m

(6 ± 1 lbf•in)
28.5 ± 1.5 N•m
(21 ± 1 lbf•ft)
NEW
NEW
28.5 ± 1.5 N•m
To front circuit
NEW
27.5 ± 2.5 N•m

(20 ± 2 lbf•ft)

vmr2013-044-101_a
vmr2016-145 3
OUTLANDER (FRONT CIRCUIT)

CE Models
NEW NEW
61 ± 9 N•m
(45 ± 7 lbf•ft) 28.5 ± 1.5 N•m
(21 ± 1 lbf•ft)
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW 5.5 ± 1.5 N•m To rear circuit

(49 ± 13 lbf•in) NEW
NEW 28.5 ± 1.5 N•m

28.5 ± 1.5 N•m (21 ± 1 lbf•ft)
(21 ± 1 lbf•ft)
5.5 ± 1.5 N•m
(49 ± 13 lbf•in)
To rear circuit
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
NEW
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
28.5 ± 1.5 N•m
(21 ± 1 lbf•ft)
vmr2012-042-102_a
4 vmr2016-145
OUTLANDER (REAR CIRCUIT)

CE Models
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
0.7 ± 0.1 N•m

(6 ± 1 lbf•in)
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW
28.5 ± 1.5 N•m
(21 ± 1 lbf•ft)
NEW
NEW
To front circuit
NEW
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
27.5 ± 2.5 N•m
(20 ± 2 lbf•ft)
NEW
To front circuit

vmr2013-044-102_a
vmr2016-145 5
CALIPERS AND BRAKE LEVERS

All Models
FRONT REAR
Brake caliper 8.5 ± 1.5 N•m
synthetic grease (75 ± 13 lbf•in)
Brake caliper
synthetic
grease
8.5 ± 1.5 N•m
(75 ± 13 lbf•in)
LH SIDE
1.3 ± 0.1 N•m
(12 ± 1 lbf•in)
Cover +
gasket
RH SIDE
8.5 ± 1.5 N•m On applicable models 1.3 ± 0.1 N•m
(75 ± 13 lbf•in) (12 ± 1 lbf•in)
XPS synthetic Cover + gasket

grease
XPS synthetic
grease
8.5 ± 1.5 N•m
(75 ± 13 lbf•in)
vmr2013-044-100_a
6 vmr2016-145
GENERAL
WARNING
Always check brake system operation after
removing or servicing a brake component.
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
bolt is unscrewed.
NOTICE Always clean the area around a tmr2011-037-110
brake component before servicing. TYPICAL
Brake Lever Verification

SYSTEM DESCRIPTION
NOTE: Do not pump up the brakes repeatedly be-
A disc brake system with twin-piston sliding fore doing the validation.
calipers is used.
1. Position force gauge perpendicularly on brake
Disc Brake Configurations lever edge.
2. Position a ruler perpendicularly to handlebar
OUTLANDER
grip.
NUMBER OF DISC BRAKES 3. Push brake lever at distance A from handlebar
MODELS
FRONT REAR grip using force gauge.
All models 2 1
Brake Controls and Circuit

Configurations
OUTLANDER
LH BRAKE
MODELS BRAKE PEDAL
LEVER
All except CE Controls front Controls rear
models and rear brakes brakes
Controls front Controls front vmr2012-042-006_a
CE models
and rear brakes and rear brakes A. Distance from handlebar (refer to table)
4. Read load recorded by the force gauge.

INSPECTION 5. Load reading must be as per the following table.
BRAKE SYSTEM PRESSURE BRAKE LEVER VERIFICATION

VALIDATION LEVER
DISTANCE MINIMUM
A LOAD
Required Tools LH side lever 25 mm (1 in) 150 N (34 lbf)
Use an appropriate compression force gauge such
as MARK-10 EG-200 and a ruler. RH side lever
25 mm (1 in) 130 N (29 lbf)
(if applicable)
vmr2016-145 7
6. If load reading is not in accordance with the PROCEDURES

specification:
6.1 Perform a brake system inspection and BRAKE LIGHT SWITCHES
cleaning.
Brake Light Switch Location
6.2 Bleed brake system.
BRAKE SWITCH
NOTE: Refer to PERIODIC MAINTENANCE MODELS
LOCATION
Brake pedal master
All Outlander
Brake Pedal Verification cylinder
NOTE: Do not pump up the brakes repeatedly be-
fore doing the validation.
1. Position force gauge perpendicularly on brake
pedal edge.
2. Position a ruler perpendicularly to brake pedal.
3. Push brake pedal from distance A using force
gauge.
vmr2012-035-004_a
BRAKE PEDAL MASTER CYLINDER

1. Brake light switch
2. Brake light switch connector
Brake Light Switch Resistance Test

1. Disconnect brake light switch connector.
vmr2012-042-007_a
2. Check switch operation as follows.
A. Distance to push (refer to table) BRAKE LIGHT
PIN RESISTANCE
SWITCH POSITION
4. Read load recorded by the force gauge.
5. Load reading must be as per the following table. Firmly pushed Close to 0
1 2
Released Infinite (OL)
BRAKE PEDAL VERIFICATION
MODELS
DISTANCE MINIMUM If switch is defective, replace with a new one.
A LOAD
If the switch tests good, verify wire continuity
All Outlander 35 mm
180 N (40 lbf)
between harness connector and ECM connector.
except CE (1-3/8 in) Refer to BRAKE SYSTEMS WIRING DIAGRAM.
55 mm REQUIRED TOOL
Outlander CE 180 N (40 lbf)
(2-5/32 in)
6. If load reading is not in accordance with the
specification:
6.1 Perform a brake system inspection and
cleaning.
6.2 Bleed brake system.
NOTE: Refer to PERIODIC MAINTENANCE
8 vmr2016-145
529036166
Brake Light Switch Replacement

Brake Light Switch Located on Brake Lever vmr2012-042-001_a

1. Disconnect brake light switch connector. 1. Master cylinder support
2. Replace brake light switch by a new one.
4. Remove brake pedal spring.
3. Connect brake light switch connector.
Brake Light Switch Located on Master
Cylinder or Manifold
1. Disconnect brake light switch connector.
2. Drain brake line.
3. Remove brake light switch.
NOTE: Use shop rags to catch any spilled brake
fluid.
4. Install NEW sealing washers.
5. Install brake light switch.
TORQUE
28.5 N•m ± 1.5 N•m vmr2012-042-002_a
Brake light switch
(21 lbf•ft ± 1 lbf•ft) 1. Brake pedal spring
6. Connect brake light switch connector. 5. Remove brake pedal.

7. Refill and bleed brake system, refer to PERI-
tion.
BRAKE PEDAL
Brake Pedal Removal
1. Drain brake system, refer to PERIODIC MAIN-
2. Remove RH footrest panel. Refer to BODY
subsection.
NOTE: Loosen brake pedal bolt before removing
support from frame.
vmr2012-042-003_a
3. Remove master cylinder support from frame. 1. Brake pedal pivot bolt
Brake Pedal Installation

vmr2016-145 9
Install NEW brake pedal O-ring.

Lubricate brake pedal pivot.
LUBRICATION
XPS SYNTHETIC
Brake pedal pivot GREASE
(P/N 293 550 010)
Tighten brake pedal nut as per the following se-

quence.
TIGHTENING SEQUENCE
STEP Brake pedal bolt 10 N•m ± 2 N•m
1 (pivot) (89 lbf•in ± 18 lbf•in)
STEP 27.5 N•m ± 2.5 N•m vmr2012-042-004_a
Brake pedal nut 1. Master cylinder
2 (20 lbf•ft ± 2 lbf•ft)
3. Remove hoses and bleeder from master cylin-
der.
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

vmr2012-042-005_a
Tighten brake hoses and bleeder to specification.
TIGHTENING SEQUENCE TORQUE
Step 1: Tighten bolt
Step 2: Hold bolt then tighten nut Brake hose screw 28.5 N•m ± 1.5 N•m
(banjo fitting) (21 lbf•ft ± 1 lbf•ft)
MASTER CYLINDER 8.5 N•m ± 1.5 N•m
Bleeder
Master Cylinder Removal (75 lbf•in ± 13 lbf•in)
1. Remove BRAKE PEDAL. See procedure in this Install NEW sealing washers.
subsection.
Refill and bleed brake system, refer to PERIODIC
2. Remove master cylinder from support. MAINTENANCE PROCEDURES subsection.
CALIPER
Caliper Removal
1. Safely lift and support the vehicle.
2. Remove wheel, refer to WHEELS AND TIRES
subsection.
3. If caliper is removed from vehicle for replace-
ment:
3.1 Drain brake system, refer to PERIODIC
MAINTENANCE PROCEDURES subsec-
tion.
3.2 Unscrew brake hose from caliper.
10 vmr2016-145
tmr2011-037-010_a
TYPICAL
1. Brake hose
2. Sealing washers
4. Remove fasteners retaining brake hose.

5. Remove screws securing caliper support.
vmr2012-042-008_a
TYPICAL
1. Caliper screws
6. Place caliper assembly onto a support.

NOTICE Do not let caliper hangs by the hose
and do not stretch or twist hose.
Caliper Installation
If caliper was removed for replacement:
– Refill and bleed brake system, refer to PERI-
tion.
– Install NEW sealing washers.
Install NEW caliper retaining screws.
Tighten caliper retaining screws to specification.
vmr2016-145 11
TORQUE REQUIRED SERVICE PRODUCT

61 N•m ± 9 N•m XPS BRAKES AND PARTS
Caliper retaining screws USA
(45 lbf•ft ± 7 lbf•ft) CLEANER (USA) (P/N 219 701 705)
For all other XPS BRAKES AND PARTS
BRAKE PADS countries CLEANER (P/N 219 701 776)
Brake Pads Replacement 6. Push caliper pistons inward.

1. Remove caliper, refer to CALIPER REMOVAL in NOTE: To avoid damaging pistons, use an old pad
this subsection. to push it into the caliper using a C-clamp.
2. Remove pin retainer securing brake pad pin. 7. Ensure brake pad spring is properly positioned
onto caliper and not damaged.
vmr2012-042-009_a
1. Pin retainer vmr2012-042-011_a
BRAKE PAD SPRING

3. Remove brake pad pin from caliper.
8. Ensure pad stopper is properly aligned with
caliper support protrusion.
vmr2012-042-010_a
TYPICAL
1. Brake pad pin
vmr2012-042-012_a
4. Carefully remove brake pads. 1. Pad stopper

2. Caliper support protrusion
5. Clean pistons end using the following product
or and equivalent. NOTICE Prior to installing brake pads, pad
stopper must be properly positioned and not
damaged.
9. Install NEW brake pads.
12 vmr2016-145
10. Clean and install brake pad pin on caliper.

11. Install pin retainer to secure brake pad pin.
12. Slide caliper support completely into caliper.
vmr2012-042-013_a
1. Brake disc screw
4. Replace brake disc.

5. Install NEW brake disc screws.
vmr2012-042-014_a
6. Tighten brake disc screws to specification.
1. Caliper support
TORQUE
13. Install caliper, refer to CALIPER INSTALLA-
33.5 N•m ± 3.5 N•m
TION in this subsection. Brake disc screws
BRAKE DISC 7. Install wheel hub then caliper.

Brake Disc Inspection 8. Install NEW cotter pin to secure wheel hub nut.
1. Check disc surfaces for scratches or grooves on
both sides.
2. Measure thickness of the disc.
DISC MINIMUM THICKNESS
FRONT 4.0 mm (.157 in)
REAR 4.0 mm (.157 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, refer to CALIPER REMOVAL in
this subsection.
2. Remove wheel hub, refer to FRONT DRIVE or
REAR DRIVE subsection.
3. Remove screws securing brake disc to wheel
hub.
vmr2016-145 13
Subsection XX (BODY)
BODY
SERVICE TOOLS
OETIKER PLIER ............................................................................. 295 000 070 ........................................... 12
BODY PARTS NOMENCLATURE (SHORT MODEL)
18
2 3 4 5 6
13 1
12
14
15
11
16
10 17 9 8
219100883-011-100_a
1. Gauge support 11. Front bumper

2. Console 12. Hood
3. Seat 13. Front rack
4. Rear top panel (under rear rack) 14. Front fascia
5. Rear rack 15. Rear fascia
6. Rear bumper 16. Rear fender
7. Rear storage compartment 17. Front fender
8. Footrest panel 18. Windshield (If equipped)
9. Side panel
10. Inner fender panels
219100883-011 1
BODY PARTS NOMENCLATURE (MAX MODEL)
21
5 7
2 3 6
1
14
13
15 16
12
17
9
20 10 18
11 19
219100883-011-101_a
1. Gauge support 11. Inner fender panels

2. Console 12. Front bumper
3. Seat 13. Hood
4. Passenger seat 14. Front rack
5. Rear top panel (under rear rack) 15. Front fascia
6. Rear rack 16. Rear fascia
7. Rear bumper 17. Rear Fender
8. Rear storage compartment 18. Rear side panel extension
9. Footrest panel 19. Panel extension
10. Side panel 20. Front fender
21. Windshield (If equipped)
2 219100883-011
FRONT AND REAR BODY MODULES (SHORT MODEL)
vmr2012-043-100_a
1. Front body module (TYPICAL)

2. Rear body module (TYPICAL)
219100883-011 3
FRONT AND REAR BODY MODULES (MAX MODEL)
vmr2013-045-105
1. Front body module (TYPICAL)

2. Rear body module (TYPICAL)
4 219100883-011
BODY PARTS (SHORT MODEL)

4.5 ± 0.5 Nm
(40 ± 4 lbfin)
See AIR INTAKE SYSTEM
See FRAME
4.5 ± 0.5 Nm

(40 ± 4 lbfin)
LH side shown, RH side identical

vmr2012-043-102_a
219100883-011 5
BODY PARTS (MAX MODEL)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
LH side shown, RH side identical

vmr2013-045-109_a
6 219100883-011
RACKS AND BODY PARTS
4.5 ± 0.5 N•m 4.5 ± 0.5 N•m

(40 ± 4 lbf•in) (40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
3
4
4.5 ± 0.5 N•m
(40 ± 4 lbf•in)
1
4.5 ± 0.5 N•m
2 (40 ± 4 lbf•in)
1.6 ± 0.4 N•m

(14 ± 4 lbf•in)
vmr2013-045-100_a
219100883-011 7
BUMPERS AND BODY PARTS
219100883-011-104_a
8 219100883-011
REAR STORAGE COMPARTMENT
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
Outlander MAX
27 ± 2 N•m
(20 ± 1 lbf•in)
14 ± 1 N•m 10 ± 2 N•m
(124 ± 9 lbf•in) (89 ± 18 lbf•in)
219100883-011-105_a
219100883-011 9
PASSENGER SEAT
25 ± 3 N•m
(18 ± 2 lbf•ft)
If equipped
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
If equipped
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
5 ± 1 N•m
(44 ± 9 lbf•in)
25 ± 3 N•m
(18 ± 2 lbf•ft)
If equipped
219100883-011-103_a
10 219100883-011
WINDSHIELD
NEW
HAND
TIGHTEN

219100883-011-102_a
219100883-011 11
PROCEDURES FRONT BODY MODULE

Front Body Module Removal
PLASTIC RIVET
1. Disconnect battery negative (-) cable.
Plastic rivets are used in the riveting of the vari-
2. Remove the following panels, see procedure in
ous body parts. Plastic rivets can be reused many
this subsection.
times. Use the OETIKER PLIER (P/N 295 000 070) to
remove them. – SIDE PANELS
– INNER FENDER PANELS.
3. Remove front skid plate retaining screws.
V06L08A 2 1
TYPICAL
1. Pliers
2. Plastic rivet vmr2012-043-001_a
1. Front skid plate retaining screws

DECALS 4. On applicable models, disconnect winch con-
Decal Removal nectors.
Using a heat gun warm up one end of decal for a
few seconds until 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 the surface and dry
thoroughly.
vmr2012-043-002_a
Apply liquid soap to new decal and carefully posi- SOME PARTS REMOVED FOR CLARITY
tion it. Using a sponge or a squeegee, remove the 1. Winch connectors
air bubbles and surplus water working from the
5. Disconnect headlights connectors.
center toward the edges. Allow to air dry.
NOTICE Do not apply isopropyl alcohol or
solvent directly on decals. Use these products
in a well ventilated area.
12 219100883-011
8. Remove screws securing front body module to

frame.
vmr2012-043-003_a
RH SIDE SHOWN
1. Headlight connectors
vmr2012-043-006_a
6. Remove screw securing front fender to footrest
RH SIDE
panel (on both sides). 1. Front body module retaining screw
vmr2012-043-004_a
vmr2012-043-007_a
TYPICAL
1. Screw securing front fender LH SIDE
1. Front body module retaining screw
7. Detach front fender from footrest panel by re-
leasing retaining tabs (on both sides). 9. Remove screws securing front fenders to
frame.
vmr2012-043-008_a
vmr2012-043-005_a
TYPICAL - RH SIDE SHOWN
1. Front fender retaining tabs 1. Screw securing front fender
219100883-011 13
10. With the assistance of a person, pull front

body module forward.
11. Install front body module on a stable and clean
support.
Front Body Module Installation

Tighten front fender screws to specification.
TIGHTENING TORQUE
Screws securing footrest 4.5 N•m ± 0.5 N•m
panels to front fenders (40 lbf•in ± 4 lbf•in)
vmr2012-043-010_a
Screws securing front 4.5 N•m ± 0.5 N•m LH SIDE SHOWN

fenders to frame (40 lbf•in ± 4 lbf•in) 1. Taillight connector
6. Move aside taillight harness from rear body

REAR BODY MODULE module (on both sides).
Rear Body Module Removal

1. Remove seat.
2. Remove the following panels, see procedure in
this section.
– LUGGAGE TRAY (MAX MODELS)
– SIDE PANEL.
3. On Short Models, remove rear top panel re-
taining screws.
vmr2012-043-029
TYPICAL - LH SIDE TAILLIGHT HARNESS
7. Disconnect connectors from voltage regulator

rectifier.
vmr2012-043-009_a
TYPICAL
1. Rear top panel retaining screws
4. Remove both rivets located in the crescent near

previously removed retaining screws.
5. Disconnect taillights connectors.
vmr2012-043-013_a
1. Voltage regulator rectifier connectors
14 219100883-011
8. Remove muffler upper retaining bolt.
vmr2012-043-016_a
vmr2012-043-014_a
LH SIDE
1. Muffler upper retaining bolt 1. Rear body module lower retaining bolts
9. Remove rear body module upper retaining

bolts.
vmr2012-043-017_a
RH SIDE - SOME PARTS REMOVED FOR CLARITY

1. Rear body module lower retaining bolts
vmr2012-043-015_a
TYPICAL - LH SIDE SHOWN 11. Remove screw securing rear fender to

1. Rear body module upper retaining bolts footrest panel (on both sides).
10. Remove rear body module lower retaining
bolts.
vmr2012-043-018_a
TYPICAL
1. Screw securing rear fender
219100883-011 15
12. Detach rear fender from footrest panel by re- TIGHTENING TORQUE
leasing retaining tabs (on both sides).
4.5 N•m ± 0.5 N•m
Rear top panel screws
CONSOLE
Console Removal
1. Remove seat.
2. Lift rear portion of console upwards.
vmr2012-043-019_a
TYPICAL
1. Rear fender retaining tabs
13. Remove fuel tank cap.

14. Place a clean rag into fuel tank filler tube.
15. With the assistance of a person, pull rear body
module rearward. vmr2012-043-020_a
16. Install rear body module on a stable and clean LIFT REAR PORTION
support. 3. Pull console rearwards.
17. Remove rag and reinstall fuel tank cap.
Console Installation
WARNING The installation is the reverse of the removal pro-
Fuel vapors are flammable and explosive cedure. However, pay attention to the following.
under certain conditions. Unless otherwise Align console front tabs with slots, then push con-
noted, the fuel tank cap must always be in- sole forward.
stalled on vehicle.
Rear Body Module Installation

Tighten rear body module retaining bolts to spec-
ification.
TIGHTENING TORQUE
Rear body module 27 N•m ± 2 N•m
upper bolts (20 lbf•ft ± 1 lbf•ft)
Rear body module 24.5 N•m ± 3.5 N•m
lower bolts (18 lbf•ft ± 3 lbf•ft)
Tighten rear fender screws to specification. vmr2012-043-021_a
SOME PARTS REMOVED FOR CLARITY

TIGHTENING TORQUE 1. Console front tabs

panels to rear fenders (40 lbf•in ± 4 lbf•in) GAUGE SUPPORT
Refer to GAUGE subsection.
Tighten rear top panel screws to specification.
16 219100883-011
INNER FENDER PANELS

Inner Fender Removal and Installation
Remove the following plastic rivets from inner
fender panels.
vmr2012-043-024_a
1. Plastic rivet securing side panel
4. Remove plastic rivet securing side panel (Short

Models) or rear side panel extension (Max
Models) to rear fender.
vmr2012-043-022_a

cedure.
SIDE PANELS
Side Panel Removal
1. Remove CONSOLE. See procedure in this sub-
section.
2. Remove plastic rivet securing side panel to in-
vmr2012-043-025_a
ner fender panel.
5. Remove luggage tray. Refer to LUGGAGE

TRAY.
6. Lift rear portion of side panel assembly then pull
it towards outside.
NOTE: For Short Models, side panel assembly
includes side panel and panel extension.
NOTE: For Max Models, side panel assembly in-
cludes side panel, panel extension and rear side
panel extension.
vmr2012-043-023_a
3. Remove plastic rivet securing side panel to air

filter housing.
219100883-011 17
vmr2012-043-026_a vmr2013-045-002_a
LIFT REAR PORTION 1. Tabs securing panel extension to side panel

2. Side panel extension
Side Panel Installation 6. Remove panel extension.
cedure. However, pay attention to the following. Panel Extension Installation
Align side panel front tab with slot, then push side Installation is the reverse of removal.
panel forward.
LUGGAGE TRAY
PANEL EXTENSIONS (MAX MODELS)
Panel Extension Removal Luggage Tray Removal
1. Remove seat. 1. Remove seat.
2. Remove console. Refer to CONSOLE RE- 2. Remove retaining screws securing luggage tray
MOVAL. and rear top panel to frame.
3. Remove rear luggage tray. Refer to LUGGAGE
TRAY.
4. Remove side panel assembly including side
panel, panel extension and rear side panel ex-
tension. Refer to SIDE PANEL REMOVAL.
5. Undo tabs securing panel extension to side
panel.
vmr2013-045-015_b
1. Retaining screws securing luggage tray and rear top panel to

frame
3. Remove retaining screws securing luggage tray

to frame.
4. Remove rivets securing luggage tray to side
panels.
18 219100883-011
4. Using a screwdriver, unclip retaining tabs secur-

ing rear top panel to rear storage compartment.
vmr2013-045-010_c
vmr2013-045-017_a
1. Retaining screws securing luggage tray to frame
2. Rivets securing luggage tray to rear side panel extension PARTS REMOVED FOR CLARITY
1. Retaining tab locations
Luggage Tray Installation 5. Slide rear top panel forward to free it from rear
Installation is the reverse of removal. However storage compartment retaining tab.
pay attention to the following:
TIGHTENING TORQUE
Luggage tray retaining 4.5 N•m ± 0.5 N•m
REAR SIDE PANEL EXTENSIONS

(MAX MODEL)
Rear Side Panel Extension Removal
1. Remove seat.
2. Refer to the appropriate sections and remove
the following:
vmr2013-045-033_a
– LUGGAGE TRAY TYPICAL - SLIDING REAR TOP PANEL TOWARDS FRONT
– SIDE PANEL.
3. Remove side panel assembly including side Rear Top Panel Installation
panel, panel extension and rear side panel ex- Installation is the reverse of removal. However
tension. Refer to SIDE PANEL REMOVAL. pay attention to the following:
4. Unclip retaining tabs securing rear side panel TIGHTENING TORQUE
extension to side panel.
4.5 N•m ± 0.5 N•m
Rear Side Panel Extension Installation (40 lbf•in ± 4 lbf•in)
Installation is the reverse of removal.
FOOTREST PANELS
REAR TOP PANEL Footrest Panel Removal
Rear Top Panel Removal Short Models
1. Remove seat.
1. Remove footrest panel retaining screws.
2. Remove rear body module. Refer to REAR
BODY MODULE.
3. Remove rear rack. Refer to REAR RACK RE-
MOVAL.
219100883-011 19
vmr2012-043-027_a
TYPICAL - FOOTREST PANEL RETAINING SCREWS
2. Remove screw securing front fender to footrest vmr2012-043-022_b

panel.
4. Remove screw securing rear fender to footrest
panel.
vmr2012-043-004_a
TYPICAL
1. Screw securing front fender
vmr2012-043-018_a
3. Remove both plastic rivet securing inner fender TYPICAL
panel to footrest panel. 1. Screw securing rear fender
5. Remove screw securing footrest panel to

frame.
20 219100883-011
vmr2012-043-028_a
TYPICAL vmr2012-043-019_a
1. Screw securing footrest panel
TYPICAL
1. Rear fender retaining tabs
6. Detach front fender from footrest panel by re-
leasing retaining tabs. 8. Remove footrest panel from vehicle.
Max Models
1. Remove footrest panel retaining screws.
vmr2012-043-005_a
TYPICAL
1. Front fender retaining tabs
7. Detach rear fender from footrest panel by relea-

sing retaining tabs. vmr2013-045-051_b
TYPICAL - RH SIDE DOWN

1. Footrest panel retaining screws
219100883-011 21
2. Remove screw securing rear fender to footrest

panel.
3. Remove plastic rivet securing footrest panel to
rear side panel extension.
frame.
vmr2013-045-050_a
TYPICAL - RH SIDE DOWN

vmr2013-045-007_b

1. Plastic rivet securing footrest panel to inner fender
2. Plastic rivet securing footrest panel to rear side panel extension
3. Retaining screw securing footrest panel to frame

panel extension.
frame.
7. Remove screw securing front fender to footrest
panel.
vmr2013-045-051_a
TYPICAL - LH SIDE SHOWN

vmr2013-045-012_b

1. Plastic rivet securing footrest panel to panel extension
vmr2013-045-050_b 2. Plastic rivet securing footrest panel to frame
TYPICAL - LH SIDE SHOWN 3. Retaining screw securing footrest panel to front fender
22 219100883-011
8. Detach front fender from footrest panel by re- PASSENGER GRIPS

leasing retaining tabs.
Passenger Grips Removal
For models with heated passenger grips, refer to
ACCESSORIES for procedures.
1. Remove retaining screw securing passenger
grips and remove passenger grips.
vmr2012-043-005_a
TYPICAL
1. Front fender retaining tabs
9. Detach rear fender from footrest panel by relea-

sing retaining tabs.
vsi2013-001-012_a
REAR GRIP SCREWS.
Passenger Grips Installation

Installation is the reverse of removal. However
TIGHTENING TORQUE
Passenger grips 25 N•m ± 3 N•m
retaining screw (18 lbf•ft ± 2 lbf•ft)
RACK (FRONT AND REAR)

Front Rack Removal
1. Remove retaining bolts securing rack assembly
vmr2012-043-019_a
TYPICAL
to frame.
1. Rear fender retaining tabs NOTE: A small wrench will be needed to remove
10. Remove footrest panel from vehicle. the retaining screw located between the rack sup-
port and fender.
Footrest Panel Installation
Tighten footrest panel screws to specification.
TIGHTENING TORQUE
Footrest panel retaining 4.5 N•m ± 0.5 N•m
panel to fenders (40 lbf•in ± 4 lbf•in)
219100883-011 23
vmr2013-045-020_a
TYPICAL - PARTS REMOVED FOR CLARITY vmr2013-045-021_a

1. Retaining bolts locations TYPICAL - LH SIDE OF ASSEMBLY SHOWN ON VEHICLE FOR
CLARITY
2. Remove rack assembly from vehicle. 1. Retaining bolt securing rack support to rail
3. Remove the 4 retaining screws securing rack 6. Remove retaining screws securing rack to rails.
moulding to rack assembly.
4. Remove both retaining screws securing rack Front Rack Installation
moulding to rack supports. The installation is the reverse of the removal pro-
TIGHTENING TORQUE
Screws and nuts 4.5 N•m ± 0.5 N•m
securing front rack to rail (40 lbf•in ± 4 lbf•in)
Bolts securing front rack 4.5 N•m ± 0.5 N•m
assembly to frame (40 lbf•in ± 4 lbf•in)
Retaining screws
1.6 N•m ± 0.4 N•m
securing fender to front
rack assembly
Screws securing rack
4.5 N•m ± 0.5 N•m
moulding to rack
vmr2013-045-022_a assembly
TYPICAL - LH SIDE OF ASSEMBLY SHOWN ON VEHICLE FOR
CLARITY
1. LH side retaining screws securing rack moulding to rack
assembly
Rear Rack Removal
2. LH side retaining screw securing rack moulding to rack support 1. Remove retaining bolts and nuts securing rack
assembly to frame.
5. Remove both retaining bolts securing rack sup-
ports to rails.
24 219100883-011
vmr2012-043-030_a
vmr2013-045-011_a TYPICAL
1. Retaining nuts and bolts securing rack to frame
2. Frame 3. Install a new rear storage compartment cover
3. Rack assembly
as the reverse of removal.
2. Remove rack from vehicle.
Rear Storage Compartment
3. Remove retaining screws securing rack to rail.
Rear storage Compartment Removal
Rear Rack Installation 1. Remove rear body module. Refer to REAR
The installation is the reverse of the removal pro- BODY MODULE.
cedure. However, pay attention to the following. 2. Remove rear rack. Refer to REAR RACK RE-
TIGHTENING TORQUE MOVAL.
Screws and nuts 4.5 N•m ± 0.5 N•m 3. Remove rear storage compartment cover.
securing rear rack to rail (40 lbf•in ± 4 lbf•in) Refer to REAR STORAGE COMPARTMENT
COVER.
Screws an nuts securing
4.5 N•m ± 0.5 N•m 4. Remove retaining screws securing bottom of
rear rack assembly
(40 lbf•in ± 4 lbf•in) RH rear storage compartment support.
to frame

COVER
Rear Storage Compartment Cover
Replacement
1. Open rear storage compartment cover.
2. Push rear storage compartment cover forward
to release it from hinges.
vmr2013-045-028_a
1. Retaining screws securing bottom of RH rear storage

compartment support
5. Remove retaining screws securing RH rear

storage compartment support to RH support.
6. Remove retaining screw securing RH fender to
rear storage compartment.
219100883-011 25
7. Remove retaining screw securing RH rear stor-

age compartment support to rear storage com-
partment.
vmr2013-045-030_a
1. Retaining screw securing LH rear storage compartment support

to rear storage compartment
2. Retaining screw securing LH support and LH rear storage
compartment support to rear storage compartment
vmr2013-045-031_a
1. Retaining screws securing RH rear storage compartment 12. Remove both retaining screws securing LH
support to RH support
2. Retaining screw securing RH fender to rear storage fender to rear storage compartment.
compartment
3. Retaining screw securing RH rear storage compartment support
to rear storage compartment
8. Remove RH rear storage compartment sup-

port.
9. Remove retaining screw securing top of RH
fender to top of rear storage compartment.
vmr2013-045-027_a
1. Retaining screws securing LH fender to rear storage

compartment
13. Remove rear storage compartment.

Rear Storage Compartment Installation
Installation is the reverse of removal. However
vmr2013-045-029_a
1. Retaining screw securing top of RH fender to top of rear storage
compartment TIGHTENING TORQUE
10. Remove retaining screw securing LH rear 4.5 N•m ± 0.5 N•m
storage compartment support to rear storage (40 lbf•in ± 4 lbf•in)
compartment. Rear storage
10 N•m ± 2 N•m
11. Remove retaining screw securing LH support compartment retaining
and LH rear storage compartment support to screws
rear storage compartment.
26 219100883-011
Subsection XX (FRAME)
FRAME
BLIND THREADED INSERT INSTALLER....................................... model 9600 ........................................... 3
vmr2013-047 1
Max 24.5 ± 3.5 N•m

24
Models (18 ± 3 lbf•ft)
Rear frame 24.5 ± 3.5 N•m

extension (18 ± 3 lbf•ft)
24.5 ± 3.5 N•m 61 ± 9 N•m

(18 ± 3 lbf•ft)
(45 ± 7 lbf•ft)
61 ± 9 N•m
(45 ± 7 lbf•ft)
Upper frame
support (welded)
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
31.5 ± 3.5 N•m

(23 ± 3 lbf•ft)
Lower frame
support
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
31.5 ± 3.5 N•m Footrest bracket

Outlander (23 ± 3 lbf•ft)
series
Trailer hitch
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
Final drive protector
Renegade
series
Front bumper
support
vmr2013-047-001
2 vmr2013-047
PROCEDURES Frame Replacement

Blind threaded inserts are not installed on replace-
FRAME ment frames. Make sure to order enough inserts
when replacing frame. Refer to ELECTRONIC
Frame Inspection PARTS CATALOG.
Check frame for bending, cracks, weld damages
or any other damage. Replace frame as neces-
sary.
Frame Welding
No welding should be done on frame except if
mentioned or required on an approved BRP Bul-
letin.
Frame Insert Replacement

To install a new blind threaded insert, use the fol-
lowing tool: BLIND THREADED INSERT INSTALLER
(P/N MODEL 9600) from Textron. See their web
site at: www.textronfasteningsystems.com.
tmr2011-039-004
After insert installation, ensure insert can hold the

torque applied to the screw it retains and measure
the compressed length of the frame insert. Oth-
erwise, install a new insert.
COMPRESSED
INSERT
LENGTH
9 mm ± 0.5 mm
Insert for M6 bolt
(.354 in ± .02 in)
11.5 mm ± 0.5 mm
Insert for M8 bolt
(.453 in ± .02 in)
vmr2012-044-002_a
INSERT FOR M6 BOLT SHOWN

A. 9 mm ± 0.5 mm (.354 in ± .02 in)
vmr2013-047 3
Subsection XX (ENGINE 570)
ENGINE 570
ENGINE
ROTAX® 570, 4-stroke, 2 cylinders
Engine type
(V-twin), liquid cooled
4 valves/cylinder (mechanical
Valve train adjustment), single over head
camshaft (SOHC) with timing chain
Bore 84 mm (3.31 in)
Stroke 51.4 mm (2.02 in)
Displacement 570 cm³ (34.8 in³)
Compression ratio 10.6:1
Maximum HP RPM 8000 RPM
Spark arrestor approved by USDA
Exhaust system
Forest Service
Air filter Synthetic paper filter with foam
Intake valve opening 3° BTDC
Intake valve closing 34 ABDC
Exhaust valve opening 39° BBDC
Exhaust valve closing 2° BTDC
0.06 mm to 0.14 mm
Intake
(.0024 in to .0055 in)
Valve clearance
0.11 mm to 0.19 mm
Exhaust
(.0043 in to .0075 in)
4.966 mm to 4.980 mm
New
Intake (.1955 in to .1961 in)
Valve stem diameter
4.956 mm to 4.970 mm
New
Intake and New 0.005 mm (.0002 in)

Valve out of round
exhaust Service limit 0.06 mm (.0024 in)
4.998 mm to 5.018 mm
New
Valve guide diameter (.1968 in to .1976 in)
New 40.81 mm (1.607 in)
Valve spring free length
1.05 mm to 1.35 mm
New
Valve seat contact width
1.25 mm to 1.55 mm
New
Service limit 2 mm (.079 in)
vmr2017-119 1
ENGINE
12.036 mm to 12.050 mm
New
Rocker arm bore diameter (.4739 in to .4744 in)
12.000 mm to 12.018 mm
New
Rocker arm shaft diameter (.4724 in to .4731 in)
83.950 mm to 83.966 mm
New
Piston diameter (3.3051 in to 3.3057 in)
0.057 mm to 0.087 mm
New
Piston/cylinder clearance (.0022 in to .0034 in)
1st Upper compression ring, rectangular
Piston ring type 2nd Lower compression ring, tapered face
3rd Oil scraper ring
0.10 mm to 0.30 mm
New
Rectangular (.004 in to .012 in)
0.35 mm to 0.55 mm
New
Ring end gap Tapered face (.014 in to .022 in)
0.20 mm to 0.70 mm
New
Oil scraper ring (.008 in to .028 in)
0.025 mm to 0.070 mm
New
0.020 mm to 0.060 mm
New
Ring/piston groove clearance Tapered face (.0008 in to .0024 in)
0.010 mm to 0.180 mm
New
84.023 mm to 84.037 mm
Cylinder bore New
(3.308 in to 3.3085 in)
Maximum
0.038 mm (.0015 in)
Cylinder taper new
Maximum
0.015 mm (.0006 in)
Cylinder out of round new
2 vmr2017-119
ENGINE
34.959 mm to 34.975 mm
Timing chain New
(1.3763 in to 1.377 in)
side
Camshaft main bearing journal
21.959 mm to 21.980 mm
Spark plug New
(.8645 in to .8654 in)
side
35.000 mm to 35.025 mm
Timing chain New
(1.378 in to 1.3789 in)
side
Camshaft main bearing journal bore
22.000 mm to 22.021 mm
Spark plug New
(.8661 in to .867 in)
side
Wear limit 22.040 mm (.8677 in)
31.830 mm to 32.030 mm
New
Intake valve (1.2531 in to 1.261 in)
Camshaft lobe
31.730 mm to 31.930 mm
New
Exhaust valve (1.2492 in to 1.2571 in)
42.016 mm to 42.040 mm
Crankshaft main bearing journal diameter New
(1.6542 in to 1.6551 in)
(MAG/PTO side)
Crankshaft radial play (MAG/PTO side) Service limit 0.07 mm (.0028 in)
34.004 mm to 34.020 mm
New
Crankshaft bearing journal diameter (in PTO cover) (1.3387 in to 1.3394 in)
Crankshaft radial play (PTO cover bearing) Service limit 0.10 mm (.0039 in)
0.200 mm to 0.500 mm
New
Crankshaft axial play (.0079 in to .0197 in)
40.001 mm to 40.025 mm
New
Crankshaft pin diameter (1.5748 in to 1.5758 in)
MAG/PTO
Crankshaft deflection New 0.050 mm (.002 in)
side
MAG/PTO
Crankcase plain bearing Service limit 42.100 mm (1.6575 in)
side
PTO cover plain bearing Service limit 34.120 mm (1.3433 in)
Connecting rod big end diameter Service limit 40.100 mm (1.5787 in)
Connecting rod big end radial play Service limit 0.09 mm (.0035 in)
0.200 mm to 0.500 mm
New
Connecting rod big end axial play (.008 in to .02 in)
vmr2017-119 3
ENGINE
20.010 mm to 20.020 mm
New
Connecting rod small end diameter (.7878 in to .7882 in)
19.996 mm to 20.000 mm
New
Piston pin diameter (.7872 in to .7874 in)
Connecting rod/piston pin clearance (radial play) Service limit 0.080 mm (.0031 in)
LUBRICATION SYSTEM
Wet sump. Replaceable cartridge
Type
oil filter
Oil filter Replaceable cartridge
Engine oil pressure Minimum 300 kPa (44 PSI) at 6000 RPM
Capacity (oil change with
2.0 L (2.1 qt (U.S. liq.))
filter)
For the summer season,
use XPS 4-stroke synth.
Engine oil blend oil (P/N 293 600 121).
For the all seasons, use XPS 4-stroke
Recommended
synthetic oil (P/N 293 600 112).
If not available, use a 5W40 motor oil
that meets the requirements for API
service classification SG, SH or SJ
COOLING SYSTEM
Finland,
Use Long life antifreeze (P/N 619
Norway and
590 204)
Sweden
All other Use long life antifreeze (P/N 219
Type countries 702 685)
Coolant
Coolant specifically designed
Alternative,
for aluminum engines
or if not
Ethyl glycol/distilled water mix
available
(50%/50%).
Capacity 3.4 L (.9 U.S. gal.)
Starts to
65°C (149°F)
Thermostat open
Fully open 75°C (167°F)
TRANSMISSION
CVT (Continuously Variable
Type
Transmission)
Engagement RPM 1800 RPM
Drive belt width Service limit 30.00 mm (1.181 in)
13.80 mm to 14.00 mm
New
Governor cup roller outer diameter (.543 in to .551 in)
4 vmr2017-119
TRANSMISSION
8.025 mm to 8.175 mm
New
Governor cup roller inner diameter (.316 in to .322 in)
6.078 mm to 6.100 mm
New
Centrifugal lever pivot bolt diameter (.239 in to .24 in)
6.035 mm to 6.078 mm
New
Centrifugal lever bore diameter (.2376 in to .2393 in)
6.113 mm to 6.171 mm
Drive pulley sliding half centrifugal lever pivot bolt bore New
(.241 in to .243 in)
diameter
55.000 mm to 55.040 mm
New
Drive pulley sliding half large bushing (2.165 in to 2.167 in)
32.000 mm to 32.040 mm
New
Drive pulley sliding half small bushing (1.26 in to 1.261 in)
Drive pulley spring free length Service limit 85 mm (3.35 in)
Drive pulley spring free squareness Service limit 4 mm (.157 in)
New 9.2 mm to 9.4 mm (.362 in to .37 in)
Spring sleeve length
30.060 mm to 30.100 mm
New
Driven pulley sliding half bushing (1.183 in to 1.185 in)
30.060 mm to 30.100 mm
New
Driven pulley sliding fixed bushing (1.183 in to 1.185 in)
Torque gear on driven pulley Service limit 7.500 mm (.295 in)
Driven pulley spring free length Service limit 125 mm (4.92 in)
Driven pulley spring free squareness Service limit 3.8 mm (.15 in)
Cam width in top surface Service limit 4.50 mm (.177 in)
vmr2017-119 5
GEARBOX
Dual range (HI-LO) with park,
Type
neutral and reverse
Angle drive
37/15 = 2.467
sub-transmission
Intermediate 45/40 = 1.125
PRO
High 36/27 = 1.33
Low 46/17 = 2.706

Gear ratios Reverse 34/12 = 2.833
Angle drive
32/13 = 2.462
sub-transmission
All other High 38/28 = 1.357

Low 46/20 = 2.300
Reverse 31/14 = 2.214
High 3.700
PRO Low 7.509
Reverse 7.863
Overall gear ratio
High 3.341
All other Low 5.662
Reverse 5,451
Capacity Approximately 450 ml (15.2 U.S. oz)
Gearbox oil XPS synthetic gear oil (75W 140)
Recommended (P/N 293 600 140) or a 75W140
API GL-5 synthetic gear oil
0.10 mm to 0.20 mm
New
Output shaft backlash (.004 in to .008 in)
5.25 mm to 5.35 mm
New
Coupling sleeve groove width (.207 in to .211 in)
4.95 mm to 5.05 mm
New
Coupling fork claw thickness (.195 in to .199 in)
4.80 mm to 4.90 mm
Shift fork claw thickness New
(.189 in to .193 in)
(high gear shift fork)
5.10 mm to 5.20 mm
(.201 in to .205 in)
(low and reverse gear shift fork)
6.92 mm to 6.97 mm
New
Shift fork pin diameter (.272 in to .274 in)
6 vmr2017-119
GEARBOX
5.30 mm to 5.40 mm
Width of shift fork engagement groove New
(.209 in to .213 in)
(low and reverse gear)
5.00 mm to 5.10 mm
(.197 in to .201 in)
(high gear)
29.000 mm to 29.013 mm
New
Diameter free pinions (1.1417 in to 1.1422 in)
24.979 mm to 25.000 mm
New
Intermediate gear shaft (.9834 in to .9843 in)
New N.A.
MAG side
New N.A.
Countershaft CVT side
Free New N.A.
pinion
bearing Service limit 24.970 mm (.9831 in)
Free
Bevel gear shaft pinion Service limit 24.984 mm (.9836 in)
bearing
ELECTRICAL SYSTEM
Without
400 W @ 6000 RPM
DPS
Magneto generator output
With DPS 500 W @ 6000 RPM
CE version 500 W @ 6000 RPM
Stator resistance (20°C (68°F)) 0.15 to 0.30
Ignition system type IDI (Inductive Discharge Ignition)
Ignition timing Not adjustable
Quantity 2
Make and
Spark plug NGK DCPR8E
type
Gap 0.7 mm to 0.8 mm (.028 in to .031 in)
Forward 8000 RPM
Engine RPM limiter setting
Reverse 15 km/h (9 MPH) without Override)
FUEL SYSTEM
Electronic Fuel Injection (EFI), 46 mm
Fuel delivery
throttle body, 1 injector per cylinder
Idle speed 1400 ± 50 (not adjustable)
vmr2017-119 7
ENGINE 650
ENGINE
ROTAX 660, 4-stroke, 2 cylinders
Engine type
Exhaust system
Forest Service
Intake valve closing 45° ABDC
Exhaust valve closing 0° ATDC
0.06 mm to 0.14 mm
Valve clearance Intake
(.0024 in to .0055 in)
0.11 mm to 0.19 mm
Exhaust
(.0043 in to .0075 in)
4.966 mm to 4.980 mm
New
Valve stem diameter
4.956 mm to 4.970 mm
New
New 0.005 mm (.0002 in)
Valve out of round Intake and Exhaust
4.998 mm to 5.018 mm
New
Valve guide diameter Intake and Exhaust (.1968 in to .1976 in)
New 40.81 mm (1.607 in)
1.05 mm to 1.35 mm
New
1.25 mm to 1.55 mm
New
12.036 mm to 12.050 mm
New
12.000 mm to 12.018 mm
New
vmr2017-120 1
ENGINE
81.950 mm to 81.966 mm
New
0.057 mm to 0.087 mm
New
Lower compression ring,
Piston ring type 2nd
tapered face
0.20 mm to 0.40 mm
New
0.20 mm to 0.40 mm
New
0.20 mm to 0.70 mm
New
0.03 mm to 0.07 mm
New
0.02 mm to 0.06 mm
Ring/piston groove New
Tapered face (.0008 in to .0024 in)
clearance
0.01 mm to 0.18 mm
New
82.023 mm to 82.037 mm
Cylinder bore New
(3.2293 in to 3.2298 in)
Maximum New 0.038 mm (.0015 in)
Cylinder taper
Cylinder out of round
34.959 mm to 34.975 mm
Timing New
(1.3763 in to 1.377 in)
chain side
21.959 mm to 21.980 mm
Spark New
(.8645 in to .8654 in)
plug side
35.000 mm to 35.025 mm
Timing New
(1.378 in to 1.3789 in)
chain side
22.000 mm to 22.021 mm
Spark New
(.8661 in to .867 in)
plug side
2 vmr2017-120
ENGINE
32.110 mm to 32.310 mm
Intake New
(1.2642 in to 1.272 in)
valve
Camshaft lobe
31.940 mm to 32.140 mm
Exhaust New
(1.257 in to 1.265 in)
valve
42.016 mm to 42.040 mm
New
Crankshaft main bearing journal diameter (MAG/PTO side) (1.6542 in to 1.6551 in)
34.004 mm to 34.020 mm
New
0.200 mm to 0.500 mm
New
40.001 mm to 40.025 mm
New
MAG/PTO
side
MAG/PTO
side
0.200 mm to 0.500 mm
New
20.010 mm to 20.020 mm
New
19.996 mm to 20.000 mm
New
LUBRICATION SYSTEM
Type
oil filter
Oil filter BRP Rotax paper type, replaceable
vmr2017-120 3
LUBRICATION SYSTEM
2.0 L (2.1 qt (U.S. liq.))
filter)
blend oil (P/N 293 600 121).
Engine oil For the winter season,
Recommended use XPS 4-stroke synthetic
oil (P/N 293 600 112).
COOLING SYSTEM
Ethyl glycol/water mix (50% coolant,
50% water). Use BRP Long life
Type
Coolant antifreeze or coolant specifically
designed for aluminum engines
Starts to open 65°C (149°F)
Thermostat
TRANSMISSION
CVT (Continuously
Variable Transmission),
Type
sub-transmission with L/H/N/R/P,
standard engine braking
Engagement RPM 1650 ± 100 RPM
13.80 mm to 14.00 mm
New
8.025 mm to 8.175 mm
New
6.078 mm to 6.100 mm
New
6.035 mm to 6.078 mm
New
6.113 mm to 6.171 mm
(.241 in to .243 in)
diameter
55.000 mm to 55.040 mm
New
32.000 mm to 32.040 mm
New
4 vmr2017-120
TRANSMISSION
30.060 mm to 30.100 mm
New
30.060 mm to 30.100 mm
New
Cam width on top surface Service limit 4.5 mm (.177 in)
Driven pulley sliding sheave - wear on cam contact
surface
Driven pulley spring free length 125 mm (4.921 in)
GEARBOX WITH EXTERNAL SWITCHES

Type
neutral and reverse
Angle drive
32/13 = 2.462
sub-transmission
Gear ratios High 35/28 = 1.250
Low 46/20 = 2.300
Reverse 31/14 = 2.214
High 3,078
Overall gear ratios Low 5.662
Reverse 5.451
Capacity 400 ml (13.5 U.S. oz)
XPS synthetic gear oil (75W
Gearbox oil 140) (P/N 293 600 140)
Recommended
or a 75W140 API GL-5
synthetic gear oil
0.10 mm to 0.20 mm
New
5.25 mm to 5.35 mm
New
4.95 mm to 5.05 mm
New
4.80 mm to 4.90 mm
(.189 in to .193 in)
5.10 mm to 5.20 mm
(.201 in to .205 in)
6.92 mm to 6.97 mm
New
vmr2017-120 5

5.30 mm to 5.40 mm
(.209 in to .213 in)
5.00 mm to 5.10 mm
(.197 in to .201 in)
(high gear)
29.000 mm to 29.013 mm
New
24.979 mm to 25.000 mm
New
MAG New N.A.
side Service limit 17.990 mm (.7083 in)
New N.A.
Free New N.A.
pinion
Free
bearing
GEARBOX WITH GBPS

Type
neutral and reverse
Angle drive
37/15 = 2.467
sub-transmission
Low 46/17 = 2.706
Reverse 34/12 = 2.833
High 3.700
Reverse 7.863
Gearbox oil 140) (P/N 293 600 140)
Recommended
synthetic gear oil
5.25 mm to 5.35 mm
New
4.95 mm to 5.05 mm
New
5.10 mm to 5.20 mm
(.201 in to .205 in)
6 vmr2017-120
GEARBOX WITH GBPS

5.10 mm to 5.20 mm
(.201 in to .205 in)
5.30 mm to 5.40 mm
(.209 in to .213 in)
5.30 mm to 5.40 mm
(.209 in to .213 in)
(high gear)
29.000 mm to 29.013 mm
New
24.979 mm to 25.000 mm
New
19.977 mm to 19.990 mm
MAG New
(.7865 in to .787 in)
side
Countershaft
24.977 mm to 24.990 mm
New
CVT side (.9833 in to .9839 in)
Free 24.987 mm to 25.000 mm
New
pinion (.9837 in to .9843 in)
Main shaft Bearing 16.980 mm to 16.991 mm
New
journal (.6685 in to .6689 in)
MAG/CVT
ELECTRICAL SYSTEM
Without DPS 400 W @ 6000 RPM
Quantity 2
Spark plug Make and type NGK DCPR8E

0.7 mm to 0.8 mm
Gap
(.028 in to .031 in)
Forward 8000 RPM
Reverse 15 km/h (9 MPH) (without override)
FUEL SYSTEM
Fuel delivery
Idle speed 1250 RPM ± 50 (not adjustable)
vmr2017-120 7
ENGINE 850
ENGINE
ROTAX 850, 4-stroke, 2 cylinders
Engine type
Bore 94 mm (3.7 in)
Exhaust system
Forest Service
0.06 mm to 0.14 mm
Intake
(.0024 in to .0055 in)
Valve clearance
0.11 mm to 0.19 mm
Exhaust
(.0043 in to .0075 in)
5.472 mm to 5.486 mm
New
Valve stem diameter
5.461 mm to 5.476 mm
New
New 0.005 mm (.0002 in)
5.506 mm to 5.518 mm
New
New 40.41 mm (1.591 in)
1.05 mm to 1.35 mm
New
1.25 mm to 1.55 mm
New
12.036 mm to 12.050 mm
New
12.000 mm to 12.018 mm
New
vmr2017-121 1
ENGINE
93.950 mm to 93.966 mm
New
0.027 mm to 0.057 mm
New
Lower compression ring,
Piston ring type 2nd
tapered face
0.20 mm to 0.35 mm
New
0.35 mm to 0.55 mm
New
0.20 mm to 0.70 mm
New
0.03 mm to 0.07 mm
New
0.02 mm to 0.06 mm
Ring/piston groove New
Tapered face (.0008 in to .0024 in)
clearance
0.01 mm to 0.18 mm
New
93.993 mm to 94.007 mm
Cylinder bore New
(3.7005 in to 3.7011 in)
Cylinder taper
34.959 mm to 34.975 mm
Timing New
(1.3763 in to 1.377 in)
chain side
21.959 mm to 21.980 mm
Spark New
(.8645 in to .8654 in)
plug side
35.000 mm to 35.025 mm
Timing New
(1.378 in to 1.3789 in)
chain side
22.000 mm to 22.021 mm
Spark New
(.8661 in to .867 in)
plug side
2 vmr2017-121
ENGINE
32.890 mm to 33.090 mm
Intake New
(1.2949 in to 1.3028 in)
valve
Camshaft lobe
32.950 mm to 33.150 mm
Exhaust New
(1.2972 in to 1.3051 in)
valve
42.016 mm to 42.040 mm
New
34.004 mm to 34.020 mm
New
0.200 mm to 0.500 mm
New
40.001 mm to 40.025 mm
New
MAG/PTO
side
MAG/PTO
side
0.200 mm to 0.500 mm
New
20.010 mm to 20.020 mm
New
19.996 mm to 20.000 mm
New
LUBRICATION SYSTEM
Type
oil filter
vmr2017-121 3
LUBRICATION SYSTEM
2.0 L (2.1 qt (U.S. liq.))
filter)
blend oil (P/N 293 600 121).
Engine oil For the winter season,
Recommended use XPS 4-stroke synthetic
oil (P/N 293 600 112).
COOLING SYSTEM
50% water). Use BRP Long life
Type
Coolant antifreeze or coolant specifically
designed for aluminum engines
Starts to open 65°C (149°F)
Thermostat
Radiator cap opening pressure 110 kPa (16 PSI)
TRANSMISSION
CVT (Continuously
Variable Transmission),
Type
sub-transmission with L/H/N/R/P,
13.80 mm to 14.00 mm
New
8.025 mm to 8.175 mm
New
6.078 mm to 6.100 mm
New
6.035 mm to 6.078 mm
New
6.113 mm to 6.171 mm
(.241 in to .243 in)
diameter
55.000 mm to 55.040 mm
New
32.000 mm to 32.040 mm
New
4 vmr2017-121
TRANSMISSION
30.060 mm to 30.100 mm
New
30.060 mm to 30.100 mm
New
Driven pulley sliding sheave - wear on cam contact
surface

Type
neutral and reverse
Angle drive
32/13 = 2.462
sub-transmission
Low 46/20 = 2.300
Reverse 31/14 = 2.214
High 2,886
Reverse 5.451
Gearbox oil 140) (P/N 293 600 140)
Recommended
synthetic gear oil
0.10 mm to 0.20 mm
New
5.25 mm to 5.35 mm
New
4.95 mm to 5.05 mm
New
4.80 mm to 4.90 mm
(.189 in to .193 in)
5.10 mm to 5.20 mm
(.201 in to .205 in)
vmr2017-121 5

6.92 mm to 6.97 mm
New
5.30 mm to 5.40 mm
(.209 in to .213 in)
5.00 mm to 5.10 mm
(.197 in to .201 in)
(high gear)
29.000 mm to 29.013 mm
New
24.979 mm to 25.000 mm
New
MAG New N.A.
New N.A.
Free New N.A.
pinion
Free
bearing
GEARBOX WITH GBPS

Type
neutral and reverse
Angle drive
37/15 = 2.467
sub-transmission
Low 46/17 = 2.706
Reverse 34/12 = 2.833
High 3.700
Reverse 7.863
Gearbox oil 140) (P/N 293 600 140)
Recommended
synthetic gear oil
5.25 mm to 5.35 mm
New
4.95 mm to 5.05 mm
New
6 vmr2017-121
GEARBOX WITH GBPS

5.10 mm to 5.20 mm
(.201 in to .205 in)
5.10 mm to 5.20 mm
(.201 in to .205 in)
5.30 mm to 5.40 mm
(.209 in to .213 in)
5.30 mm to 5.40 mm
(.209 in to .213 in)
(high gear)
29.000 mm to 29.013 mm
New
24.979 mm to 25.000 mm
New
19.977 mm to 19.990 mm
MAG New
(.7865 in to .787 in)
side
Countershaft
24.977 mm to 24.990 mm
New
Free 24.987 mm to 25.000 mm
New
pinion (.9837 in to .9843 in)
Main shaft Bearing 16.980 mm to 16.991 mm
New
MAG/CVT
ELECTRICAL SYSTEM
Quantity 2
Spark plug Make and type NGK LMAR8D-J
0.7 mm to 0.9 mm
Gap
(.028 in to .035 in)
Forward 8000 RPM
FUEL SYSTEM
Fuel delivery
vmr2017-121 7
Subsection XX (ENGINE 1000R)
ENGINE 1000R
ENGINE
ROTAX 1010HO, 4-stroke, 2 cylinders
Engine type
4 valves/cylinder (mechanical adjustment),
Valve train single over head camshaft (SOHC)
with timing chain
Stroke 75 mm (2.95 in)
Exhaust system
Forest Service
Intake 0.06 mm to 0.14 mm (.0024 in to .0055 in)
Valve clearance
Exhaust 0.11 mm to 0.19 mm (.0043 in to .0075 in)
Intake
Valve stem diameter
Exhaust
New 0.005 mm (.0002 in)
5.506 mm to 5.518 mm
New
New 40.41 mm (1.591 in)
Intake
Exhaust
12.036 mm to 12.050 mm
New
vmr2017-123 1
ENGINE
12.000 mm to 12.018 mm
New
90.950 mm to 90.966 mm
New
0.027 mm to 0.057 mm
New
Piston ring type 2nd Lower compression ring, tapered face
Rectangular
Ring end gap Tapered face
Oil scraper ring
Rectangular
Ring/piston groove clearance Tapered face
Oil scraper ring
90.993 mm to 91.007 mm
Cylinder bore New
(3.5824 in to 3.583 in)
Cylinder taper
34.959 mm to 34.975 mm
Timing New
(1.3763 in to 1.377 in)
chain side
21.959 mm to 21.980 mm
Spark plug New
(.8645 in to .8654 in)
side
2 vmr2017-123
ENGINE
35.000 mm to 35.025 mm
Timing New
(1.378 in to 1.3789 in)
chain side
22.000 mm to 22.021 mm
Spark plug New
(.8661 in to .867 in)
side
32.960 mm to 33.160 mm
Intake New
(1.2976 in to 1.3055 in)
valve
Camshaft lobe
32.860 mm to 33.060 mm
Exhaust New
(1.2937 in to 1.3016 in)
valve
42.016 mm to 42.040 mm
New
34.004 mm to 34.020 mm
New
0.200 mm to 0.500 mm
New
41.986 mm to 42.010 mm
New
MAG/PTO
side
MAG/PTO
side
0.250 mm to 0.550 mm
New
22.010 mm to 22.020 mm
New
vmr2017-123 3
ENGINE
21.996 mm to 22.000 mm
New
LUBRICATION SYSTEM
Type Wet sump. Replaceable cartridge oil filter
Capacity (oil change with filter) 2.0 L (2.1 qt (U.S. liq.))
For the summer season, use XPS 4-stroke
synth. blend oil (P/N 293 600 121).
Engine oil For the winter season, use XPS 4-stroke
Recommended synthetic oil (P/N 293 600 112).
COOLING SYSTEM
Ethyl glycol/water mix (50% coolant, 50%
water). Use BRP Long life antifreeze
Type
Coolant or coolant specifically designed for
aluminum engines
TRANSMISSION
CVT (Continuously Variable Transmission),
Type sub-transmission with L/H/N/R/P,
Governor cup roller outer diameter
Governor cup roller inner diameter
Centrifugal lever pivot bolt diameter
6.035 mm to 6.078 mm
New
Drive pulley sliding half centrifugal lever pivot bolt bore diameter
4 vmr2017-123
TRANSMISSION
55.000 mm to 55.040 mm
New
32.000 mm to 32.040 mm
New
30.060 mm to 30.100 mm
New
30.060 mm to 30.100 mm
New
Driven pulley sliding sheave - wear on cam contact surface Service limit 1.0 mm (.039 in)

Dual range (HI-LO) with park, neutral
Type
and reverse
Angle drive
32/13 = 2.462
sub-transmission

Low 46/20 = 2.300
Reverse 31/14 = 2.214
High 2,886
Reverse 5.451
Recommended (P/N 293 600 140) or a 75W140 API GL-5
synthetic gear oil
Output shaft backlash
Coupling sleeve groove width
vmr2017-123 5

Coupling fork claw thickness
Shift fork claw thickness New 4.80 mm to 4.90 mm (.189 in to .193 in)
(high gear shift fork) Service limit 4.70 mm (.185 in)
(low and reverse gear shift fork) Service limit 5.0 mm (.197 in)
Shift fork pin diameter
Width of shift fork engagement groove New 5.30 mm to 5.40 mm (.209 in to .213 in)
(low and reverse gear) Service limit 5.50 mm (.217 in)
(high gear) Service limit 5.20 mm (.205 in)
29.000 mm to 29.013 mm
New
24.979 mm to 25.000 mm
New
New N.A.
MAG side
New N.A.
Free pinion New N.A.

Free pinion
Bevel gear shaft Service limit 24.984 mm (.9836 in)
bearing
GEARBOX WITH GBPS

Dual range (HI-LO) with park, neutral
Type
and reverse
Angle drive
37/15 = 2.467
sub-transmission
Gear ratios
High 36/27 = 1.333
Low 46/17 = 2.706
Reverse 34/12 = 2.833
High 3.700
Reverse 7.863
6 vmr2017-123
GEARBOX WITH GBPS

Recommended (P/N 293 600 140) or a 75W140 API GL-5
synthetic gear oil
Coupling sleeve groove width
Coupling fork claw thickness
(high gear shift fork) Service limit 5.0 mm (.197 in)
(low and reverse gear shift fork) Service limit 5.0 mm (.197 in)
(low and reverse gear) Service limit 5.50 mm (.217 in)
(high gear) Service limit 5.50 mm (.217 in)
29.000 mm to 29.013 mm
New
24.979 mm to 25.000 mm
New
19.977 mm to 19.990 mm
New
MAG side (.7865 in to .787 in)
Countershaft
24.977 mm to 24.990 mm
New
24.987 mm to 25.000 mm
Free pinion New
(.9837 in to .9843 in)
bearing
Main shaft
Bearing 16.980 mm to 16.991 mm
New
MAG/CVT
ELECTRICAL SYSTEM
vmr2017-123 7
ELECTRICAL SYSTEM
Quantity 2
Spark plug Make and type NGK LMAR8D-J
Forward 8000 RPM
FUEL SYSTEM
Fuel delivery
8 vmr2017-123
Subsection XX (OUTLANDER)
OUTLANDER
COOLING SYSTEM
Ethyl glycol and distilled
water (50%/50%).
Use BRP LONG LIFE
ANTIFREEZE (P/N 219
Type 702 685) or (P/N 619 590
204) (Finland, Norway
and Sweden) or coolant
Coolant specifically formulated for
aluminum engines
450 2.9 L (.77 U.S. gal.)
570
3.4 L (.9 U.S. gal.)
Quantity 650
850
3.5 L (.92 U.S. gal.)
1000R
EXHAUST SYSTEM
Spark arrestor approved by
Exhaust system
USDA Forest Service
ELECTRICAL SYSTEM (650 / 850 / 1000R)

Type Maintenance free
Voltage 12 volts
Battery
Nominal rating 18 A•h
Power starter output 0.7 KW
High 2 x 60 W (HB3)
Headlight
Low 2 x 55 W (H1)
Taillight 2 X 5/21 W
Turn signal lights (CE models only) 4 x 10 W
Position lights (CE models only) 2 x 5 W
Licence plate light (CE models only) 1 x 10 W
Main FL-1 16 gauge
Fusible links Fan
FL-2 16 gauge
Main accessories power
vmr2017-124 1
ELECTRICAL SYSTEM (650 / 850 / 1000R)

Accessory relay control
Brake lights relay control
Communication connector
F4 5 A
Gauge
Brake relay
DPS control
Ignition coils
Fuel injectors F5 5 A
Vehicle speed sensor
Engine control module power (ECM)
F6 5 A
Fan relay control
Position lights (Europe)
Winch control F7 5 A
2W/4W control
ECM (wake up signal)
Fuses F8 5 A
Ignition switch
(fuse box 1)
Fan motor F9 25 A
Clock
Hazard lights
F10 5 A
Hazard/Signal lights/Horn
(Europe)
Headlights power F11 30 A
Connector DC3
12 V power outlet
F12 15 A
Communication connector
(DB6)
Connectors DC5 and DC6
Taillights F14 15 A
License plate light
Fuel pump relay F15 5 A
Fuse in fuse box 2 DPS / ACS F3 40 A
ELECTRICAL SYSTEM (450 / 570)

Voltage 12 volts
Battery
Headlight High / Low HS1 35 W
Taillight 5/21 W
Turn signal lights (CE models only) 4 x 10 W
Position lights (CE models only) 2 x 5 W
Licence plate light (CE models only) 1 x 10 W

Main FL-1 16 gauge
Fusible links Fan
FL-2 16 gauge
Main accessories power
2 vmr2017-124
ELECTRICAL SYSTEM (450 / 570)

Gauge
F4 10 A
Diagnostic connector
Injectors/Ignition,
ECM,
Fuel Pump, F5 10 A
VSS
F an relay control
Fuses Key Switch,
(fuse box 1) Engine control
module power (ECM), F8 10 A
Starter Solenoid,
Clock
Fan motor F9 20 A
DC Outlet/Light/Accessories,
Euro Control (CE), F12 20 A
2WD/4WD
Fuse in fuse box 2 DPS / ACS F3 40 A
FUEL SYSTEM
Fuel delivery Electronic Fuel Injection (EFI)
Type Electrical (in fuel tank)
Fuel pump Operating
350 kPa (51 PSI)
pressure
Type Regular unleaded gasoline
Inside North
87 (R+M)/2 or higher
Fuel America
Octane rating
Outside North
92 RON or higher
America
Fuel tank capacity 20.5 L (5.4 U.S. gal.)
Fuel remaining when low fuel light turns ON ± 5 L (1.3 U.S. gal.)
DRIVE SYSTEM
Base models Visco-lok† front differential
Front drive All other
Visco-lok † QE front differential
models
Front drive ratio 3.6:1
Straight bevel gear / Shaft

Rear drive
driven final drive
Rear drive ratio 3.6:1
Capacity 500 ml (17 U.S. oz)
XPS synthetic gear
Front differential oil oil (P/N 293 600 043)
Recommended
or synthetic gear oil 75W90
API GL-5
vmr2017-124 3
DRIVE SYSTEM
Rear final drive oil 140) (P/N 293 600 140)
Type
or synthetic gear oil 75W140
API GL-5
CV joint grease (P/N 293 550
CV joint grease
062) or an equivalent
Propeller shaft grease (P/N 293

Propeller shaft grease for spline connections
550 063) or an equivalent
STEERING
1-UP 450 / 570 212.1 cm (83.5 in)
X mr 650 256.5 cm (101 in)
X mr 850 294 cm (115.7 in)
MAX X mr
Turning radius 431.8 cm (170 in)
1000R
2-UP 650 /
850 / 1000R 233.7 cm (92 in)
Except X mr
2-UP 450 / 570 239 cm (94 in)
Total toe (vehicle on the ground) 0.1° to 0.5° toe-in
Camber angle (vehicle on the ground) 0°
Tie-rod maximum length unengaged threads 348.5 mm (13.72 in)
FRONT SUSPENSION
Double suspension-arm with
Suspension type
dive-control geometry
X mr 850
149 mm (5.9 in)
MAX X mr 1000R
Suspension travel X mr 570 137 mm (5.4 in)
All others 216 mm (8.5 in)
Qty 2
HPG shock with piggy back
XT-P
reservoir. QS3† compression
X mr 1000R
and preload adjustments
Shock absorber
Type X mr 570
HPG
X mr 850
All other
Oil
models
4 vmr2017-124
FRONT SUSPENSION
DPS 650
DPS 850 340 mm (13.39 in)
DPS 1000R
450
326 mm (12.83 in)
570
X mr 850 322.5 mm (12.7 in)
1-UP X mr 570
370 mm (14.57 in)
X mr 650
STD 650 350 mm (13.78 in)
STD 850 340 mm (13.39 in)
XT 350 mm (13.78 in)
Spring free length
XT-P 320 mm (12.6 in)
X mr 1000R 322.5 mm (12.7 in)
DPS 650
DPS 850 354 mm (13.94 in)
DPS 1000R
STD 354 mm (13.94 in)
2-UP
LTD
362 mm (14.25 in)
XT 1000R
XT 650
362 mm (14.25 in)
XT 850
XT-P 320 mm (12.6 in)
HPG Variable positions
Preload adjustment type
Oil 5 positions cam
REAR SUSPENSION
Torsional Trailing arm Independant
Suspension type
(TTI) with external stabilizer bar
X mr 850
180 mm (7.1 in)
MAX X mr 1000R
450
216 mm (8.5 in)
Suspension travel 570
650
850 (except X mr) 227 mm (8.9 in)
1000R (except X mr)
Qty 2
X mr 570
HPG
850 X mr
HPG shock with piggy back
XT-P
Shock absorber QS3† compression and preload
Type X mr 1000R
adjustments
LTD ACS
All other
Oil
models
vmr2017-124 5
REAR SUSPENSION
XT-P 306 mm (12.05 in)
450
315.6 mm (12.43 in)
570
Outlander 570 X mr
1-UP 650 X mr 366.7 mm (14.44 in)
850 X mr
All other
355.9 mm (14.01 in)
Spring free length models
STD 354 mm (13.94 in)
DPS
366.4 mm (14.43 in)
XT 1000R
Outlander
2-UP XT Except
1000R 370 mm (14.57 in)
X mr 1000R
XT-P 306 mm (12.05 in)
0.35 bar to
6.90 bar
ACS pneumatic pressure range LTD
(5 PSI to
100 PSI)
LTD 6 Presets
Preload adjustment type XT-P Variable positions
Oil 5 position cam
BRAKES
Qty 2
Front brake 214 mm cross drilled disc brakes

Type
with hydraulic twin-piston calipers
Qty 1
Rear brake 214 mm cross drilled disc brake
Type
with hydraulic twin-piston caliper
Brake fluid
Type DOT 4
Caliper Floating twin pistons (2 x 26 mm)
Brake pad material Organic
Minimum brake pad thickness 1 mm (.04 in)
Minimum brake disc thickness 4 mm (.157 in)
Maximum brake disc warpage 0.2 mm (.01 in)
6 vmr2017-124
TIRES
UP TO 164 kg
41.4 kPa (6 PSI)
(360 lb)
1-UP FROM 164 kg
(360 lb) TO 48.2 kPa (7 PSI)
235 kg (517 lb)
Front
UP TO 132 kg
41.4 kPa (6 PSI)
(290 lb)
2-UP FROM 132 kg
(290 lb) TO 48.2 kPa (7 PSI)
272 kg (600 lb)
Pressure
UP TO 164 kg
41.4 kPa (6 PSI)
(360 lb)
1-UP FROM 164 kg
(360 lb) TO 68.9 kPa (10 PSI)
235 kg (517 lb)
Rear
UP TO 132 kg
41.4 kPa (6 PSI)
(290 lb)
2-UP FROM 132 kg
(290 lb) TO 68.9 kPa (10 PSI)
272 kg (600 lb)
Minimum tire thread depth 3 mm (.118 in)
X mr 1000R 762 x 229 x 355 mm (30 x 9x 14 in)
X mr 570 711 x 203 x 305 mm (28
X mr 650 x 8 x 12 in)
450 / 570
635 x 203 x 305 mm (25
Except X mr and Mossy
x 8 x 12 in)
Oak Hunting edition
Front
STD 650
STD 850
660 x 203 x 305 mm (26
STD 1000R
x 8 x 12 in)
All Mossy Oak Hunting
edition
Size All other models 660 x 203 x 356 (26 x 8 x 14)
X mr 1000R 762 x 229 x 355 mm (30 x 9x 14 in)
X mr 570 711 x 254 x 305 mm (28

X mr 650 x 10 x 12 in)
450 / 570
635 x 254 x 305 mm (25
Rear Except X mr and Mossy
x 10 x 12 in)
Oak Hunting edition
Standard 650 / 850
660 x 254 x 305 mm (26
/ 1000R models
x 10 x 12 in)
All Mossy Oak Hunting edition
All other models 660 x 203 x 356 (26 x 10 x 14)
vmr2017-124 7
WHEELS
Standard models Steel
Type XT-P Aluminium beadlocks
All other models Cast aluminum
X mr 1000R 355 x 165 mm (14 x 6.5 in)
Standard models
Mossy Oak Hunting edition
305 x 152 mm (12 x 6 in)
Front X mr 570
X mr 650
XT-P 356 x 165 (14 x 6.5)
All other models 356 x 152 (14 x 6)
Rim size
X mr 1000R 355 x 165 mm (14 x 6.5 in)
Standard models
Mossy Oak Hunting edition
305 x 191 mm (12 x 7.5 in)
Rear X mr 570
X mr 650
XT-P 356 x 165 (14 x 8)
All other models 356 x 152 (14 x 8.5)
100 N•m ± 10 N•m
Wheel nut torque
DIMENSION
1-UP 450 / 570 211 cm (83 in)
1-UP 650 / 850 / 1000R 218.4 cm (86 in)
2-UP 450 / 570 231 cm (91 in)
Overall length 2-UP 650 / 850 / 1000R exept
238.8 cm (94 in)
X mr
X mr 650
224 cm (88 in)
X mr 850
X mr 1000R 246 cm (97 in)
X mr 650 118 cm (46 in)

X mr 850
Overall width 127 cm (50 in)
X mr 1000R
All other models 117 cm (46.1 in)
1-UP 450 / 570 124 cm (49 in)

1-UP 650 / 850 / 1000R
126 cm (49.5 in)
Except X mr
2-UP 450 / 570 133 cm (52.5 in)
Overall height 2-UP 650 / 850 / 1000R
135 cm (53 in)
Except X mr
X mr 650 128 cm (50.5 in)
X mr 850
131 cm (51 in)
X mr 1000R
8 vmr2017-124
DIMENSION
1-UP 129.5 cm (51 in)
Wheel base
2-UP 149.9 cm (59 in)
X mr 850
103.5 cm (40.7 in)
Front X mr1000R
All other models 97.5 cm (38.4 in)
X mr 650 94.5 cm (37.2 in)
Wheel track X mr 850
100 cm (39.4 in)
X mr 1000R
Rear
650 / 850 / 1000R
93 cm (36.6 in)
Except X mr
450 / 570 92.3 cm (36 in)
X mr 650 30 cm (11.8 in)
X mr 850
33 cm (13 in)
X mr 1000R
650 / 850 / 1000R
28 cm (11 in)
Ground clearance Except X mr
570 Mossy Oak Hunting Edition 29.2 cm (11.5 in)
450 / 570
Except Mossy Oak Hunting 26.7 cm (10.5 in)
Edition
WEIGHT AND LOADING CAPACITY

450 308 kg (678 lb)
570 except X mr 319 kg (704 lb)
X mr 570 382 kg (843 lb)
1-UP
1000R 361 kg (795 lb)
X mr 650 396 kg (874 lb)
X mr 850 437 kg (963 lb)
Dry weight
450 324 kg (715 lb)
570 336 kg (741 lb)
650 372 kg (820 lb)
XT 650 361 kg (796 lb)
2-UP
850 372 kg (820 lb)
1000R except X mr 381 kg (840 lb)
X mr 1000R 449 kg (990 lb)
450
54 kg (120 lb)
Front rack 570
All other models 45 kg (100 lb)
450
109 kg (240 lb)
Rear rack 570
All other models 90 kg (200 lb)
vmr2017-124 9
WEIGHT AND LOADING CAPACITY

450 11 L (2.9 U.S. gal.)or
Rear storage compartment loading 570 10 kg (22 lb)
capacity
All other models 21.4 L (5.7 U.S. gal.)
Total vehicle load allowed (including driver, X mr 189 kg (417 lb)

passenger, all other loads and added 1-UP except X mr 235 kg (517 lb)
accessories) 2-UP except X mr 272 kg (600 lb)
Except CE version 590 kg (1,300 lb)
Towing capacity
CE version 135 kg (300 lb)
Except CE version 23 kg (50 lb)
Tongue capacity
CE version 13.5 kg (30 lb)
10 vmr2017-124
Subsection 01 (WIRING DIAGRAM INFORMATION)
WIRING DIAGRAM INFORMATION

GENERAL
WIRING DIAGRAM LOCATION
Wiring diagrams are found in the WIRING DIA-
GRAM BOOKLET.
WIRING DIAGRAM WITH

COLORED LINES
The wiring diagram on the KNOWLEDGE CENTER
is in color.
mmr2015-147-004_a
WIRING DIAGRAM INDEX

WIRING DIAGRAM CODES
The wiring diagrams use the following codes. Connector Code
The wire connects to the indicated connector.
1 (-C-3) YL/BU-22 5 Connector Pin

YL/BK-16
The wire is the indicated pin in the connector.
F11 R5 NOTE: Could be identified by either a number or
C6
D6
by a letter depending on the type of connector

30A
30 86 used.
87 85
FOLLOWING A CIRCUIT
C7
OR/BK-22 (-B-5) 1 To follow a circuit, search the in section of the

3 wiring diagram shown in the wiring diagram index.
OR/BK-22
3 HIC1_F
JT-OR/BK
C
NOTE: The arrow indicates the direction of the
OR/BK-22
2 power in the circuit.

4 In this example, the power comes from section
(-C-3).
vmr2016-149-001_a
1. Wiring diagram index

2. Connector code
3. Connector pin
4.
5.
Splice
Color and size (-C-3) YL/BU-22
Wiring Diagram Index vmr2016-149-002
The wiring diagram is separated by rows (letters) In following example, the power goes to the sec-
and columns (numbers). tion (-B-5).
OR/BK-22 (-B-5)
vmr2016-149-003
vmr2016-149 1
WIRE COLORS AND SIZES 2. If an electrical issue can not be found with the
usual tests, locate the main harness splice that
is involved in the faulty circuit and repair it as
per the SPLICES REPAIR PROCEDURE.
3. To repair a splice, we recommend the use of a
tin solder meeting the followings requirements
or an equivalent.
TIN SOLDER REQUIREMENTS
SN 60
mmr2015-147-003_a PB 40
1. Wire color
2. Wire gauge (AWG) DIA 0.062
The first color of a wire is the main color, second FLUX RA 2%

color is the stripe.
Example: YE/BK is a YELLOW wire with a BLACK SPLICES REPAIR PROCEDURE
stripe.
CASE 1: Wire Detached from Splice
COLOR CODE
1. Locate splice. Refer to splices location dia-
BG — BEIGE OG — ORANGE grams.
BK — BLACK RD — RED 2. Remove wires from protector tube.
BU — BLUE VT — VIOLET 3. Locate the shrink tube protecting the defective
splice.
BN — BROWN WH — WHITE
GN — GREEN YE — YELLOW
GY — GRAY PK — PINK
LT prefix means a "light" color. E.g: LT GN = Light
green.
SPLICES IN WIRING HARNESS

Splices in wiring harness are indicated on the
wiring diagram as follows. mmr2010-043-001_a
1. Shrink tube
1 2 4. Remove the shrink tube.

4.1 Using a blade, cut the shrink tube.
JT
T - RD
RD/BU
vmr2016-149-004_a
1. JT: Splice indication

2. Spliced wire color
PROCEDURES
This section gives the procedures in order to mmr2010-043-002
quickly repair electrical harness splices.
1. Make sure to perform the usual tests described NOTICE Be careful with the blade to
in ELECTRICAL SYSTEM sections before inves- avoid cutting wires insulation.
tigating the harness splices. 4.2 Slightly heat the shrink tube using a heat
gun.
2 vmr2016-149
CASE 2: Wire Broken from Splice

1. Locate splice. Refer to splices location dia-
grams.
2. Remove wires from protector tube.
3. Locate the shrink tube protecting the defective
splice.
mmr2010-043-003
4.3 Remove the shrink tube with long nose pli-

ers.
5. Locate detached wire from splice.
mmr2010-043-001_a
1. Shrink tube
4. Remove the shrink tube.

4.1 Using a blade, cut the shrink tube.
mbg2008-021-116_a
1. Detached wire
2. Splice
6. Twist detached wire around splice.

mmr2010-043-002
NOTICE Be careful with the blade to

avoid cutting wires insulation.
4.2 Slightly heat the shrink tube using a heat
gun.
mbg2008-021-117_a
1. Twisted wire
7. Perform a tin solder on twisted wire.

8. Apply electrical tape to cover splice.
mmr2010-043-003
NOTE: Make sure tape overlaps on wire insula-
tion, approximately 13 mm (1/2 in) each side. 4.3 Remove the shrink tube with long nose pli-
9. Reinstall wires into protector tube. ers.
5. Locate broken wire from splice.
vmr2016-149 3
mbg2008-021-118_a
1. Broken wire
2. Splice
6. Strip wire insulation at the end of broken wire.

7. Strip wire insulation below the splice.
mbg2008-021-119_a
1. Broken wire stripped

2. Splice wire stripped
8. Twist wire around stripped wire.
mbg2008-021-120_a
1. Twisted wire
9. Perform a tin solder on twisted wire.

10. Apply electrical tape to cover splice.
NOTE: Make sure tape overlaps on wire insula-
tion, approximately 13 mm (1/2 in) each side.
11. Reinstall wires into protector tube.
NOTE: Always perform a solder on a bigger wire
(lower gage).
4 vmr2016-149
1 2 3 4 5 6 7 8 9 10
LINE TYPES
55 / 60 VOLTS
2018 OUTLANDER / RENEGADE

12 VOLTS SWITCHED
12 VOLTS UNSWITCHED
5 OR 3.3 VOLTS
DIGITAL SIGNAL
A A
POWER CONTROL
ANALOG SIGNAL
With mechanical dess key

COMMUNICATION
A-D GROUND
POWER GROUND
AC VOLTAGE
COOLING
FAN
F9 : 25A
MAIN POWER FUEL PUMP COOLING FAN HEADLAMPS BRAKE LIGHTS ACCESSORY
IGNITION RELAYS
R2 COILS R4 R1 R5 DPS R8 ACC 2 R3 4WD DC
KEY SWITCH INJECTORS FUEL PUMP ECM HEADLAMPS GAUGE TAIL LAMP WINCH OUTLET CLOCK
BP1 F8 : 5A F5 : 5A F15 : 5A F6 : 5A F11 : 30A JP1: 15A F4 : 5A F14 : 15A F7 : 5A F12: 15A F10: 5A
B B
87a
87a
30
87
30
87
30
87
87
30
30
87
30
87
85
86
85
86
85
86
86
85
85
86
85
86
RD-12
PF1
E4
E5
A2
B1
A1
B2
B3
B4
D4
C10
D5
A12
B11
B12
A11
A3
A4
C5
C4
E1
D3
D1
E3
E6
E7
D7
C6
D6
C7
B5
C1
C2
B6
C9
D8
C8
D9
C11
D12
E10
E12
D10
A6
A5
E9
E8
A7
A8
OG/WH-22
WH/OG-22
RD/WH-22
OG/GN-20
BN/WH-16
RD/OG-20
RD/GN-14
RD/GN-14
OG/BK-22
OG/BK-22
RD/GY-16
RD/GY-16
BN/RD-16
BN/RD-16
RD/BU-16
RD/BU-16
RD/BN-18
RD/YE-14
RD/YE-14
RD/YE-14
RD/BK-20
RD/YE-14
RD/VT-18
RD/VT-18
VT/RD-20
YE/BU-22
YE/BK-16
YE/BK-16
OG/GN-20
OG/BU-22
RD/GY-18
RD/GY-16
RD/GY-16
RD/BG-18
RD/BG-18
RD/BG-18
RD/BG-18
RD/BG-18
BU/GY-20
BU/GY-20
BU/GY-20
BK/BU-22
VT/RD-20
VT/BU-18
GN-18
BG-22
BG-22
DIAGNOSTIC
DB
JT RD/YE JT RD/BN 6
CHASSIS ENGINE RD/BN-18
JT BU/GY JT OG/BK JT RD/PK 5
RD/PK-16
JT RD/BG JT OG/GN 4
OG/GN-20
JT RD
FL-1 JT RD/GY 3
RD-12 RD/GY-12 BK-16
40A
JT WH/BK 2
JT VT/RD WH/BK-20
FL-2 JT RD/GN
COOLING FAN JT WH/BG
WH/BG-20
1
REGULATOR
RD-12
40A
RD/GN-12 FT
B +
C RD1 BN/WH-16 BU C
1 A M JT BK 2
RD-10 BK-16 BK -
RD/BN-18
3 DC2-
BK-10
JT BK 3 BK-16
FUEL PUMP
JT RD/BK
DC1-
FP
BN1- 3 +
JT BK 3
4 M
BK-20 -
DC3 DC3_C
RIGHT STEERING SWITCH 2
RD/BN-18
INTER CONNECTOR
JT BK 2 1
HIC2_F RIGHT STEERING SWITCH 2X4 BK-18
B
R2 CONTROL OG/BU-22 BD 4X4
D11
C 5
S12V VT/BU-18 RD/BK-20 BK OG/GN-20
A 6 JT BK 3
JT RD/VT
S12V VT/RD-20 WH/BU-22 BU
H 3
4WD ACTUATOR WH/BU-22 WH-22 WH
D D
G 1 REAR BRAKE SWITCH
4WD ACTUATOR WH/BK-22 WH/BK-22 WH/BU REMOTE WINCH
D 2 FRR
STOP SWITCH BK/WH-22 BK-22 RD 2 WINCH SWITCH SWW
E RD/OG-20 A
GROUND BK-16 1 RD/BK-20 SW2
F BK-20 OUT B
GROUND BK-16 LT BU-18 LT BU-18
C TO WINCH RELAY
JT BK 3 GN/BU-18 GN/BU-18
IN
INTER CONNECTOR JT BK 1 JT BK 1 SW1-
JT BK 2
HIC1_F
D5
D6
H
FUEL PUMP RELAY CONTROL BK/BU-22 JT WH/OG
G
COOLING FAN RELAY CONTROL OG/WH-22
M ELECTRONIC
4WD ACTUATOR WH-22
C GAUGE
HEADLAMP / ACC RELAY CONTROL OG/BK-22
BRAKE SWITCH
L JT RD/OG CI
RD/OG-20
A JT BG 16
U12V BG-22 BG-22 U12V
E N 9
SW4 E
SPEED SENSOR SIGNAL PK-22 PK-22 SPEED SENSOR SIGNAL
F 7
4WD ENABLED SWITCH BK/BG-22 BK/BG-22 4WD ENABLED SWITCH
JT VT/GY 6 CHASSIS
K VT/GY-22 REV. OVER
REV. OVERRIDE SWITCH VT/GY-22 KEY SWITCH FUEL LEVEL
JT WH/BG
WH/BG-22
19
CAN HI LEFT TAIL LIGHT RIGHT TAIL LIGHT
FUEL PUMP JT WH/BK PRG PRD
18
S JT WH/BG OFF SENSOR FP WH/BK-22 CAN LO 3 3
CAN HI WH/BG-22 CC ON W LIGHT RD/VT-22 RD/VT-22
CAN LO R JT WH/BK B ON W/O LIGHT
1 21 1 1
WH/BK-22 BG-22 VT/PK-22 FUEL LEVEL SIGNAL (+) WH/OG-22 WH/OG-22
A 2 4 2 2
YE/BU-22 BN/PK-22 FUEL LEVEL SIGNAL (-) BK-22 BK-22
D E
DESS DATA OG/RD-22 OG/RD-22 DESS
E C
LOW POWER GROUND BK/BN-22 5
BU-22 HIGH BEAM ACC
J D JT BK 2 JT BK 2
STARTER CONTROL OG/BN-20 DC5 DC5_C
B F 20 B
RUN SWITCH VT/BG-20 OG/VT-20 BK-22 GROUND RD/VT-18
8 A
OG-22 BK-18
17
P SS2- OG/YE-22 S12V
GROUND BK-22
F LICENCE PLATE LIGHT ACC F
JT BK 1 PL JT BK 3 DC6 DC6_C
2 B
STARTER SOLENOID RD/VT-22 RD/VT-18
D2
JT BK 1 1 A
LEFT STEERING SWITCHES BK-22 BK-18
LEFT STEERING SWITCHES
MG2
6 SS1-
START SWITCH RD/VT YE/RD-20 YE/RD-20 JT BK 2 JT BK 2
1 JT VT/BG
YE/RD VT/BG-20
3
BK BK/BN-22
HI 5
BU BU-18
HEADLAMP FLASHER HARNESS
LO 2
GN GN-18 HICA
4 JT RD/BU AUXILIARY LIGHT POWER
RD/YE RD/BU-16 D
BU-20 DC5-1- RD/WH-22
E
RD/BK-20
JT GN
JT BU
C
OG/YE-22
LEFT HIGH HEADLAMP RIGHT HIGH HEADLAMP
B
G LEFT STEERING SWITCHES PGH PDH OG-22 G
B B F
MG1 BU-20 BU-20 GY-22
OFF 4 A A G
RD/BU-16 BK-20 BK-20 BN-22
3 A
ENGINE STOP SWITCH BK/WH BK/WH-22 BK-20
2
YE VT/BG-20
RUN 1 LEFT LOW HEADLAMP JT BK 3 JT BK 3 RIGHT LOW HEADLAMP
BN OG/VT-20
5 PGB PDB JT BK 3
OG VT/GY-22 B B
6 GN-20 GN-20
BK-22 REAR LEFT FLASHER REAR RIGHT FLASHER
WH A A
REVERSE OVERRIDE BK-20 BK-20 CRG CRD
2 2
OG GY-22 BN-22 OG
1 1
GN BK-22 BK-22 GN
JT BK 1 JT BK 3 JT BK 3
BN1
JT BK 2 JT BK 3
BK-12 BK-12
JT BK 2 JT BK 2
JT BK 1
BK-14
H CHASSIS H
BK-10
BK-22
BK-22
BK-16
BK-16
BK-22
BK-16
BK-18
BK-20
BK-20
BK-22
BK-22
BK-16
BK-18
BK-18
BK-16
BK-20
BK-20
BK-20
BK-20
(-G-5)
(-G-5)
(-G-8)
(-C-1)
(-D-2)
(-D-2)
(-H-2)
(-C-9)
(-D-8)
(-D-6)
(-H-7)
(-H-7)
(-D-3)
(-C-9)
(-D-9)
(-C-8)
(-H-5)
(-H-5)
(-F-6)
(-F-2)
(-F-9)
(-F-8)
(-F-9)
(-F-8)
(-F-9)
PAGE 01
CI-20
MG1-6
DB-3
PL-1
FT-A
PDH-A
PGB-A
RD1-3
DC6-A
FP-4
FRR-1
PRD-2
PRG-2
CRG-1
CRD-1
BD-2
DC3-1
DC5-A
PDB-A
PGH-A
HIC1_F-P
HIC2_F-F
HIC2_F-E
DC1-
HICA-A
219100875-003
REF: 710005280 REV: 2
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
LINE TYPES
2018 OUTLANDER / RENEGADE

55 / 60 VOLTS
12 VOLTS SWITCHED
12 VOLTS UNSWITCHED
5 OR 3.3 VOLTS
DIGITAL SIGNAL
A A
POWER CONTROL
ANALOG SIGNAL
With RF dess
COMMUNICATION
A-D GROUND
POWER GROUND
AC VOLTAGE
BP1
COOLING
FAN
F9 25A
COOLING FAN ACCESSORY
RD-12
MAIN POWER IGNITION RELAYS FUEL PUMP HEADLAMPS BRAKE LIGHTS
R2 COILS DPS R4 R1 R5 R8 R3
KEY SWITCH INJECTORS ECM GAUGE FUEL PUMP HEADLAMPS ACCESSORY WINCH DC OUT
F8 : 5A F5 : 5A F6 : 5A F4 : 5A F15 : 5A F11 : 30A F14 : 15A F7 : 5A F12: 15A
B B
87a
87a
30
87
30
87
30
87
87
30
30
87
30
87
85
86
85
86
85
86
86
85
85
86
85
86
PF1
E4
E5
A2
B1
A1
B2
B3
B4
A3
A4
B5
B6
D4
D5
A12
B11
B12
A11
C5
C4
E1
D3
E3
E6
E7
D7
C6
D6
C7
C9
D8
C8
D9
C11
C10
D12
E10
E12
D10
A6
A5
E9
E8
D1
CHASSIS ENGINE FUEL PUMP
FP
OG/WH-22
WH/OG-22
OG/GN-20
OG/GN-20
OG/GN-20
BN/WH-16
RD/OG-20
RD/GN-14
RD/GN-14
OG/BK-22
OG/BK-22
RD/GY-14
BN/RD-16
BN/RD-16
RD/BU-16
RD/BN-18
RD/YE-14
RD/YE-14
RD/YE-14
RD/BK-20
RD/YE-14
RD/VT-18
RD/VT-18
VT/RD-20
YE/BK-16
YE/BK-16
OG/GN-20
OG/BU-22
RD/GY-18
RD/GY-18
RD/GY-18
RD/BG-18
RD/BG-18
RD/BG-18
RD/BG-18
RD/BG-18
BU/GY-20
BU/GY-20
BU/GY-20
VT/RD-20
BK/BU-22
VT/BU-18
3 +
BG-22
BK/RD-18
4 M
BK-20 - DIAGNOSTIC
JT RD/BG JT BU/GY DB
JT RD
FL-1 JT RD/GY
JT RD/YE JT RD/BN
RD/BN-18
6
RD-12 RD/GY-12 JT RD/PK 5
40A FROM F3 (DPS FUSE) RD/PK-16
JT OG/GN 4
OG/GN-20
FL-2 JT RD/GN 3
RD-12 RD/GN-12 BK-16
REGULATOR 40A
JT WH/BK 2
RD1 WH/BK-20
1 JT WH/BG 1
RD-10 WH/BG-20
JT BK 2
C C
3
BK-10 JT BK 2
JT RD/BK
JT VT/RD
JT OG/BK RD/BN-18
DC2-
BN1- BK-16
DC1-
JT BK 3
INTER CONNECTOR
HIC2_F RIGHT STEERING SWITCHES 2X4 DC3 DC3_C
B COOLING FAN 2
R2 CONTROL OG/BU-22 BD 4X4 RD/BN-18
JT RD/VT
C 5 FT 1
S12V VT/BU-18 RD/BK-20 BK B BK-18
BN/WH-16 BU +
A 6
S12V VT/RD-20 WH/BU-22 BU A M
H 3 BK-16 BK -
4WD ACTUATOR WH/BU-22 WH-22 WH
G 1 JT BK 3
4WD ACTUATOR WH/BK-22 WH/BK-22 WH/BU
D D
D 2
STOP SWITCH BK/WH-22 BK-22 RD JT BK 3 REMOTE WINCH
E
GROUND BK-16 SWW
F A
GROUND BK-16 RD/BK-20 SW2
REAR BRAKE SWITCH OUT B
JT BK 3 LT BU-18 LT BU-18
FRR C TO WINCH RELAY
2 GN/BU-18 GN/BU-18
RD/OG-20 IN
INTER CONNECTOR JT BK 1 JT BK 1 1 SW1-
BK-20
HIC1_F
H
FUEL PUMP RELAY CONTROL BK/BU-22 JT WH/OG
G
COOLING FAN RELAY CONTROL OG/WH-22 JT BK 2
M
D5
D6
4WD ACTUATOR WH-22
C CI ELECTRONIC
HEADLAMP / ACC RELAY CONTROL OG/BK-22
L JT RD/OG 17 GAUGE
BRAKE SWITCH RD/OG-20 OG/GN-20 S12V
A JT BG 16
U12V BG-22 BG-22 U12V
E N 9 E
SPEED SENSOR SIGNAL PK-22 PK-22 SPEED SENSOR SIGNAL
BK-18
BK-18
F 7
4WD ENABLED SWITCH BK/BG-22 BK/BG-22 4WD ENABLED SWITCH
REV. OVERRIDE SWITCH

K
VT/GY-22
JT VT/GY
VT/GY-22
6
REV. OVER SW4
JT WH/BG 19
S JT WH/BG WH/BG-22 CAN HI
CAN HI WH/BG-22 JT WH/BK 18
JT WH/BK FUEL PUMP WH/BK-22 CAN LO
CAN LO R RF DESS
WH/BK-22 RFID FP
D
VT/RD-22 S12V 1 21
D C VT/PK-22
DESS DATA OG/RD-22 OG/RD-22 DATA 2 4
E A BN/PK-22
LOW POWER GROUND BU/BK-20 BU/BK-20 GROUND
J B HALL
STARTER CONTROL OG/BN-20 OG/BN-20 OG/VT-22 CONTACT 5
B SS2- BU-22 HIGH BEAM
VT/BG-20 VT/BG-20
20
WAKE_M WAKE_F- GROUND
D2
P RIGHT TAIL LIGHT

F
GROUND BK-22 BU-20 DC5-1- F
PRD
LEFT HIGH HEADLAMP 3
RD/VT-22
JT BK 1 PGH JT BK 1 1
SS1- B WH/OG-22
VT/BG-20 BU-20 2
A BK-22
BK-20
JT BU
RIGHT HIGH HEADLAMP
LEFT TAIL LIGHT
JT VT/BG
PDH JT BK 2
LEFT STEERING SWITCHES B PRG
BU-20 3
MG2 A RD/VT-22
6 BK-20 1
START SWITCH RD/VT VT/BG-20 WH/OG-22
1 2
YE/RD BG-22 BK-22
3
BK VT/RD-22 JT BK 3 JT BK 3 ACC
HI 5
BU BU-18 DC5 DC5_C
HEADLAMP LO 2 B
GN GN-18 RD/VT-18
4 LEFT LOW HEADLAMP A
RD/YE RD/BU-16 BK-18
G PGB G
B
GN-20
ACC
A
BK-20 DC6 DC6_C
B
RD/VT-18
JT GN
RIGHT LOW HEADLAMP A

MG1 BK-18
OFF 4 JT RD/BU PDB
RD/BU-16 B
3 JT BK/WH GN-20
ENGINE STOP SWITCH BK/WH BK/WH-22 A
2 BK-20
YE BK/WH-22 JT BK 2 JT BK 3 JT BK 2
RUN 1
BN OG/VT-22
5 LICENCE PLATE LIGHT
OG VT/GY-22 JT BK 3 JT BK 3
6 PL
WH BK-22 2
REVERSE OVERRIDE BN1 RD/VT-22
JT BK 2 JT BK 3 1
BK-12 BK-12 BK-22
JT BK 1
JT BK 1 BK-14
H H
JT BK 2
BK-10
BK-22
BK-22
BK-16
BK-16
BK-22
BK-16
BK-18
BK-20
BK-20
BK-22
BK-22
BK-22
BK-22
BK-16
BK-18
BK-18
BK-16
BK-20
BK-20
BK-20
BK-20
(-G-8)
(-G-7)
(-G-8)
(-G-6)
(-G-5)
(-C-1)
(-D-2)
(-D-2)
(-H-2)
(-C-8)
(-C-4)
(-H-7)
(-D-4)
(-C-8)
(-D-8)
(-D-5)
(-H-6)
(-H-5)
(-E-6)
(-F-6)
(-F-2)
(-F-8)
PAGE 01
CI-20
MG1-6
DB-3
PL-1
FT-A
PDH-A
PGB-A
RD1-3
DC6-A
FP-4
PRD-2
PRG-2
PGH-A
FRR-1
BD-2
DC3-1
DC5-A
PDB-A
HIC1_F-P
HIC2_F-F
HIC2_F-E
DC1-
219100875-004 REF: 710005755 REV: 2

1 2 3 4 5 6 7 8 9 10
2018 ENGINE HARNESS (All Except 450)
1 2 3 4 5 6 7 8 9 10
LINE TYPES
55 / 60 VOLTS
12 VOLTS SWITCHED
12 VOLTS UNSWITCHED
A SPEED SENSOR 5 OR 3.3 VOLTS A
VSS DIGITAL SIGNAL
A JT 4
VT/BU-18 POWER CONTROL
B
HALL
PK-18 ANALOG SIGNAL

C
GN/BN-18 COMMUNICATION
ECM ECM A-D GROUND
POWER GROUND
COOLANT ELECTRONIC
AC VOLTAGE
TEMPERATURE SENSOR CONTROL
CTS
2
GN/BN-18
JT 3
GN/BN-18
C3
SGND MODULE
1 F4
BG/OG-18 BG/OG-18 COOLANT TEMP. SIGNAL
B B
IGNITION COILS
BA
1 M1
BN/OG-16 BN/OG-16 IGN-A
2
VT/BU-16
3 M2
BN/BK-16 BN/BK-16 IGN-B
FUEL INJECTOR 1
C INJ1 C
2
VT/BU-18
1 L4
BK/RD-18 BK/RD-18 INJ-A
FUEL INJECTOR 2
INJ2
2
VT/BU-18
1 K4 IDLE AIR
BN/BU-18 BN/BU-18 INJ-B
CONTROL VALVE
IACV
D3 A
WINDING 1 GY/WH-18
E4 B
WINDING 2 GY/GN-18
D C4 C M D
WINDING 2 GY/BK-18
D4 D
WINDING 1 GY/VT-18
CRANKSHAFT
POSITION SENSOR CPS
1 E1
CPS (+)
HIC2_M
BU/YE-18 K1 B
2 D1 POWER RELAY CONTROL OG/BU-18 OG/BU-18 POWER RELAY CONTROL
YE/WH-18 CPS (-) C
VT/BU-16 S12V
L1 A
S12V POWER VT/BU-16 VT/BU-16 S12V
OIL PRESSURE SWITCH H
OPS WH/BU-18 4WD ACTUATOR
E2 G
LT BU-18 OIL PRESSURE SWITCH WH/BK-18 4WD ACTUATOR
K3 D
STOP SWITCH BK-18 BK-18 STOP SWITCH
M4 F
GROUND BK-16 BK-16 GROUND
E ENGINE
E
M3 E
GROUND BK-16 BK-16 GROUND
4WD ACTUATOR
MD 4WD CONTROL VOLTAGES
CONTINUITY TEST FOR GEAR POSITIONS
BR BN/GY-18
J3
GEAR SWITCH 1
2
WH/BU-18
1
M WH/BK-18
WH 4
WH-18
H2
WH/RD-18 GEAR SWITCH 2
OR HIC1_M
H4 J1 H
OG/GY-18 GEAR SWITCH 3 FUEL PUMP RELAY CONTROL BK/BU-18 BK/BU-18 FUEL PUMP RELAY CONTROL
B3 G
COOLING FAN RELAY CONTROL OG/WH-18 OG/WH-18 COOLING FAN RELAY CONTROL
F F
M
WH-18 4WD ACTUATOR
K2 C
HEADLAMP / ACC RELAY CONTROL OG/BK-18 OG/BK-18 HEADLAMP / ACC RELAY CONTROL
J4 L
BRAKE SWITCH RD/OG-18 RD/OG-18 BRAKE SWITCH
GEAR POSITION SENSOR B4 A
GEARBOX WITH GBPS U12V BG-20 BG-20 U12V
GPBS N
3 4WD_SW- PK-18 SPEED SENSOR SIGNAL
GN/BN-18 F
2 D2 BK/BG-18 4WD ENABLED SWITCH
HALL WH/GY-18 GEAR POSITION SIGNAL
1 F1 K
BU/RD-18 REV. OVERRIDE SWITCH VT/GY-18 VT/GY-18 REV. OVERRIDE SWITCH
B1 S
CAN HI WH/BG-18 WH/BG-18 CAN HI
C1 R
CAN LO BG/GN-18 BG/GN-18 CAN LO
G TPS PIN POSITIONS G
THROTTLE POSITION SENSOR
TPS DESS DATA
H1 D
DESS DATA
X G3 OG/RD-18 OG/RD-18
SIGNAL WH/BN-18 WH/BN-18 TPS SIGNAL E
Y BU/BK-18 LOW POWER GROUND
GROUND BU/BK-18 L3 J
Z STARTER CONTROL OG/BN-16 OG/BN-16 STARTER CONTROL
5V BU/RD-18 A4 B
RUN SWITCH VT/BG-18 VT/BG-18 RUN SWITCH
MANIFOLD PRESSURE AND
AIR TEMPERATURE
SENSOR G1 P
SELECT_MODE- SW PK/BK-18 PK/BK-18
MAPTS
3 JT 2 A1
5V BU/RD-18 BU/RD-18 5V
4 F2
PRESSURE GY/BU-18 PRESSURE SIGNAL
H 2 F3 H
TEMPERATURE WH/GY-18 TEMPERATIRE SIGNAL
1 JT 1 G2
GROUND BU/BK-18 BU/BK-18 LOW POWER GROUND
219100875-006
REF: 265950 / 864690 / 264791 / 666 507 REV:
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2018 DPS
A A
(Part of main harness)

B DPS B
F3: 40A
PF2
A
B
C C
RD/PK-14
RD-14
JT RD
FROM BATTERY
JT RD/PK C DPS
POWER FOR AIR SUSPENSION OPTION HIC8- RD/PK-16 RD/PK-18 U12V
POWER STEERING
D D D
RD/PK-18 U12V
E
RD/PK-18 U12V
JT OG/GN G
SWITCHED 12 VOLTS FROM F4 OG/GN-20 S12V
JT WH/BG J
WH/BG-20 CAN HI
CAN BUS JT WH/BK K
WH/BK-20 CAN LO
A
E BK-18 GROUND E
B
BK-18 GROUND
BN2
F
BK-18 GROUND
CHASSIS
F F
G G
H H
PAGE 02
219100875-007 REF: ATV NEW DPS (TYPICAL) REV:
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2018 VISOR ADAPTOR A
B B
C C
HVA
DC3-1
JT RD/BK 2 641
RD/BK-16 RD/BK-16
1321 JT BK 1
BK-16 BK-16
D D
GHVA
E E
DC3-2
2 355
RD/BK-16
1
BK-16
F F
G G
H H
PAGE 01
219100875-008 8½ X 11 REF: 710002571, 710006105 REV:
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2018 HEATED GRIPS EXTENSION

A A
B B
C C
RPCF DC3M
363 2 JT RD/BN 2 354
RD/BN-16 RD/BN-16
1 JT BK 1
BK-16 BK-16
D D
E E
DC3F
2 355
RD/BN-16
1
BK-16
F F
G G
H H
PAGE 01
219100875-009 8½ X 11 REF: 710003899 REV:
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
A
2018 POWER SPLITTER A
B B
C C
TO CHASSIS
DC5 DC3M
B JT RD/BK 2
D RD/BK-18 RD/BK-18 D
A JT BK 1
BK-18 BK-18
DC3F
E 2 E
RD/BK-18
1
BK-18
F F
G G
H H
PAGE 01
219100875-010 REF: 710004567 REV:
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
LINE TYPES
2018 FLASHER HARNESS

55 / 60 VOLTS
12 VOLTS SWITCHED
A A
12 VOLTS UNSWITCHED
5 OR 3.3 VOLTS
DIGITAL SIGNAL
POWER CONTROL
ANALOG SIGNAL
COMMUNICATION
A-D GROUND
B B
POWER GROUND
AC VOLTAGE
RIGHT
MG3 MC1
C FLASHER SWITCH C
LEFT 1 1
BG/GN BG/BN-20 BG/BN-20 RIGHT FLASHER SWITCH
2 2
BG/GY BG/GY-20 BG/GY-20 LEFT FLASHER SWITCH
HAZARD 5
RD/BK-20 S12V
5 6
BG/RD BG/RD-20 BG/RD-20 HAZARD SWITCH
4
HORN BG/BK BG/BK-20 KX1- R
3 4
RD/BK RD/WH-20 BG/RD-20 BK-20 GROUND
D D
KX2-
FLASHER
BK-20
D10
TO CHASSIS HARNESS MODULE
HICA MC2
D JT RD/WH 1
U12V RD/WH-20 RD/WH-20 U12V
E JT RD/BK
S12V RD/BK-20
E C E
CLUSTER HAZARD POWER OG/YE-20
B 4
CLUSTER HAZARD LAMP OG-20 OG-20 HAZARD LAMP
F JT BN 3
LEFT REAR FLASHER GY-20 GY-20 LEFT FLASHER OUTPUT
G JT GY 2
RIGHT REAR FLASHER BN-20 BN-20 RIGHT FLASHER OUTPUT
A JT BK
GROUND BK-20
F F
LEFT FRONT FLASHER RIGHT FRONT FLASHER

CAG CAD
2 2
OG GY-20 BN-20 OG
1 1
GN BK-20 BK-20 GN
G G
RD/BK-20 RD/BK-20
PPG2- PPD2-
LEFT POSITION LAMP RIGHT POSITION LAMP
PPG1- PPD1-
BK-20 BK-20
H H
PAGE 01
219100875-011
REF: 710004842 REV: 1
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
LINE TYPES
2018 REAR HEATED GRIP HARNESS

55 / 60 VOLTS
A 12 VOLTS SWITCHED A
12 VOLTS UNSWITCHED
5 OR 3.3 VOLTS
DIGITAL SIGNAL
POWER CONTROL
B ANALOG SIGNAL B
COMMUNICATION
A-D GROUND
POWER GROUND
AC VOLTAGE
C C
12 VOLTS INPUT
D PV1 D
RPCM
2 JT RD/BN
RD/BN-18 RD/BN-18 HEATED VISOR
1 JT BK
BK-18 PVG
BK-18 GROUND
HEATED GRIP SWITCH
E RS2- LEFT HEATED GRIP E

RD/BN-18
PCG
HI RS1- JT RD/YE 3
RD/YE-18 RD/YE-18 RD
JT RD/GN 2
RD/GN-18 RD/GN-18 GN
LO RS3- 1
BK-18 GY
F F
RIGHT HEATED GRIP
PCD
3
RD/YE-18 RD
2
RD/GN-18 GN
1
BK-18 GY
G G
H H
PAGE 01
219100875-012 REF: 710005933 REV:
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P TERMINAL IDENTIFICATION AWG MAX. CURRENT MAX. FUSE CURRENT MAX. WATT ZONE # ZONE DESCRIPTION WELDED JOINT P
OUTLANDER 2017/2018
FRAME GROUND COLOR CODE
1 MAIN LTD # 6 100 amps 125 amps 1450 watts

1 STEERING AREA
SHRINKED JOINT EGINE GROUND
BE
BK
BEIGE
BLACK
NAME ZONE- CONNECTOR NAME- TERMINAL #/A # 8 65 amps 80 amps 930 watts
3 5 HARNESS HARNESS # 10 40 amps 50 amps 580 watts 2 MODULE AREA
CROSSED WIRE PHILLIPS SCREW BU BLUE
ACS SYSTEM
2 SIDE SIDE EX: CI 1 - CI - 15 # 12 25 amps 30 amps 365 watts WIRE BUS NUT CONNECTION
BR
GN
BROWN
GREEN
4 EX: CV 4 - CV - A
# 14 16 amps 20 amps 230 watts 3 FRONT OF VEHICLE SIMPLE CONDUCTOR WIRE SPLICE CONNECTION GY GREY
PF1 VOIR/SEE # 16 10 amps 15 amps 145 watts

4 ENGINE AREA FEMALE TERMINAL COMPONENT CONNECTION
OR
RD
ORANGE
RED
# 18 6 amps 7.5 amps 85 watts
N DC OUTLETS EX: ME 2 - ME N
FUSE ( F12 ) 15 A DB * AT 50°C MAX 5 REAR OF VEHICLE
MALE TERMINAL SECTION OF MODULE VI
WH
VIOLET
WHITE
3-PF1-9E
4- DB1- 6 STEEL LINK (FRAME ) SLOTTED SCREW YL YELLOW
3-PF1-8E
TERMINAL PK PINK
OPTIONAL
LT BU
RD/PK
RD/BR
4- DB2- 6
JT RD/GY
M JT OR/GN M
DB1
RD/GN-12
RD/GN-12
RD/GY-12
RD/BR
OR/GN-18 CI SPEEDOMETER
MAIN HARNESS
1-CI-17 HIC8 HIC8
& PILOT LAMPS
DIAGNOSTIC
3-PF1-6B
PF1
P
RD/PK
RELAYS
4-R5-30 4-R5-85 CONNECTOR
B
SPEEDO
PF2
FL-1 FL-2
FUSE RD YL YL BU
L 40A
L
HIC 8
F1
( F4 )
10 A FUEL ENGINE 4WD HI
R5
MAIN HARNESS
PF2
3-PF1-5B
BEAM
RD/BE-14
A
RD/BR POWER
4-R5-87 4-R5-86
CONNECTOR
1-CI-21 1-CI-4 1-CI-19 1-CI-18 1-CI-7 1-CI-20 1-CI-5
WH/BE-18
BR/PK-18
WH/BK
RD/WH
VI/PK-18
BK/BE-18
LTD
BU-18
BK-18
OR/PK
RD-12
K 4- M1- C K
OR/GN-18
M
CONFIGURATION
5-BP2 5-BP1
5-SS1 AIR
COMPRESSOR 4-PCM-8
4- M1- A
SS
J STARTER
RD/GY 4- DB1- 5 J
SOLENOID
5-SS2 RD/GY BK
5-BP3
OR/BR-18
4- DB2- 5
D7
RD-12
RD-6
RD-6
A C
WH/BK-18
H H
WH/BE-18
BK/GN
4-PCM-9
OR/GN 4- DB1- 4 OR/GN 4-PCM-12
4-BV1-2 4-BV1-1
5-BAT1
4-SM
JT OR/GN
BAT JT WH/BK
( VENT VALVE )
BATTERY SM 4- DB2- 4
G 12 VDC M STARTER G
18 AH MOTOR PCM
CAN LOW 4- DB1- 2 4-PCM-5
WH/BK WH/BK PRESSURE
JT WH/BK CONTROL
5-BAT2
MODULE
4- DB2- 2
BK-6
JT WH/BE CAN HI WH/BE 4-PCM-6

F WH/BE
F
RD-12
4- DB1- 1 JT WH/BE
BE/GN-18
WH/BE-18
5-RD1-1
4- DB2- 1
RD 4-PCM-7
RECTIFIER
E E
U V W
5-RD2-1 5-RD2-2 5-RD2-3 5-RD1-3

BK-12
YL-12
YL-12
YL-12
BK-6
D 4-PCM-10 4-PCM-3 4-PCM-2 D
PK/OR
PK/BR
CA-1 CA-2 CA-3
4-PS-3 4-PS-2
YL-14
YL-14
YL-14
+ P
BK
C U C
P
CA
RD/GY-16
WH/BK-18
RD/BR
OR/GN
MAGNETO
BK-12
BK-6
4- PS- 1 4-DB-4 4-DB-5 4-DB-6 4-DB-2
5-BN4 SEE MAIN HARNESS 4- DB1- 3

DB
5-BN3
B
BK-6 JT BK B
4-BN5
5-BN1 DIAGNOSTIC
CONNECTOR
BK-12
JT BK1 4-DB-3 4-DB-1

BK-12
WH/BE-18
BK-16
4- DB2- 3
BK-12
JT BK2
VOIR/ SEE
DB
BK-12 BK-12
A JT BK3 A
DB
219001865-009
JT BK4
2015/04/22 710004328F3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
OUTLANDER/RENEGADE
2018 - Volume 2
OUTLANDER/RENEGADE
Volume 2
2018 - Volume 2
2018 Flat Rate
OUTLANDER/RENEGADE
Schedule
2018 - Volume 2
Barème de temps
à taux fixe
OUTLANDER/RENEGADE
2018 - Volume 2
OUTLANDER / MAX
TM
650/850/1000
OUTLANDER X mr
TM
650/850/1000
OUTLANDER/RENEGADE
RENEGADE TM
2018 - Volume 2
Effective April 26th, 2017 570/850/1000

En vigueur le 26 avril 2017
RENEGADE X mr
TM
® MC ET LE LOGO BRP SONT DES MARQUES DE COMMERCE DE BOMBARDIER PRODUITS RÉCRÉATIFS INC. OU DE SES SOCIÉTÉS AFFILIÉES.
©2017 BOMBARDIER PRODUITS RÉCRÉATIFS INC. TOUS DROITS RÉSERVÉS. IMPRIMÉ AU CANADA.
®™ AND THE BRP LOGO ARE TRADEMARKS OF BOMBARDIER RECREATIONAL PRODUCTS INC. OR ITS AFFILIATES.
570/1000
©2017 BOMBARDIER RECREATIONAL PRODUCTS INC. ALL RIGHTS RESERVED. PRINTED IN CANADA.
INTRODUCTION
This publication governs all warranty labor allowances 4. JOB REQUIREMENTS
for 2018 BRP ATV. All the flat rate times mentioned in the following pages
1. HOW DOES IT WORK include the required operations such as: engine timing
(rotary valve and ignition), connecting rod(s) alignment,
We follow the procedures detailed in the BRP ATV cylinder head(s) torque or use of parallel bar, use of ig-
Shop Manual. The flat rate time is the maximum time nition tester, piston clearance/ring end gap measure-
allowed for a repair involving any given part. FLAT ment, crankshaft to crankcase measurement, cylinder
RATE TIME IS NOT CUMULATIVE. You must use the honing, engine leak test.
flat rate time given for the longest lasting operation.
NOTE: The Flat Rate Time Schedule was prepared by 5. ILLUSTRATIONS
skilled mechanics using the hand tool usually found in The illustrations contained in this manual do not neces-
workshops and all the special tools mentioned in the sarily show every components of a given system as
Shop Manual. Parts Catalog do. Their purpose is to facilitate recogni-
tion of parts related to a flat rate time. Item numbers
2. COMPILATION on illustrations correspond to the four digit Job
The Flat Rate Time Schedule is compiled as follows: Code.
The actual required time to perform the repair plus (+)
30% correction factor up to 3.0 hours or (+) 15% over 6. FLAT RATE TIME SUGGESTION
3.0 hours time to take into account, among others: SEND A WARRANTY CASE ON BOSSWeb INFO
– Vehicle handling CENTER
– Obtaining the parts In the case, you must provide the following information:
– Diagnosis Section Subject:
– Cleaning – Flat rate time suggestion
– Special compensation (rusted bolts).
Section Your Question:
3. HOW TO USE IT – Model year;
Refer to the system you need, locate part of series of – Model description;
parts replaced. List JOB CODE in the appropriate col- – Description job code;
umn on claim. – Job code;
SYSTEM PAGE – Present flat rate;
– Suggested flat rate;
01 ENGINE 5 – Detailed repair procedure;
02 CARBURETOR AND FUEL SYSTEM 21 To ensure that your case will be promptly and efficiently
processed please indicate the step by step repair
03 IGNITION SYSTEM 24 procedure you performed.
04 STARTER 26
05 TRANSMISSION SYSTEM 27
06 BRAKE SYSTEM 33
STEERING SYSTEM AND FRONT
07 35
SUSPENSION
REAR SUSPENSION SYSTEM AND
08 TRACK 41
09 BODY 46
10 ELECTRICAL SYSTEM 57
NOTE: Unless otherwise specified, dismantling order

is: top to bottom, exterior to interior, front to rear.
All fractions of hours are in tenths:
0.1 = 6 minutes
0.2 = 12 minutes, and so on
LEGEND:
* REQUIRES PRIOR AUTHORIZATION BY DISTRIBUTOR.
INDICATE LABOUR TIME ON LINE “LABOUR ONLY“ OF
**
CLAIM.
INDICATE $$$ AMOUNT ON “SUB-CONTRACTED
***
LABOUR“ OF CLAIM.
IMPORTANT: Always use the longest flat rate time ap-
plicable to the repair performed.
Volume 2 - Can-Am 1
2018 VTF2018-002_OUTLANDER
INTRODUCTION
Cette publication détermine le temps de main-d’oeuvre LÉGENDE:
couvert par la garantie pour les VTT BRP 2018. * AUTORISATION REQUISE AVANT LE REMPLACEMENT.
INSCRIRE LE TEMPS À LA LIGNE «MAIN-D’OEUVRE
**
1. UTILISATION DU MANUEL SEULEMENT».
En procédant de la façon indiquée dans le Manuel de *** INSCRIRE LE MONTANT $$$ À LA LIGNE «OUVRAGE
SOUS-CONTRACTÉ».
réparation VTT BRP, chaque temps donné représente
le maximum permis pour une réparation portant sur IMPORTANT: Toujours utiliser le temps donné à l’opé-
cette pièce. LES TEMPS NE SONT PAS CUMULA- ration qui nécessite le plus de temps.
TIFS. On doit inscrire le temps donné pour l’opération
qui prend le plus de temps. 4. TRAVAUX REQUIS
REMARQUE: Le Barème de temps à taux fixe a été Tous les temps mentionnés dans les pages suivantes
préparé par des mécaniciens compétents utilisant les incluent les opérations telles que: réglage du moteur
outils que l’on retrouve normalement dans les ateliers (valve rotative et allumage), alignement de la ou des
de réparation, en plus de tous les outils spéciaux men- bielles, couple de serrage de la ou des culasses ou l’uti-
tionnés dans le Manuel de réparation. lisation de barres parallèles, utilisation du vérificateur
d’allumage, mesure du jet des pistons/jeu en bout des
2. COMPILATION segments, mesure de l’écart entre le vilebrequin et le
Le Barème de temps à taux fixe a été établi en compi- carter, rectification du cylindre, vérification de fuite du
lant le temps nécessaire pour faire la réparation plus (+) moteur.
un facteur de correction de 30% lorsqu’un travail dure 5. ILLUSTRATIONS
3.0 heures et moins, ou (+) 15% lorsqu’un travail dure
plus de 3.0 heures. Cette compilation comprend, entre Contrairement aux Catalogues de pièces, les illustra-
autres, les étapes suivantes: tions de ce manuel ne montrent pas nécessairement
chacune des pièces qu’elles représentent, leur raison
– Manutention du véhicule d’être étant plutôt de faciliter la reconnaissance des
– Nettoyage pièces reliées à un barème de temps à taux fixe. Les
– Aller chercher les pièces, essais physiques numéros d’items sur les illustrations correspondent
– Compensation spéciale (boulons rouillés) aux quatre derniers chiffres du code de travail.
– Diagnostic. 6. SUGGESTION DE BARÈME DE TEMPS À
3. UTILISATION DU BARÈME TAUX FIXE
Se reporter à la section désirée, repérer la pièce ou l’en- ENVOYEZ UNE REQUÊTE GARANTIE BOSSWeb
semble de pièces remplacées et inscrire le CODE DE DEPUIS LA SECTION INFO CENTRE
TRAVAIL dans la colonne appropriée sur la formule de Dans cette requête, vous devez fournir les informations
réclamation. suivantes:
Section Objet:
SYSTÈME PAGE – Suggestion de barème de temps à taux fixe
01 MOTEUR 5 Section Votre Question:
CARBURATEUR ET SYSTÈME – L'année modèle;
02 21 – Description du modèle;
D’ALIMENTATION D’ESSENCE
– Description du code de travail;
03 SYSTÈME D’ALLUMAGE 24
– Code de travail;
04 DÉMARREUR 26 – Temps actuel;
– Temps suggéré;
05 SYSTÈME DE TRANSMISSION 27
– Détails de la marche à suivre;
06 SYSTÈME DE FREIN 33 Pour s'assurer que votre demande sera traitée dans les
SYSTÈME DE DIRECTION ET plus brefs délais et efficacement, s.v.p. nous fournir
07 35 toutes les étapes de réparation dans les détails de la
SUSPENSION AVANT
marche à suivre
SYSTÈME DE SUSPENSION ARRIÈRE ET
08 41
CHENILLE
09 CARROSSERIE 46
10 SYSTÈME ÉLECTRIQUE 57
REMARQUE: Sauf indication contraire, le démontage

doit s’effectuer de haut en bas, de l’extérieur vers l’in-
térieur, de l’avant vers l’arrière.
Toutes les fractions d’heures sont exprimées en dixiè-
mes:
0.1 = 6 minutes
0.2 = 12 minutes, et ainsi de suite
2 Can-Am - Volume 2
2018
2018
ATV / VTT
MODEL/ ENGINE TYPE/
TABLE DESCRIPTION MODÈLE TYPE DE MOTEUR DPS
OUTLANDER 650 2NJA/2NJB N/A

OUTLANDER DPS 650 2BJA/2BJB
3PJA/3PJB
OUTLANDER PRO 650
3PJC
650 CVT
2PJA/2PJB DPS
2PJC/2PJD
OUTLANDER XT 650
2PJE/2PJF
2PJG/2PGH
OUTLANDER WIN 650 5PJA
OUTLANDER DPS 850 2AJA/2AJB
OUTLANDER MOS850 4NJA
2JJA/2JJB
6
OUTLANDER XT 850 2JJC/2JJD 850 CVT DPS
2JJE/2JJF
OUTLANDER XTP 850 5RJA/5RJB
OUTLANDER WIN 850 2HJB
OUTLANDER DPS 1000 5LJA/5LJB
OUTLANDER MOS 1000 4MJB/4MJC
5TJA/5TJB
OUTLANDER XT 1000 5TJC/5TJD
1000R CVT DPS
5TJE
5XJA/5XJB
OUTLANDER XTP 1000
5XJC
OUTLANDER XXC 1000 1XJA/1XJB
OUTLANDER MAX DPS 650 2DJA/2DJB
2SJA/2SJB
2SJC/2SJD
OUTLANDER MAX XT 650 2SJE/2SJF
2SJG/2SJH 650 CVT DPS
2SJJ
OUTLANDER MAX XTP 650 3DJB/3DJC
7 OUTLANDER MAX WIN 650 2RJB/2RJC
2LJA/2LJB
2LJC/2LJD
OUTLANDER MAX XT 850
2LJE/2LJF
2LJG
850 CVT DPS
5FJA/5FJB
OUTLANDER MAX XTP 850
5FJC
OUTLANDER MAX WIN 850 5HJB
Volume 2 - Can-Am 3
2018
OUTLANDER MAX PRO 1000 3UHA
5UJA/5UJB
OUTLANDER MAX XT 1000 5UJC/5UJD
5UJE
7 1000R CVT DPS
5WJA/5WJB
OUTLANDER MAX LTD 1000
5WJC
5JJA/5JJB
OUTLANDER MAX XTP 1000
5JJC
OUTLANDER XMR 650 5EJA/5EJB 650 CVT
OUTLANDER XMR 850 4KJA 850 CVT
8 DPS
5KJA/5KJB
OUTLANDER XMR 1000 1000R CVT
5KJC
4EJA/4EJB
RENEGADE 570 570 CVT N/A
4EJC
RENEGADE 850 4BJA/4BJB N/A
4DJA/4DJB 850 CVT
9 RENEGADE XXc 850 DPS
4DJC
RENEGADE 1000 4GJA N/A
5VJA/5VJB 1000R CVT
RENEGADE XXc 1000 DPS
5VJC
RENEGADE XMR 570 4TJA/4TJB 570 CVT DPS
10 4FJA/4FJB
RENEGADE XMR 1000 1000R CVT DPS
4FJC
4 Can-Am - Volume 2
2018
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
NO LABOR INVOLVED
01 00 AUCUNE MAIN D’OEUVRE 0 0 0 0 0
01 01 REMOVE AND REPLACE ENGINE (ASS’Y) 4.7 4.7 5.0 4.4 4.4
* REMPLACEMENT DU MOTEUR (COMPLET)
OIL PRESSURE SWITCH
01 03 INTERRUPTEUR DE PRESSION D’HUILE 0.3 0.3 0.3 0.3 0.3
HEAT SHIELD AND/OR RUBBER MOUNT

01 04 DÉFLECTEUR DE CHALEUR ET/OU BUTÉE DE CAOUTCHOUC 0.4 0.4 0.4 0.4 0.4
FAN AND/OR FAN SUPPORT

01 08 1.3 1.3 0.6 1.1 1.1
VENTILATEUR ET/OU SUPPORT DE VENTILATEUR
CYLINDERS AND/OR GASKETS (ALL)
01 17 CYLINDRES ET/OU JOINTS D’ÉTANCHÉITÉ (TOUS) 4.5 4.5 4.5 4.5 4.5
SENDER TEMPERATURE (ENGINE)

01 18 0.9 0.9 0.9 0.9 0.9
CAPTEUR DE TEMPÉRATURE (MOTEUR)
THERMOSTAT
01 19 THERMOSTAT 0.5 0.5 0.5 0.5 0.5
RADIATOR INLET HOSE

01 37 BOYAU D’ENTRÉ DU RADIATEUR 0.5 0.5 0.5 0.5 0.5
WATER PUMP SHAFT (ALL PARTS)

01 38 ARBRE DE POMPE À L'EAU (TOUTES LES PIÈCES) 5.5 5.5 5.5 5.2 5.2
ENGINE DAMPERS (1 OR ALL)

01 45 TAMPONS ANTI-VIBRATION (1 OU TOUS) 4.0 4.0 4.0 3.8 3.8
RADIATOR AND/OR GROMMMET

01 46 1.6 1.6 1.0 1.4 1.4
RADIATEUR ET/OU PASSE-FILS
CRANKSHAFT AND/OR BEARINGS (FRONT/REAR)
01 50 VILEBREQUIN ET/OU ROULEMENTS (AVANT/ARRIÈRE) 7.0 7.0 7.3 6.7 6.7
CRANKCASE COVER GASKET

01 56 JOINT DE COUVERCLE DE CARTER 1.3 1.3 1.3 1.3 1.3
PTO CRANKCASE COVER

01 57 COUVERCLE DE CARTER PDM 1.3 1.3 1.3 1.3 1.3
INTAKE OR EXHAUST VALVE GUIDE (1)

01 58 GUIDE DE SOUPAPE D'ADMISSION OU D'ÉCHAPPEMENT (1) 2.8 2.8 2.8 2.8 2.8
INTAKE OR EXHAUST VALVE GUIDES (2)

01 59 GUIDES DE SOUPAPE D'ADMISSION OU D'ÉCHAPPEMENT (2) 2.9 2.9 2.9 2.9 2.9
MUFFLER AND/OR EXHAUST GASKET AND/OR CLAMP

01 70 SILENCIEUX D’ÉCHAPPEMENT ET/OU JOINT D’ÉCHAPPEMENT ET/OU 0.3 0.3 0.3 0.3 0.3
BRIDE DE SERRAGE
EXHAUST MANIFOLD (REAR)
01 73 CONNECTEUR D'ÉCHAPPEMENT (ARRIÈRE) 0.5 0.5 0.5 0.5 0.5
RUBBER ISOLATOR
01 77 ISOLATEUR DE CAOUTCHOUC 1.0 1.0 1.0 1.0 1.0
Volume 2 - Can-Am 5
2018
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
COOLANT HOSE (ENGINE TO TANK)
01 79 BOYAU DU SYSTÈME DE REFROIDISSEMENT (RÉSERVOIR AU MOTEUR) 0.4 0.4 0.4 0.4 0.4
EXHAUST MANIFOLD (FRONT)

01 83 0.5 0.5 0.5 0.5 0.5
CONNECTEUR D'ÉCHAPPEMENT (AVANT)
TUNE PIPE HEAT SHIELD (1)
01 84 DÉFLECTEUR DE CHALEUR TUYAU D'ÉCHAPPEMENT (1) 0.3 0.3 0.3 0.3 0.3


RUBBER MOUNT (MUFFLER)

01 88 TAMPON D'ANCRAGE (SILENCIEUX) 0.3 0.3 0.3 0.3 0.3
ENGINE OIL FILTER

01 90 0.3 0.3 0.3 0.3 0.3
FILTRE À HUILE DU MOTEUR
OIL SIEVE AND/OR O-RING AND/OR COLLECTOR AND/OR RUBBER RING
AND/OR COVER
01 96
CRIBLE D’HUILE ET/OU JOINT TORIQUE ET/OU COLLECTEUR ET/OU ANNEAU DE
6.7 6.7 7.0 6.4 6.4
CAOUTCHOUC ET/OU COUVERCLE
COOLING RESERVOIR
01 98 RÉSERVOIR D’ANTIGEL 1.0 1.0 1.0 1.0 1.0
RADIATOR OUTLET HOSE

01 100 0.4 0.4 0.4 0.4 0.4
BOYAU DE SORTIE DU RADIATEUR
PISTON, PIN, CIRCLIP, RINGS (1)
01 101 PISTON, GOUPILLE, CIRCLIP, SEGMENTS (1) 3.0 3.0 3.0 3.0 3.0
PISTONS, PINS, CIRCLIPS, RINGS (2)

01 102 PISTONS, GOUPILLES, CIRCLIPS, SEGMENTS (2) 4.7 4.7 4.7 4.7 4.7
VALVE COVER AND/OR GASKET

01 109 COUVERCLE DE SOUPAPE ET/OU JOINT D’ÉTANCHÉITÉ 0.5 0.5 0.5 0.5 0.5
TIMING GEAR
01 111 PIGNON DE DISTRIBUTION 1.2 1.2 1.2 1.2 1.2
ROCKER ARM AND/OR PUSH ROD AND/OR ROCKER ARM SHAFT

01 113 1.3 1.3 1.3 1.3 1.3
CULBUTEUR ET/OU TIGE POUSSOIR ET/OU ARBRE DE CULBUTEUR
CYLINDER HEAD
01 114 CULASSE 3.5 3.5 3.5 3.5 3.5
EXHAUST AND/OR INLET VALVE AND/OR SPRING AND/OR SEAL

01 116 VALVE ADMISSION ET/OU ÉCHAPPEMENT ET/OU RESSORT ET/OU ANNEAU 2.7 2.7 2.7 2.7 2.7
D’ÉTANCHÉITÉ
CYLINDER AND/OR GASKET
01 117 CYLINDRE ET/OU JOINT D’ÉTANCHÉITÉ 2.8 2.8 2.8 2.8 2.8
WATER PUMP HOUSING AND/OR IMPELLER

01 119 CARTER DE LA POMPE À EAU ET/OU ROUE À AILETTES 0.4 0.4 0.4 0.4 0.4
OIL PUMP GEAR

01 132 1.5 1.5 1.5 1.5 1.5
ENGRENAGE DE LA POMPE À HUILE
6 Can-Am - Volume 2
2018
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
CAMSHAFT
01 134 ARBRE À CAME 2.3 2.3 2.3 2.3 2.3
OIL PUMP COVER AND/OR SHAFT AND/OR ROTOR

01 137 1.5 1.5 1.5 1.5 1.5
COUVERCLE DE LA POMPE À HUILE ET/OU ARBRE ET/OU ROTOR
CRANKCASE RESEAL OR GASKET
01 138 RECELLEMENT DU CARTER ET/OU JOINT D’ÉTANCHÉITÉ 6.9 6.9 7.2 6.6 6.6
CRANKCASE REPLACEMENT
01 139 REMPLACEMENT DU CARTER 7.2 7.2 7.5 6.9 6.9
DRIVE SHAFT AND/OR BEARINGS AND/OR SEALS

01 152 ARBRE D’ENTRAÎNEMENT ET/OU ROULEMENT À BILLES ET/OU ANNEAUX 6.9 6.9 7.2 6.6 6.6
D’ÉTANCHÉITÉ
TIMING CHAIN
01 154 CHAÎNE D’ENGRENAGE 3.1 3.1 3.1 3.1 3.1
CHAIN GUIDE
01 179 1.0 1.0 1.0 1.0 1.0
GUIDE DE CHAÎNE
OIL RADIATOR AND/OR O-RING
01 182 RADIATEUR D’HUILE ET/OU JOINT TORIQUE 1.7 1.7 1.7 1.7 1.7
CHAIN TENSION GUIDE

01 191 GUIDE DE TENSION DE CHAÎNE 3.1 3.1 3.1 3.1 3.1
CHAIN TENSIONER (ASS’Y)

01 192 TENDEUR DE CHAÎNE (COMPLET) 0.3 0.3 0.3 0.3 0.3
HEAT SHIELD (RH OR LH)

01 196 DÉFLECTEUR DE CHALEUR (DR OU GA) 0.5 0.5
WATER PUMP GEAR

01 200 1.6 1.6 1.6 1.6 1.6
ENGRENAGE DE LA POMPE À EAU
REAR OUTPUT SHAFT SEAL
01 205 ANNEAU D’ÉTANCHÉITÉ DE L’ARBRE DE SORTIE ARRIÈRE 5.2 5.2 5.5 4.9 4.9
OIL DIPSTICK
01 215 JAUGE À HUILE 0.3 0.3 0.3 0.3 0.3
PRESSURE CAP
01 216 BOUCHON À PRESSION 0.3 0.3 0.3 0.3 0.3
ENGINE BRACKET AND/OR RUBBER MOUNT

01 217 ATTACHE MOTEUR ET/OU TAMPON D'ANCRAGE 0.3 0.3 0.3 0.3 0.3
MAIN DRIVE GEAR AND/OR PIN

01 220 ROUAGE D'ENTRAÎNEMENT PRINCIPALE ET/OU GOUPILLE 1.6 1.6 1.6 1.6 1.6
INTERMEDIATE GEAR AND/OR PIN AND/OR THRUST WASHER

01 221 ROUAGE INTERMEDIAIRE ET/OU GOUPILLE ET/OU RONDELLE D'APPUI 1.6 1.6 1.6 1.6 1.6
FRONT OUTPUT SHAFT SEAL

01 223 2.7 2.7 2.7 2.7 2.7
ANNEAU ÉTANCHÉITÉ ARBRE SORTIE AVANT
OUTPUT CRANKSHAFT SEAL (PTO SIDE)
01 245 ANNEAU ÉTANCHÉITÉ SORTIE VILBREQUIN (CÔTÉ PDM) 0.6 0.6 0.6 0.6 0.6
WATER PUMP GEAR AND/OR SEAL

01 246 ARBRE POMPE À EAU ET/OU JOINT ÉTANCHÉITÉ 5.5 5.5 5.8 5.2 5.2
Volume 2 - Can-Am 7
2018
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
REED VALVE AND/OR STOPPER
01 247 SOUPAPE À CLAPET ET/OU BUTOIR 1.6 1.6 1.6 1.6 1.6
BREATHER GEAR AND/OR V-RING

01 248 1.6 1.6 1.6 1.6 1.6
RENIFLARD ET/OU ANNEAU ÉTANCHÉITÉ EN «V»
CAMSHAFT POSITION SENSOR
01 249 CAPTEUR DE POSITION DE L’ARBRE À CAME 0.3 0.3 0.3 0.3 0.3
CRANKSHAFT POSITION SENSOR (CPS)

01 250 CAPTEUR DE POSITION DU VILEBREQUIN (CPV) 0.3 0.3 0.3 0.3 0.3
EXHAUST AND/OR INLET VALVES AND/OR SPRINGS AND/OR SEALS (4)

01 255 ÉCHAPPEMENT ET/OU VALVES ADMISSION ET/OU RESSORTS ET/OU 3.3 3.3 3.3 3.3 3.3
ANNEAUX D’ÉTANCHÉITÉ (4)
EXHAUST AND/OR INLET VALVES AND/OR SPRINGS AND/OR SEALS (8)
01 256 ÉCHAPPEMENT ET/OU VALVES ADMISSION ET/OU RESSORTS ET/OU 6.4 6.4 6.1 6.1 6.1
ANNEAUX D’ÉTANCHÉITÉ (8)
TIMING CHAIN (MAG SIDE)
01 261 CHAÎNE D’ENGRENAGE (CÔTÉ MAG) 2.8 2.8 2.8 2.8 2.8
LONG BLOCK
01 264 ENSEMBLE CARTER - CYLINDRE - CULASSE 6.7 6.7 7.0 6.4 6.4
WATER PUMP DYNAMIC SEAL AND/OR OIL SEAL

01 301 ANNEAU D’ÉTANCHÉITÉ DYNAMIQUE DE LA POMPE À EAU 2.1 2.1 2.1 2.1 2.1
TIMING CHAINS (ALL)

01 303 5.3 5.3 5.3 5.3 5.3
CHAÎNES D’ENGRENAGE (TOUTES)
CHAINS TENSION GUIDE (ALL)
01 304 GUIDE DE TENSION DE CHAÎNES (TOUS) 5.3 5.3 5.3 5.3 5.3
CHAINS GUIDE (ALL)

01 305 GUIDE DE CHAÎNES (TOUS) 1.8 1.8 1.8 1.8 1.8
VALVE COVERS AND/OR GASKETS (2)

01 307 COUVERCLES SOUPAPE ET/OU JOINTS D’ÉTANCHÉITÉ (2) 0.6 0.6 0.6 0.6 0.6
CYLINDER HEAD GASKET (1)

01 308 JOINT D’ÉTANCHÉITÉ DE LA CULASSE (1) 1.4 1.4 1.4 1.4 1.4
CYLINDER HEAD GASKETS (2)

01 309 2.3 2.3 2.3 2.3 2.3
JOINTS D’ÉTANCHÉITÉ DE LA CULASSE (2)
MUFFLER END CAP
01 316 EMBOUT DE SILENCIEUX 0.3 0.3 0.3 0.3 0.3
RADIATOR SUPPORT
01 318 0.4
SUPPORT DE RADIATEUR
FAN SUPPORT
01 324 SUPPORT DU VENTILATEUR 0.5
RADIATOR COVER
01 333 COUVERCLE DE RADIATEUR 0.3
FILLER NECK AND/OR HOSE

01 334 GOULOT REMPLISSAGE ET/OU BOYAU 1.1
8 Can-Am - Volume 2
2018
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
COOLANT HOSE (ENGINE INLET)
01 336 BOYAU DE REFROIDISSEMENT (ENTRÉE DU MOTEUR) 0.4 0.4 0.4 0.4 0.4
PLUG SCREW
01 340 0.5 0.5 0.5 0.5 0.5
BOUCHON FILETÉ
INJECTORS (ALL)
01 353 INJECTEURS (TOUS) 1.9 1.9 1.9 1.6 1.6
Volume 2 - Can-Am 9
2018
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
V800/1000
FRONT/REAR
AVANT/ARRIÈRE
01109
01307
01113
0119
01111
01191 01192
01304
01116
01255
01154 01256
01261
01303 01134
01179
01305
01249
0158 01114
0159
01113
01116
01255
01256 01116
01255
01256
01308
01309
V07C2RY
10 Can-Am - Volume 2
2018
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
Volume 2 - Can-Am 11
2018
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
01247 0156
0157
01139
01245
V07C2TS
2018
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01119
01301
0138
01246
01200
V07C2VV
2018
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
0103 01215
0190
01248
0196
01220
01137
V07C2WS 01132
2018
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01205
01152
01223
vtf2009-001-001_a
2018
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
01216
01100 0198
0179
0146
0108
0108
0137
vtf2012-002-001_a
2018
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01318
01333
01100
01216
01100
01334
0146
0108
0119
01324
0119
0137
01336
vtf2013-002-001_a
2018
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
0146
01216
0108
01100 0119
0119
0137
01336
vtf2012-002-002_b
2018
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
0145
0177
0145 0145
vtf2016-001-001
2018
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
0183
0184
0184
0173
0104
0185
0186
01196
01316
0170
0104
vtf2013-002-002_a
2018
CARBURETOR AND FUEL SYSTEM
CARBURATEUR ET SYSTÈME D’ALIMENTATION D’ESSENCE 02
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
NO LABOR INVOLVED
AIR INTAKE SILENCER (ASS’Y)

02 01 SILENCIEUX D’ADMISSION D’AIR (COMPLET) 1.8 1.8 1.8 1.5 1.5
THROTTLE CABLE
02 06 CÂBLE D’ACCÉLÉRATEUR 0.6 0.6 0.6 0.6 0.6
INTAKE ADAPTOR
02 16 ADAPTATEUR D’ADMISSION 1.0 1.0 1.0 1.0 1.0
AIR INTAKE TUBE

02 19 1.0 1.0 1.3 1.0 1.0
TUYAU D’ADMISSION D’AIR
REAR AIR INTAKE TUBE AND/OR SLEEVE
02 23 1.8 1.8 2.2 1.5 1.5
TUYAU D’ADMISSION D’AIR ARRIÈRE ET/OU DOUILLE
AIR TEMPERATURE SENSOR
02 46 0.3 0.3 0.3 0.3 0.3
CAPTEUR DE TEMPÉRATURE D’AIR
FUEL FILTER
02 57 FILTRE À ESSENCE
1.0 1.0 1.0 1.0 1.0
FUEL TANK
02 58 RÉSERVOIR D’ESSENCE
1.6 1.6 1.6 1.6 1.6
INTAKE COVER AND/OR SEAL

02 59 COUVERCLE D’ADMISSION ET/OU JOINT D’ÉTANCHÉITÉ
0.3 0.3 0.3 0.3 0.3
FUEL CAP
02 60 BOUCHON DU RÉSERVOIR À ESSENCE
0.3 0.3 0.3 0.3 0.3
AIR FILTER
02 69 FILTRE À AIR
0.3 0.3 0.3 0.3 0.3
INTAKE MANIFOLD
02 72 CONNECTEUR D’ADMISSION
1.9 1.9 1.9 1.6 1.6
FUEL RAIL (1 OR 2)
02 79 RAMPE D’ESSENCE (1 OU 2)
1.9 1.9 1.9 1.6 1.6
THROTTLE BODY (ASS’Y)

02 81 CARTER ACCÉLÉRATEUR (COMPLET) 1.7 1.7 2.0 1.4 1.4
THROTTLE SENSOR
02 82 CAPTEUR POSITION D’ACCÉLÉRATEUR 1.5 1.5 1.5 1.2 1.2
IDLE BY-PASS VALVE

02 84 1.5 1.5 1.5 1.2 1.2
VALVE DU RALENTI
FUEL PUMP MODULE
02 89 1.0 1.0 1.0 1.0 1.0
MODULE POMPE À ESSENCE
FEMALE QUICK FITTING
02 94 CONNECTEUR RAPIDE FEMELLE 0.4 0.4 0.4 0.4 0.4
FUEL INJECTION HOSE (ASS’Y)

02 99 BOYAU À INJECTION D’ESSENCE (COMPLET) 0.4 0.4 0.4 0.4 0.4
2018
02
SYSTEM/SYSTÈME
CARBURATEUR ET SYSTÈME D’ALIMENTATION D’ESSENCE
0289
0294
0262
0258
vtf2012-002-004_a
2018
CARBURATEUR ET SYSTÈME D’ALIMENTATION D’ESSENCE 02
SYSTEM/SYSTÈME
0219
0201
0269
0223
vtf2012-002-005_a
2018
03
SYSTEM/SYSTÈME
IGNITION SYSTEM
SYSTÈME D’ALLUMAGE
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
NO LABOR INVOLVED
MAGNETO (ASS’Y)
03 02 MAGNÉTO (COMPLET) 2.3 2.3 2.3 2.3 2.3
IGNITION COIL (EACH)

03 08 0.5 0.5 0.5 0.5 0.5
BOBINE D’ALLUMAGE (CHAQUE)
IGNITION CABLE
03 10 CÂBLE D’ALLUMAGE 0.5 0.5 0.5 0.5 0.5
STATOR (ASS’Y)
03 27 2.0 2.0 2.0 2.0 2.0
STATOR (COMPLET)
MAGNETO COVER
03 32 COUVERCLE DE MAGNÉTO 2.1 2.1 2.1 2.1 2.1
MAGNETO COVER GASKET

03 33 JOINT D’ÉTANCHÉITÉ COUVERCLE DE MAGNÉTO 2.0 2.0 2.0 2.0 2.0
2018
IGNITION SYSTEM
SYSTÈME D’ALLUMAGE 03
SYSTEM/SYSTÈME
0332
0333 0327
0302
V07G29T
2018
04
SYSTEM/SYSTÈME
STARTER SYSTEM
SYSTÈME DE DÉMARREUR
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
NO LABOUR INVOLVED
04 00 AUCUNE MAIN-D’OEUVRE 0 0 0 0 0
ELECTRIC STARTER (ASS’Y)

04 02 DÉMARREUR (COMPLET) 1.6 1.6 1.6 1.6 1.6
STARTER RELAY
04 03 0.3 0.3 0.3 0.3 0.3
SOLÉNOÏDE DE DÉMARRAGE
STARTER DRIVE
04 19 LANCEUR DÉMARREUR 1.9 1.9 1.9 1.9 1.9
2018
TRANSMISSION AND LINKAGE SYSTEM
SYSTÈME DE TRANSMISSION ET DE TRINGLERIE
05
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENAGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
NO LABOR INVOLVED
05 00 AUCUNE MAIN-D’OEUVRE IMPLIQUÉE 0 0 0 0 0
DRIVEN PULLEY SLIDING HALF

05 12 DEMI-POULIE MENÉE COULISSANTE 0.5 0.6 0.6 0.5 0.5
05 19 BELT
COURROIE
0.4 0.5 0.5 0.4 0.4
LEVER BUTTON
05 55 BOUTON DE LEVIER 0.3 0.3 0.3 0.3 0.3
LEVER (ASS’Y) AND/OR LEVER SPRING

05 56 LEVIER (COMPLET) ET/OU RESSORT DE LEVIER 0.3 0.3 0.3 0.3 0.3
05 59 SPEED SENSOR
CAPTEUR DE VITESSE
0.6 0.6 0.6 0.6
LEVER
05 77 LEVIER 0.7 0.7 0.7 0.7 0.7
CVT COVER
05 78 COUVERCLE CVC 0.3 0.4 0.4 0.3 0.3
05 79 GASKET
JOINT D’ÉTANCHÉITÉ
0.3 0.4 0.4 0.3 0.3
GOVERNOR CUP
05 80 COUPOLE RÉGULATEUR 0.6 0.7 0.7 0.6 0.6
ONE WAY CLUTCH, FLANGE, RING, SPRING

05 81 EMBRAYAGE À ROUE LIBRE, FLASQUE, ANNEAU, RESSORT 0.6 0.7 0.7 0.6 0.6
05 82 DRIVE PULLEY (ASS’Y)

POULIE MOTRICE (COMPLET)
0.7 0.8 0.8 0.7 0.7
DRIVE PULLEY FIXED HALF

05 83 POULIE MOTRICE FIXE 0.7 0.8 0.8 0.7 0.7
DRIVEN PULLEY OUTER CAM AND/OR SPRING

05 84 CAME DE POULIE MENÉE EXTERNE ET/OU RESSORT 0.5 0.6 0.6 0.5 0.5
05 85 CENTRIFUGAL LEVER
LEVIER CENTRIFUGE
0.8 0.9 0.9 0.8 0.8
SLIDER SHOES
05 86 GLISSIÈRES 0.7 0.8 0.8 0.7 0.7
LEVER SPRING
05 87 LEVIER À RESSORT 0.3 0.3 0.3 0.3 0.3
05 89 REMOVE AND REPLACE TRANSMISSION (ASS’Y)

REMPLACEMENT DE LA TRANSMISSION (COMPLET)
5.1 5.1 5.4 4.8 4.8
MAIN SHAFT (ASS'Y)

05 91 ARBRE DE RENVOI (COMPLET) 6.7 6.7 7.0 6.7 6.7
AIR INTAKE (CVT)

05 95 ENTRÉE D'AIR (CVT) 0.3 0.3 0.4 0.3 0.3
AIR OUTLET (CVT)

05 96 0.3 0.3 0.4 0.3 0.3
SORTIE D'AIR (CVT)
2018
05
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENAGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
FLEXIBLE ADAPTOR
05 97 ADAPTATEUR FLEXIBLE 0.3 0.3 0.3 0.3 0.3
CAM, PLATE, DRIVEN SHAFT, SPRING

05 98 0.5 0.6 0.6 0.5 0.5
CAME, PLAQUE, ARBRE POULIE MENÉE, RESSORT
OUTPUT SHAFT
05 99 ARBRE DE SORTIE 5.9 5.9 6.2 5.6 5.6
REAR OUTPUT SHAFT SEALS

05 100 ANNEAUX ÉTANCHÉITÉ DE L’ARBRE DE SORTIE ARRIÈRE 2.2 2.2 2.2 2.2 2.2
GEARS KIT/MAIN SHAFT

05 101 ENSEMBLE D'ENGRENAGES/ARBRE PRINCIPAL 6.0 6.0 6.3 5.7 5.7
SHIFT SHAFT (ASS'Y )

05 102 ARBRE D'EMBRAYAGE (COMPLET) 6.0 6.0 6.3 5.7 5.7
SHIFT DRUM
05 103 6.0 6.0 6.3 5.7 5.7
TAMBOUR D'EMBRAYAGE
INDEX LEVER (ASS'Y)
05 104 LEVIER D'INDEXATION (COMPLET) 6.0 6.0 6.3 5.7 5.7
MAIN SHAFT SEAL

05 105 0.9 0.9 0.9 0.9 0.9
JOINT D'ÉTANCHÉITÉ DE L'ARBRE PRINCIPAL
LH HOUSING GEAR AND/OR BEARINGS AND/OR GEAR
05 106 LOGEMENT DE TRANSMISSION GAUCHE ET/OU ROULEMENT À BILLE ET/OU 6.0 6.0 6.3 5.7 5.7
ENGRENAGE
SPACER AND/OR O-RING
05 107 ENTRETOISE ET/OU JOINT TORIQUE 0.9 0.9 0.9 0.9 0.9
ACTUATOR AND/OR FORK AND/OR SEAL

05 108 0.5 0.5 0.5 0.5 0.5
ACTUATEUR ET/OU FOURCHETTE ET/OU JOINT D'ÉTANCHÉITÉ
FORK AND/OR PIN
05 109 FOURCHETTE ET/OU GOUPILLE 0.7 0.7 0.7 0.7 0.7
CENTER HOUSING GEAR AND/OR BEARING

05 110 LOGEMENT DE TRANSMISSION CENTRE ET/OU ROULEMENT 6.0 6.0 6.3 5.7 5.7
RH HOUSING GEAR AND/OR BEARING

05 111 LOGEMENT DE TRANSMISSION DROIT ET/OU ROULEMENT 5.9 5.9 6.2 5.6 5.6
SHIFTING SWITCH
05 113 INTERRUPTEUR D'EMBRAYAGE 0.3 0.3 0.3 0.3 0.3
SHIFT SHAFT SEAL

05 114 JOINT D'ÉTANCHÉITÉ D’ARBRE D’EMBRAYAGE 0.7 0.7 0.7 0.7 0.7
CVT AIR GUIDE AND/OR O-RINGS

05 115 GUIDE D'AÉRATION ET/OU JOINT D'ÉTANCHÉITÉ 0.8 0.8 0.8 0.8 0.8
GEARBOX POSITION SENSOR

05 120 0.4 0.4 0.4 0.4 0.4
CAPTEUR DE POSITION D’ENGRENAGE
SHIFT ARM BASE
05 166 BASE DU BRAS D’EMBRAYAGE 0.5 0.5 0.5 0.5 0.5
2018
05
SYSTEM/SYSTÈME
05115
0598
0512
0584
0519
0583
0581 0579
0578
0582
0585
0580
0586
V07K15S
2018
05
SYSTEM/SYSTÈME
V500/650/800
05111 05100
05100
05114
05113
05112
05109
0599
05102
05110
05108 05101
05103
05104
0591
05106
05101
05105
05106
05107
V07K16S
2018
05
SYSTEM/SYSTÈME
V1000
05120
0559 05114
05111
05113
0599
05100
05103
05110
05111 05102
05108
05104
05109
0591
0599
05110
05101
0589
ttf2011-001-008_a
2018
05
SYSTEM/SYSTÈME
V1000
05104
05110
05101
05106
05101
05107
05106
05105
ttf2011-001-009_b
2018
BRAKE SYSTEM
SYSTÈME DE FREIN 06
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENAGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
NO LABOR INVOLVED
MASTER CYLINDRE
06 06 MAÎTRE-CYLINDRE 0.3 0.3 0.3 0.3 0.3
FRONT CALIPER (RH OR LH)

06 09 0.4 0.4 0.4 0.4 0.4
ÉTRIER AVANT (DROIT OU GAUCHE)
FRONT BRAKE PAD (RH OR LH)
06 10 PLAQUETTE DE FREIN AVANT (DROIT OU GAUCHE) 0.3 0.3 0.3 0.3 0.3
FRONT BRAKE DISC (RH OR LH)

06 11 0.5 0.5 0.5 0.5 0.5
DISQUE DE FREIN AVANT (DROIT OU GAUCHE)
FRONT FLEXIBLE BRAKE HOSE
06 12 BOYAU FLEXIBLE DE FREIN AVANT 0.6 0.6 0.6 0.6 0.6
FRONT BRAKE HANDLE HOSE

06 15 BOYAU DE FREIN DE LA MANETTE AVANT 0.6 0.6 0.6 0.6 0.6
FRONT MASTER CYLINDER

06 16 MAÎTRE-CYLINDRE AVANT 0.8 0.8 0.8 0.8 0.8
REAR BRAKE PEDAL

06 17 PÉDALE DE FREIN ARRIÈRE 0.4 0.4 0.4 0.4 0.4
REAR BRAKE PEDAL SPRING

06 18 0.3 0.3 0.3 0.3 0.3
RESSORT DE LA PÉDALE DE FREIN ARRIÈRE
BRAKE SWITCH
06 19 INTERRUPTEUR DE FREIN 0.5 0.6 0.6 0.5 0.5
REAR MASTER CYLINDER

06 22 MAÎTRE-CYLINDRE ARRIÈRE 0.7 0.7 0.7 0.7 0.7
REAR OIL HOUSING HOSE

06 23 BOYAU CARTER D’HUILE ARRIÈRE 0.6 0.6 0.6 0.6 0.6
REAR OIL HOUSING

06 24 CARTER D’HUILE ARRIÈRE 0.3 0.3 0.3 0.3 0.3
REAR BRAKE HOSE

06 25 0.6 0.6 0.6 0.6 0.6
BOYAU DE FREIN ARRIÈRE
REAR CALIPER
06 26 ÉTRIER ARRIÈRE 0.4 0.4 0.4 0.4 0.4
REAR BRAKE PAD

06 27 0.3 0.3 0.3 0.3 0.3
PLAQUETTE DE FREIN ARRIÈRE
REAR BRAKE DISC AND/OR HUB
06 28 DISQUE DE FREIN ARRIÈRE ET/OU MOYEU 0.5 0.5 0.5 0.5 0.5
BRAKE LINE
06 30 BOYAU DE FREIN 3.5 3.5 3.8 3.5 3.5
2018
34
Europe
0628
06
SYSTEM/SYSTÈME
vtf2013-002-003_a
0627
0625
0622
0619
BRAKE SYSTEM
0610
Europe
SYSTÈME DE FREIN
0606
0615
0617 0618
0609 0611
0630
2018
0619
0624
0622
0625
0612
0616
0612
0610
0611
0609
Can-Am - Volume 2
STEERING - FRONT DRIVE SYSTEM AND SUSPENSION
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION 07
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENAGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
NO LABOR INVOLVED
ARM PROTECTOR (RH OR LH)
07 04 PROTECTEUR DE BRAS (DROIT OU GAUCHE) 0.3 0.3 0.3 0.3 0.3
STEERING CLAMP AND/OR STEERING COVER SUPPORT
07 05 BRIDE DE DIRECTION ET/OU SUPPORT DU COUVRE-GUIDON 0.4 0.4 0.4 0.4 0.4
INTERNAL BALL JOINT (RH OR LH)
07 12 JOINT À ROTULE INTERNE (DROIT AU GAUCHE) 0.9 0.9 0.9 0.9 0.9
EXTERNAL BALL JOINT (RH OR LH)
07 13 JOINT À ROTULE EXTERNE (DROIT OU GAUCHE) 0.8 0.8 0.8 0.8 0.8
TIE ROD (RH OR LH)
07 19 BARRE D’ACCOUPLEMENT (DROIT OU GAUCHE) 0.9 0.9 0.9 0.9 0.9
MAIN TUBE
07 24 TUBE PRINCIPAL 2.6 2.6 3.0 2.6 2.6
HANDLEBAR
07 25 GUIDON 1.1 1.1 1.1 1.1 1.1
HANDLEBAR GRIP KIT (RH AND/OR LH)
07 26 ENSEMBLE DE GAINE DE GUIDON (DROIT ET/OU GAUCHE) 0.3 0.3 0.3 0.3 0.3
STEERING COVER
07 27 COUVRE-GUIDON 0.3 0.3 0.3 0.3 0.3
HALF HOUSING AND HOUSING BUSHING
07 28 DEMI-LOGEMENT ET DOUILLE DE LOGEMENT 2.1 2.1 2.4 2.1 2.1
LOWER STEERING MAIN TUBE BUSHING
07 29 DOUILLE INFÉRIEURE DE LA COLONNE DE DIRECTION 1.0 1.0 1.0 1.0 1.0
LOWER ARM AND/OR BALL JOINT (RH OR LH)
07 32 BRAS INFÉRIEUR ET/OU JOINT À ROTULE (DROIT OU GAUCHE) 0.7 0.7 0.7 0.7 0.7
UPPER ARM (RH OR LH)
07 33 BRAS DE SUSPENSION SUPÉRIEUR (DROIT OU GAUCHE) 0.8 0.8 0.8 0.8 0.8
HANDLE STEERING SUPPORT (ALL)
07 35 SUPPORT DE GUIDON (TOUS) 0.3 0.3 0.3 0.3 0.3
FRONT SHOCK AND/OR SPRING AND/OR STOPPER AND/OR PROTECTOR
AND/OR SEAT (RH OR LH)
07 37 0.7 0.7 0.7 0.7 0.7
AMORTISSEUR AVANT ET/OU RESSORT ET/OU BUTÉE ET/OU SIÈGE ET/OU
PROTECTEUR (DROIT OU GAUCHE)
FRONT DIFFERENTIEL (ASS’Y)
07 40 DIFFÉRENTIEL AVANT (COMPLET)
2.4 2.4 2.4 2.4 2.4
FRONT PROPELLER SHAFT (ASS’Y)
07 42 ARBRE DE PROPULSION AVANT (COMPLET)
1.3 1.3 1.3 1.3 1.3
CV JOINT (RH OR LH)
07 45 JOINT HOMOCINÉTIQUE (DROIT OU GAUCHE)
0.8 0.8 0.8 0.8 0.8
FRONT WHEEL HUB (SEAL AND/OR BEARING) (RH OR LH)
07 46 MOYEU DE ROUE AVANT (JOINT ET/OU ROULEMENT) (DROIT OU GAUCHE)
0.5 0.5 0.5 0.5 0.5
KNUCKLE (RH OR LH)
07 47 PORTE-FUSÉE (DROIT OU GAUCHE)
0.8 0.8 0.8 0.8 0.8
2018
07
SYSTEM/SYSTÈME
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION
OUTLANDER
OUTLANDER
OUTLANDER
RENAGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
FRONT RIM AND/OR TIRE
07 50 JANTE AVANT ET/OU PNEU 0.4 0.4 0.4 0.4 0.4
THROTTLE HANDLE
07 56 MANETTE D’ACCÉLÉRATEUR 0.3 0.3 0.3 0.3 0.3
PITMAN ARM
07 65 2.6 2.6 2.6 2.6 2.6
LEVIER DE DIRECTION
INTERNAL BUSHING AND/OR CUSHION (LOWER AND/OR UPPER ARM) (RH OR
LH)
07 72 DOUILLE INTERNE ET/OU COUSSIN (BRAS INFÉRIEUR ET/OU SUPÉRIEUR)
0.4 0.4 0.4 0.4 0.4
(DROIT OU GAUCHE)
BALL JOINTS REPLACEMENT (2)
07 73 REMPLACEMENT DES JOINTS A ROTULE (2)
1.0 1.0 1.0 1.0 1.0
FRONT RIM
07 80 JANTE AVANT
0.4 0.4 0.4 0.4 0.4
RADIAL BALL BEARINGS
07 82 0.8 0.8 0.8 0.8 0.8
ROULEMENTS À BILLE RADIALES
RING GEAR AND/OR CARRIER AND/OR SHIM
07 85 COURONNE DE LANCEMENT ET/OU SUPPORT ET/OU CALE
3.0 3.0 3.0 3.0 3.0
RING GEAR DRIVE GEAR AND/OR BEARING AND/OR SHIM
07 88 PIGNON DE COMMANDE DE LA COURONNE ET/OU ROULEMENT À BILLE ET/OU 2.7 2.7 2.7 2.7 2.7
CALE
COVER AND/OR PINION COVER AND/OR SEAL AND/OR BEARING
07 89 COUVERCLE ET/OU COUVERCLE DE PIGNON ET/OU JOINT D’ÉTANCHÉITÉ ET/OU 3.0 3.0 3.0 3.0 3.0
ROULEMENT À BILLE
BOOT WHEEL KIT AND/OR CV JOINT (RH OR LH)
07 90 0.8 0.8 0.8 0.8 0.8
ENSEMBLE DE SOUFFLET DE ROUE ET/OU JOINT CV (DROIT OU GAUCHE)
BOOT DIFFERENTIAL KIT AND/OR PLUNGING JOINT (RH OR LH)
07 91 ENSEMBLE DE SOUFFLET DE DIFFÉRENCIEL ET/OU JOINT PLONGEANT (DROIT 0.8 0.8 0.8 0.8 0.8
OU GAUCHE)
SLEEVE AND/OR WEARRING
07 92 MANCHON ET/OU BAGUE D'USURE
1.3 1.3 1.3 1.3 1.3
UNIT PACK KIT
07 94 ENSEMBLE JOINT CARDAN
2.3 2.3 2.3 2.3 2.3
UPPER ARM BRACKET
07 96 ATTACHE BRAS SUPÉRIEUR
2.2 2.2 2.2 2.2 2.2
POWER STEERING
07 99 SERVODIRECTION
2.6 2.6 2.6 2.6 2.6
DEFLECTOR (LH OR RH)
07 101 DÉFLECTEUR (GA OU DR)
0.3 0.3 0.3 0.3 0.3
DIFFERENTIAL SEAL (1)
07 103 JOINT D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (1)
0.8 0.8 0.8 0.8 0.8
DIFFERENTIAL SEALS (2)
07 104 JOINTS D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (2)
1.5 1.5 1.5 1.5 1.5
DIFFERENTIAL BELLOW
07 119 SOUFFLET DU DIFFÉRENTIEL
0.3 0.3 0.3 0.3 0.3
2018
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENAGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
DIFFERENTIAL OIL SEAL
07 120 ANNEAU D’ÉTANCHÉITÉ DU DIFFÉRENTIEL 2.6 2.6 2.6 2.6 2.6
GPS SUPPORT
07 123 SUPPORT DU GPS 0.3
2018
07
SYSTEM/SYSTÈME
07101
0726 Europe
0724
A
XT 0799
0727
A
0735 0724
0725
0735 0765
0728 DPS System/
LTD Direction Assistée
Renegade STD
07123 0719
0729
0727
0713
vtf2013-002-004_a
2018
SYSTEM/SYSTÈME
0737
0733
0733
0733
0796
0733
0732
0732
0732
0704
0732
vtf2012-002-009_a
2018
07
SYSTEM/SYSTÈME
07120
2018
REAR DRIVE SYSTEM AND SUSPENSION
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION 08
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
NO LABOR INVOLVED
REAR WHEEL HUB (RH)

08 05 MOYEU DE ROUE ARRIÈRE (DROIT) 0.5 0.5 0.5 0.5 0.5
COMPRESSOR
08 21 1.3
COMPRESSEUR
PNEUMATIC HOSE
08 24 BOYAU PNEUMATIQUE 0.5
REAR DIFFERENTIAL (ASS’Y)

08 07 1.8 1.8 1.8 1.8 1.8
DIFFÉRENTIEL ARRIÈRE (COMPLET)
REAR PROPELLER SHAFT (ASS’Y)
08 26 ARBRE DE PROPULSION ARRIÈRE (COMPLET) 1.5 1.5 1.5 1.5 1.5
SWING ARM
08 62 BRAS OSCILLANT 1.2 1.2 1.2 1.2 1.2
LH PROTECTOR
08 101 PROTECTEUR GAUCHE 0.3 0.3 0.3 0.3 0.3
RH PROTECTOR
08 102 PROTECTEUR DROIT 0.3 0.3 0.3 0.3 0.3
REAR WHEEL HUB (LH)

08 109 0.3 0.3 0.3 0.5 0.5
MOYEU DE ROUE ARRIÈRE (GAUCHE)
REAR SHOCK (RH OR LH)
08 111 AMORTISSEUR ARRIÈRE (DROIT OU GAUCHE) 0.4 0.4 0.4 0.4 0.4
REAR RIM AND/OR TIRE

08 114 JANTE ARRIÈRE ET/OU PNEU 0.4 0.4 0.4 0.4 0.4
CV JOINT (RH OR LH)

08 120 JOINT HOMOCINÉTIQUE (DROIT OU GAUCHE) 0.8 0.8 0.8 0.8 0.8
STABILIZER BAR
08 121 BARRE STABILISATRICE 2.3 2.3 2.3 2.3 2.3
RING GEAR AND/OR SHIM

08 122 3.1 3.1 3.1 3.1 3.1
COURONNE DE LANCEMENT ET/OU CALE
RING GEAR DRIVE GEAR AND/OR BEARING AND/OR SHIM
08 123 PIGNON DE COMMANDE DE LA COURONNE ET/OU ROULEMENT À BILLE ET/OU 3.1 3.1 3.1 3.1 3.1
CALE
COVER AND/OR PINION COVER AND/OR SEAL AND/OR BEARING
08 124 COUVERCLE ET/OU COUVERCLE DE PIGNON ET/OU JOINT D’ÉTANCHÉITÉ ET/OU 3.3 3.3 3.3 3.3 3.3
ROULEMENT À BILLE
BOOT WHEEL KIT AND/OR CV JOINT (RH OR LH)
08 125 0.9 0.9 0.9 0.9 0.9
ENSEMBLE DE SOUFFLET DE ROUE ET/OU JOINT CV (DROIT OU GAUCHE)
BOOT DIFFERENTIAL KIT AND/OR PLUNGING JOINT (RH OR LH)
08 126 ENSEMBLE DE SOUFFLET DE DIFFÉRENTIEL ET/OU JOINT PLONGENT 0.9 0.9 0.9 0.9 0.9
(DROIT OU GAUCHE)
RADIAL BALL BEARINGS
08 127 ROULEMENTS À BILLE RADIALES 1.0 1.0 1.0 1.0 1.0
2018
08
SYSTEM/SYSTÈME
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
UNIT PACK KIT
08 128 ENSEMBLE DE JOINT CARDAN 1.7 1.7 1.7 1.7 1.7
UNIT PACK KIT (2)

08 129 1.8 1.8 1.8 1.8 1.8
ENSEMBLE DE JOINT CARDAN (2)
DIFFERENTIAL SEAL (1)
08 134 JOINT D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (1) 0.9 0.9 0.9 0.9 0.9
PRESSURE COLLECTOR ASS'Y

08 137 COLLECTEUR DE PRESSION COMPLET 0.6
AIR SUSPENSION MODULE

08 138 MODULE DE SUSPENSION À AIR 0.6
AIR SUSPENSION SENSOR

08 139 CAPTEUR DE LA SUSPENSION À AIR 0.4
AUXILIARY FITTING AND SUPPORT

08 140 0.4
RACCORD AUXILIAIRE ET SUPPORT
DIFFERENTIAL SEALS (2)
08 135 JOINTS D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (2) 1.8 1.8 1.8 1.8 1.8
DIFFERENTIAL OIL SEAL

08 148 1.9 1.9 1.9 1.9 1.9
ANNEAU D’ÉTANCHÉITÉ DU DIFFÉRENTIEL
AXIAL PIVOT
08 149 AXE DE PIVOT 0.5 0.5 0.5 0.5 0.5
2018
SYSTEM/SYSTÈME
08124
08122
08126
08123
08125
08126
0807
0807
08114
0826
0805
08109
08127
vtf2012-002-011_a
2018
08
SYSTEM/SYSTÈME
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION
08140
08121 08139
0824
08121
08137
0862
08127
0862
0821
08101
0862 08127
08102 08149
vtf203-002-005_a
2018
SYSTEM/SYSTÈME
08137
0824
08138
08111
vtf2013-002-006_a
2018
09
SYSTEM/SYSTÈME
BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
NO LABOR INVOLVED
09 00 AUCUNE MAIN D’OEUVRE IMPLIQUÉE 0 0 0 0 0
HOOD
09 01 CAPOT 0.3 0.3 0.3
LUGGAGE RACK KIT (FRONT OR REAR)

09 13 0.5 0.5 0.5
ENSEMBLE DE PORTE-BAGAGES (AVANT OU ARRIÈRE)
CONSOLE
09 17 CONSOLE 0.3 0.3 0.3 0.3 0.3
SEAT
09 21 0.3 0.3 0.3 0.3 0.3
SIÈGE
SEAT COVER
09 22 HOUSSE DE SIÈGE 1.0 1.0 1.0 1.0 1.0
FRONT BUMPER
09 26 PARE-CHOCS AVANT 0.9 0.9 0.9 0.7 0.7
WINCH LATCH
09 27 ATTACHE DE TREUIL 0.3 0.3 0.3 0.3 0.3
FRONT FASCIA
09 28 FASCIA AVANT 0.9 0.9 0.9 0.7 0.7
REAR FASCIA
09 29 0.3 0.3 0.3 0.3 0.3
FASCIA ARRIÈRE
REAR BUMPER
09 34 PARE-CHOCS ARRIÈRE 0.3 0.3 0.3 0.4 0.4
FRONT OR REAR MUDGUARD KIT (RH OR LH)

09 39 GARDE DE BOUE AVANT/ARRIÈRE (DROIT OU GAUCHE) 0.3 0.3
REAR HANDLE (RH OR LH)

09 45 POIGNÉE ARRIÈRE (GAUCHE OU DROITE) 0.3
FOOTREST (RH OR LH)

09 48 MARCHEPIED (DROIT OU GAUCHE) 0.4 0.5 0.5 0.4 0.4
09 49 FRAME 13.0 14.0 14.0 12.5 13.0

* CHÂSSIS
SIDE BRACKET (RH OR LH)
09 52 SUPPORT LATÉRAL (DROIT OU GAUCHE) 0.6 0.6 0.6
REAR FENDER
09 56 AILE ARRIÈRE 0.9 0.9 0.9 0.8 0.8
FRONT FENDER AND/OR SUPPORT (RH OR LH)

09 57 AILE AVANT ET/OU SUPPORT (DROIT OU GAUCHE) 1.0 1.0 1.0 1.5 1.5
FOOTREST SUPPORT (RH OR LH)

09 74 0.4 0.5 0.5 0.4 0.4
SUPPORT DE REPOSE PIED (DROIT OU GAUCHE)
AIR INTAKE DEFLECTOR
09 84 DÉFLECTEUR ADMISSION AIR 0.3
STORAGE SUPPORT
09 85 SUPPORT DU COFFRE 0.7 0.7 0.7
2018
CARROSSERIE ET ACCESSOIRES 09
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
FOOTWELL (RH OR LH)
09 91 REPOSE-PIED (DROIT OU GAUCHE) 0.3 0.4 0.4 0.3 0.3
PROTECTION PLATE
09 93 0.5 0.5 0.5
PLAQUE DE PROTECTION
EACH DECAL (1)
09 95 CHAQUE AUTOCOLLANT (1) 0.3 0.3 0.3 0.3 0.3
REAR SEAT ASS'Y

09 108 SIÈGE ARRIÈRE ASS. 0.4
FRONT LIGHT FASCIA

09 120 FASCIA DE LUMIÈRE AVANT 0.4 0.4
HAND PROTECTOR
09 138 PROTÈGE MAIN 0.3 0.3 0.3 0.3 0.3
ENGINE SIDE PANELS (2)

09 149 0.3 0.3 0.3 0.3 0.3
PANNEAUX MOTEUR (2)
UPPER CONSOLE
09 157 CONSOLE SUPÉRIEURE 0.3 0.3 0.3 0.3 0.3
FRONT FENDER SUPPORT

09 158 1.0 1.0 1.0 1.6 1.6
SUPPORT D’AILE AVANT
REAR BUMPER (XT)
09 161 PARE-CHOC ARRIÈRE (XT) 0.3 0.3 0.3
FRONT BUMPER (XT)

09 162 PARE-CHOC AVANT (XT) 0.3 0.3 0.3 0.3
BACKREST PARTS
09 198 PIÈCES DU DOSSIER 0.4
REAR SEAT BASE A/O ALL PARTS

09 199 BASE SIÈGE ARRIÈRE ET/OU TOUTES LES PIÈCES 1.0
REAR FENDER SUPPORT

09 200 1.9 1.9 1.9 1.5 1.5
SUPPORT D’AILE ARRIÈRE
REAR SEAT COVER
09 203 HOUSSE DE SIÈGE ARRIÈRE 1.0
FRONT FASCIA (RH OR LH)

09 210 FASCIA AVANT (DROIT OU GAUCHE) 0.4 0.4
CONSOLE SUPPORT
09 244 SUPPORT DE CONSOLE 0.5 0.5 0.8 0.5 0.5
REAR BOX
09 283 COFFRE ARRIÈRE 1.1 1.1 1.1
BOX DOOR
09 284 PORTE DE COFFRE 0.3 0.3 0.3
REAR SUPPORT
09 304 SUPPORT ARRIÈRE 1.9 1.9 1.9
INNER FENDER (RH OR LH)

09 305 0.3 0.3 0.3 0.3 0.3
FAUSSE AILE (DROIT OU GAUCHE)
2018
09
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
HITCH
09 316 ATTACHE 0.3 0.3 0.3
CENTRAL SKID PLAT

09 336 0.4 0.4 0.4 0.4 0.4
PLAQUE DE PROTECTION CENTRALE
LOCK
09 367 VERROU 0.3 0.3 0.3
REAR STORAGE COVER

09 389 COUVERCLE DU COFFRE ARRIÈRE 0.7 0.7 0.7
FOOTREST (RIGHT OR LEFT)

09 390 APPUI-PIEDS (DROIT OU GAUCHE) 0.3
BUMPER (RH OR LH)

09 398 PARE-CHOC (DROIT OU GAUCHE) 0.4
UPPER INLET
09 478 0.4
ENTRÉE D’AIR SUPÉRIEUR
UPPER OULET
09 479 SORTIE D’AIR SUPÉRIEUR 0.4
2018
SYSTEM/SYSTÈME
0929
0956
0991
0948
0929
0956
0991
0948
0917
09149
0957
09305
09157
09149
0901
09305
0957
vtf2012-002-013_a
2018
09
SYSTEM/SYSTÈME
09200
0974
09304
0949
0974
09316
vtf2012-002-016_a
2018
SYSTEM/SYSTÈME
0913
0913
09161
09158
0928 0949
0926
0993
09162
09336
vtf2012-002-014_a
2018
09
SYSTEM/SYSTÈME
0952
0985
0934
0985
0952
09389
09283
09284
09367
vtf2012-002-015_a
2018
SYSTEM/SYSTÈME
0984
09244
0917
09398
0993 09157
09149
0928
0957
09149
0901
09158 0956
0926
0929
0991
09305
09162
09305
09149
09336
0956
09149
0957 09390
0929
0991 09161
0948
vtf2013-002-007_a
2018
09
SYSTEM/SYSTÈME
09198
09198
0945 09199
09199
0945
vmo2015-002-001
2018
SYSTEM/SYSTÈME
0957
0939 09162
0917 0928
09157
1
09305 16
09158
0939 0928
09149
09479
0956 0991 09478

0926
0929
09149
09305
0991 0993
0939
0929
0939
09336
vtf2016-001-005
2018
09
SYSTEM/SYSTÈME
09157
0917 0929
09305 0929
09149
0956
0928
0957
09210 0991
09210
09158
09305
09149
vtf2012-002-017_a
2018
ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE 10
SYSTEM/SYSTÈME
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
NO LABOR INVOLVED
IGNITION SWITCH
10 01 INTERRUPTEUR D’ALLUMAGE 0.3 0.3 0.3 0.3 0.3
HEADLAMP AND/OR HEADLAMP SUPPORT (ASS’Y) (RH OR LH)

10 09 0.3 0.3 0.3 0.3 0.3
PHARE AVANT ET/OU SUPPORT (COMPLET) (DROIT OU GAUCHE)
VOLTAGE REGULATOR
10 10 RÉGULATEUR DE TENSION 0.3 0.3 0.3 0.3 0.3
BATTERY
10 13 0.3 0.3 0.3 0.3 0.3
BATTERIE
MULTIFUNCTION SWITCH
10 21 INTERRUPTEUR MULTIFONCTION 0.8 0.8 1.1 0.3 0.3
SPEEDOMETER/TACHOMETER
10 28 INDICATEUR DE VITESSE/COMPTE-TOURS 0.3 0.3 0.3 0.3 0.3
TAIL LAMP HOUSING (ASS’Y)

10 29 BOÎTIER DE FEU ARRIÈRE (COMPLET) 0.3 0.3 0.3 0.3 0.3
DC OUTLET PLUG
10 31 PRISE D’ACCESSOIRE DC 0.3 0.3 0.3 0.3 0.3
ELECTRONIC MODULE
10 34 0.4 0.4 0.4 0.4 0.4
MODULE ÉLECTRONIQUE
ENGINE HARNESS
10 41 CÂBLAGE DU MOTEUR 1.4 1.4 1.4 1.3 1.3
WINCH (ASS’Y) (XT)

10 45 TREUIL (COMPLET) (XT) 0.4 0.4 0.4 0.4
WINCH SOLENOID (XT)

10 46 SOLÉNOÏDE DE TREUIL (XT) 0.5 0.5 0.5 0.5
WINCH SWITCH (XT)

10 47 INTERRUPTEUR DE TREUIL (XT) 0.4 0.4 0.4 0.4
MAIN WIRE HARNESS

10 51 2.5 2.7 3.0 2.2 2.2
CÂBLAGE PRINCIPAL
STARTING RELAY
10 52 RELAIS DE DÉMARRAGE 0.3 0.3 0.3 0.3 0.3
FRONT FLASHERS 1 OR 2 (CE ONLY)

10 61 0.3 0.3 0.3 0.3
CLIGNOTANTS AVANT 1 OU 2 (CE SEULEMENT)
REAR FLASHERS 1 OR 2 (CE ONLY)
10 62 CLIGNOTANTS ARRIÈRE 1 OU 2 (CE SEULEMENT) 0.3 0.3 0.3 0.3
12 VOLT RELAY (CE ONLY)

10 65 RELAIS 12 VOLT (CE SEULEMENT) 0.3 0.3 0.3 0.3 0.3
HORN
10 66 AVERTISSEUR 0.3 0.3 0.3 0.3 0.3
RELAY
10 67 RELAIS 0.3 0.3 0.3 0.3 0.3
2018
10
SYSTEM/SYSTÈME
ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE
OUTLANDER
OUTLANDER
OUTLANDER
RENEGADE
RENEGADE
X MR
MAX
XMR
SYSTÈME
CODE
SYSTEM
DESCRIPTION
6 7 8 9 10
ANY BULBS
10 68 TOUTES LES AMPOULES 0.6 0.6 0.6 0.6 0.6
LICENSE LIGHT (ASS’Y) (CE ONLY)

10 71 0.3 0.3 0.3 0.3
LUMIÈRE D’IMMATRICULATION (COMPLET) (CE SEULEMENT)
MULTIFONCTION SWITCH (RH)
10 101 INTERRUPTEUR MULTIFONCTION (DR) 0.3 0.3 0.3 0.3 0.3
REMOTE CONTROL
10 113 COMMENDE À DISTANCE 0.3 0.3 0.3
WINCH CONNECTOR
10 114 CONNECTEUR DE TREUIL 0.4 0.4 0.4 0.4
BATTERY SUPPORT
10 122 SUPPORT DE BATTERIE 0.5 0.5 0.5 0.5 0.5
2018
ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE 10
SYSTEM/SYSTÈME
1009
1069
1009
1045
1066
1046
1009
1065
1031
1010
1047
1001
1028
1052
1021
1010
1028
1013
10122
1071
1062
1029
vtf2013-002-009_a
2018
T3 4x4 OUTLANDER / OUTLANDER MAX 570/650/1000 Series
THIS VEHICLE CAN BE HAZARDOUS TO OPERATE.
A collision or rollover can occur quickly, even during
routine maneuvers such as turning and driving on hills
or over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if

you do not follow these instructions:
• BEFORE YOU OPERATE THIS VEHICLE, READ THIS

OPERATOR’S GUIDE, ALL ON PRODUCT SAFETY
2018
LABELS AND WATCH THE SAFETY VIDEO.
• NEVER OPERATE THIS VEHICLE WITHOUT
PROPER INSTRUCTIONS. Complete a certified
training course.
• FOR MAX MODELS, NEVER CARRY MORE THAN
ONE PASSENGER. You increase your risk of losing
control if you carry more than one passenger.
• FOR 1UP MODELS, NEVER CARRY A
PASSENGER. You increase your risk of losing control
if you carry a passenger. Operator’s
• NEVER OPERATE THIS VEHICLE ON A PAVED
SURFACE unless it is for short distances, at reduced
speed and in order to move the vehicule from an
Guide
off-road location to another. Includes
• ALWAYS RESPECT THE ROAD TRAFFIC LAWS Safety, Vehicle
when you operate the vehicule on the roadway, even a
dirt or gravel road. and Maintenance Information
• OPERATOR AND PASSENGER (MAX models)
SHOULD ALWAYS WEAR AN APPROVED HELMET,
eye protection, and protective clothing.
• NEVER USE WITH DRUGS OR ALCOHOL.
They slow reaction time and impair judgment.
• NEVER OPERATE THIS VEHICLE AT EXCESSIVE
SPEEDS. You increase your risk of losing control if you
operate this vehicle at speeds too fast for the terrain,
visibility conditions, or your experience.
T3 4x4 OUTLANDER TM/

• NEVER ATTEMPT WHEELIES, JUMPS, OR OTHER
STUNTS.
OUTLANDERTM MAXTM
570/650/1000 Series
WARNING
2018
Read this guide thoroughly. It contains important safety information.

219 001 872
Minimum recommended age: Operator: 16 years old. Driving tractor requires at least a tractor
OPERATOR’S GUIDE T3 4x4 OUTLANDER / MAX Series / ENGLISH driving license. Keep this Operator’s Guide in the vehicle.
GUIDE DU COND. Séries T3 4x4 OUTLANDER / MAX / ANGLAIS
FAIT AU / MADE IN CANADA U/M:P.C.

©2017 BOMBARDIER RECREATIONAL PRODUCTS INC. ALL RIGHTS RESERVED. PRINTED IN CANADA. 2 1 9 0 0 1 8 7 2 Original Instructions
Original Instructions
WARNING
YOUR VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rollover
can occur quickly, if you fail to take proper precautions, even during routine
maneuvers such as turning and driving on hills or over obstacles.
For your safety, understand and follow all the warnings contained in this
Operator's Guide and on the labels on your vehicle. Failure to follow these
warnings can result in SEVERE INJURY OR DEATH!
Keep this Operator's Guide with the vehicle at all times.
WARNING
Disregarding any of the safety precautions and instructions contained in
this Operator’s Guide, SAFETY VIDEO and on-product safety labels could
result in an injury including the possibility of death!
WARNING
This vehicle may exceed the performance of other vehicles you may have
ridden in the past. Take time to familiarize yourself with your new vehicle.
The following trademarks are the property of Bombardier Recreational

Products Inc.:
In Finland, products are distributed by BRP Finland Oy.
Can-Am® D.E.S.S.™ DPS™ Outlander™ Rotax® TTI™ XPS™
This document contains the trademark of the following companies:
– † Visco-Lok is a trademark of GKN Viscodrive GmbH.

– † QS3 is a trademark of Fox Factory, Inc.
219001872 en AG
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.
©2017 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
I VEHICLE IDENTIFICATION
The main components of your vehicle 2) Engine Identification
(engine and frame) are identified using Number (EIN)
different serial numbers. It may some-
times become necessary to locate
these numbers for warranty purposes
or to trace your vehicle in the event of
loss. These numbers are also required
by the authorized Can-Am dealer to
complete warranty claims properly.
No warranty will be allowed by BRP if
the engine identification number (EIN)
or vehicle identification number (VIN)
is removed, mutilated or altered in any
way. We strongly recommend that
you take note of all the serial numbers tmr2011-002-002_a
on your vehicle and supply them to TYPICAL - RH SIDE OF ENGINE

your insurance company. 1. Engine Identification Number (EIN)
1) Vehicle Identification 3) Compliance Labels

Number These labels indicate vehicle's compli-
ance.
fvmo2016-002-009_a
TYPICAL 704904067
1. VIN location VEHICLE IDENTIFICATION
_______________ 1
2 _______________
Please verify with your dealer to en-

sure your vehicle has been registered
with BRP.
4) Intended use
Agricultural tractor that can be used to
carry materials. Check the maximum
allowable load of the vehicle indicated
on the statutory plate and vehicle ma-
ximum load label, refer to IMPORTANT
ON-PRODUCT LABELS. The Can-Am
T3 tractor can tow a trailer on the road.
Check the maximum allowable load of
the trailer. Check the regulations for
your area regarding the use of a tractor
and trailer on the road. Connect the
trailer lights on the vehicle and install
a triangle for slow moving vehicles at
rear of the trailer.
_______________ 3
II FOREWORD
Dieses Handbuch ist möglicherweise in Ihrer Landessprache

Deutsch verfügbar. Bitte wenden Sie sich an Ihren Händler oder besuchen Sie:
www.operatorsguides.brp.com
This guide may be available in your language. Check with your dealer or
English
go to: www.operatorsguides.brp.com
Es posible que este manual esté disponible en su idioma. Consulte a su
Español
distribuidor o visite: www.operatorsguides.brp.com
Ce guide peut être disponible dans votre langue. Vérifier avec votre
Français
concessionnaire ou aller à: www.operatorsguides.brp.com
本手册可能有您的语种的翻译版本。请向经销商问询，或者登录
中文 www.operatorsguides.brp.com 查询。
このガイドは、言語によって翻訳版が用意されています。.
日本語ディーラーに問い合わせるか、次のアドレスでご確認ください：
Deze handleiding kan beschikbaar zijn in uw taal. Vraag het aan uw dealer
Nederlands
of ga naar: www.operatorsguides.brp.com
Denne boken kan finnes tilgjengelig på ditt eget språk. Kontakt din
Norsk
forhandler eller gå til: www.operatorsguides.brp.com
Este manual pode estar disponível em seu idioma. Fale com sua
Português
concessionária ou visite o site: www.operatorsguides.brp.com
Käyttöohjekirja voi olla saatavissa omalla kielelläsi. Tarkista jälleenmyyjältä
Suomi
tai käy osoitteessa: www.operatorsguides.brp.com
Denna bok kan finnas tillgänglig på ditt språk. Kontakta din återförsäljare
Svenska
eller gå till: www.operatorsguides.brp.com
This operator's guide is regarded as part of the vehicle and should be remain with
the vehicle when it is sold.
Congratulations on your purchase of a At delivery, you were also informed of
new Can-Am® ATV. It is backed by the the warranty coverage and signed the
BRP warranty and a network of autho- PREDELIVERY CHECK LIST to ensure
rized Can-Am dealers ready to provide your new vehicle was prepared to your
the parts, service or accessories you entire satisfaction.
may require.
Your dealer is committed to your sat- 1) Know Before you Go
isfaction. He has taken training to per- To learn how to reduce the risk for you
form the initial setup and inspection of or bystanders being injured or killed,
your vehicle as well as completed the read this Operator's Guide before you
final adjustment before you took pos- operate the vehicle.
session. If you need more complete
servicing information, please ask your Also, read all safety labels on your ATV
dealer. and watch attentively your SAFETY
VIDEO.
4 _______________
II FOREWORD
This vehicle is mainly for general recre- NOTICE Indicates an instruction

ational use but it may also be used for which, if not followed, could se-
utility purposes. verely damage vehicle components
Failure to follow the warnings con- or other property.
tained in this Operator's Guide can
result in SERIOUS INJURY or DEATH. 3) About this Operator's
Guide
Age Recommendation This Operator's Guide has been pre-
This vehicle is a category G, always fol- pared to acquaint the owner/operator
low this age recommendation: of a new vehicle with the various ve-
– A person under 16 years old should hicle controls, maintenance and safe
never operate this vehicle. operating instructions. It is indispens-
– This vehicle is for recreational use able for the proper use of the product.
by experienced operator's only. After reading, please keep this Opera-
– Passenger on 2-UP models must be tor's Guide with the vehicle. If the ve-
capable of keeping his feet on the hicle is resold, please give the guide to
footrests and his hands on grab han- the new owner for his awareness.
dles at all times when seated on this If you have any question regarding any
vehicle. topic whether or not it is covered in this
Operator's Guide, refer to CONTACT
Training Course US.
Never operate this vehicle without If you need more information, please
proper instruction. Take a training ask your dealer.
course. All operators should receive
training from a certified instructor.
WARNING
For more information about ATV safety, Throughout this Operator's Guide,
contact an authorized Can-Am dealer the term “1-UP” refers to vehi-
to find out about available training cles designed to carry the operator
courses nearest you. only while the term “2-UP” refers
to vehicles designed to carry also
2) Safety Messages a passenger.
The types of safety messages, what Make sure to identify and follow
they look like and how they are used in the warnings and instructions
this guide are explained as follows: that are applicable to your specific
model.
The safety alert symbol indicates
a potential injury hazard. Note that this guide is available in sev-
eral languages. In the event of any dis-
crepancy, the English version shall pre-
WARNING vail.
Indicates a potential hazard, if not
avoided, could result in serious in- Keep this Operator's Guide in the vehi-
jury or death. cle as you can refer to it for things such
as maintenance, troubleshooting and
instructing others.
CAUTION Indicates a hazard If you want to view and/or print an
situation which, if not avoided, extra copy of your Operator's Guide,
could result in minor or moderate simply visit the following website
injury. www.operatorsguides.brp.com.
_______________ 5
II FOREWORD
The information contained in this doc-

ument are correct at the time of publi-
cation. However, BRP maintains a pol-
icy of continuous improvement of its
products without imposing upon itself
any obligation to install them on prod-
ucts previously manufactured. Due
to late changes, some differences be-
tween the manufactured product and
the descriptions and/or specifications
in this guide may occur. BRP reserves
the right at any time to discontinue or
change specifications, designs, fea-
tures, models or equipment without
incurring any obligation upon itself.
This Operator's Guide and the SAFETY
DVD should remain with the vehicle
when it is sold.
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious
injury or death.
6 _______________
TABLE OF CONTENTS
I VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1) Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2) Engine Identification Number (EIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3) Compliance Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4) Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
II FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1) Know Before you Go . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2) Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3) About this Operator's Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A) SAFETY INFORMATION
I GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1) Avoid Carbon Monoxide Poisoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2) Avoid Gasoline Fires and Other Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3) Avoid Burns from Hot Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4) Accessories and Modifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
II SPECIAL SAFETY MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1) European Community. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
III OPERATION WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
IV RIDING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1) Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2) Riding Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3) Carrying a Passenger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4) Recreational Riding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5) Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6) Design Limitation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7) Off-Road Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8) Riding Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
V MOVING LOADS AND DOING WORK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1) Working with your Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2) Carrying Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3) Loading the Cargo Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4) Hauling a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5) Pulling a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
VI IMPORTANT ON-PRODUCT LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1) Hang Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2) Vehicle Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3) Compliance Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4) Technical Information Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
B) VEHICLE INFORMATION
I CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1) Throttle Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
_______________ 7
TABLE OF CONTENTS
I CONTROLS (cont’d)
2) Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3) Brake Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4) Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5) Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6) Ignition Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7) Multifunction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8) 2WD/4WD Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9) Winch Control Switch (Models with Winch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10) Shift Lever Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
II MULTIFUNCTION GAUGE (LCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1) Multifunction Gauge Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2) Multifunction Gauge Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3) Multifunction Gauge Set-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
III MULTIFUNCTION GAUGE (ANALOG/DIGITAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1) Multifunction Gauge Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2) Gauge Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
IV EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1) Operator's Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2) Passenger's Seat (2-UP Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3) Grab Handles (2-UP Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4) Footpegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5) 12-Volt Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6) Rear Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7) Cargo Racks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8) Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9) Trailer Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10) Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
11) Recovery Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
12) Winch (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
13) License Plate Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
V FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1) Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2) Recommended Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3) Vehicle Fueling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
VI BREAK-IN PERIOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Operation During Break-In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
VII BASIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1) Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2) Changing Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3) Stopping the Engine and Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
VIII SPECIAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1) What to Do if Water Entered the CVT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2) What to Do if Water Entered the Air Filter Housing. . . . . . . . . . . . . . . . . . . . . . 111
3) What to Do if Vehicle is Turned Over. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4) What to Do if Vehicle is Immersed in Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
8 _______________
TABLE OF CONTENTS
IX TUNE YOUR RIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1) Suspension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2) Dynamic Power Steering (DPS) Assist Level Adjustment . . . . . . . . . . . . . . 114
X VEHICLE TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
C) MAINTENANCE
I MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1) SEVERE DUSTY CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2) MAINTENANCE SCHEDULE LEGEND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3) MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
II MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1) Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2) Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3) Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4) Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5) Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6) Muffler Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7) CVT Air Filter (1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8) Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9) Throttle Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
10) Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
11) Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
12) Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
13) Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
14) Drive Shaft Boot and Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
15) Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
16) Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
17) Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
18) Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
19) Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
III VEHICLE CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1) Post-Operation Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2) Vehicle Cleaning and Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
IV STORAGE AND PRESEASON PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
D) TECHNICAL INFORMATION
I SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
E) TROUBLESHOOTING
TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

II MULTIFUNCTION GAUGE MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
_______________ 9
TABLE OF CONTENTS
F) SPARE PARTS
I CATALOGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
G) WARRANTY
I BRP INTERNATIONAL LIMITED WARRANTY: 2018 CAN-AMTM ATV T3 174

II BRP LIMITED WARRANTY FOR THE EUROPEAN ECONOMIC AREA, THE
COMMONWEALTH OF THE INDEPENDENT STATES AND TURKEY: 2018
CAN-AMTM ATV T3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
H) CUSTOMER INFORMATION
I PRIVACY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

II CONTACT US. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Oceania . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
South America. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Asia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
III CHANGE OF ADDRESS/OWNERSHIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
IV MAINTENANCE RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
10 ______________
A) SAFETY
INFORMATION
________ A) SAFETY INFORMATION _______ 11

I GENERAL PRECAUTIONS
1) Avoid Carbon – For refueling, strictly adhere to in-
Monoxide Poisoning structions in FUEL.
All engine exhaust contains carbon – Never start or operate the engine if
monoxide, a deadly gas. Breathing car- the fuel cap is not properly installed.
bon monoxide can cause headaches, Gasoline is poisonous and can cause
dizziness, drowsiness, nausea, confu- injury or death.
sion and eventually death. – Never siphon gasoline by mouth.
Carbon monoxide is a colorless, odor- – If you swallow gasoline, get any in
less, tasteless gas that may be present your eye(s), or inhale gasoline vapor,
even if you do not see or smell any en- see your doctor immediately.
gine exhaust. Deadly levels of carbon If gasoline spills on you, wash with
monoxide can collect rapidly, and you soap and water and change your
can quickly be overcome and unable clothes.
to save yourself. Also, deadly levels of
carbon monoxide can linger for hours
or days in enclosed or poorly ventilated 3) Avoid Burns from Hot
areas. If you experience any symp- Parts
toms of carbon monoxide poisoning, Certain components become hot dur-
leave the area immediately, get fresh ing operation. Avoid contact with
air and seek medical treatment. those parts during and shortly after
To prevent serious injury or death from operation to avoid burns.
carbon monoxide:
– Never run the vehicle in poorly ven- 4) Accessories and
tilated or partially enclosed areas Modifications
such as garages, carports or barns. Any modifications or addition of acces-
Even if you try to ventilate engine sories may affect the handling of your
exhaust with fans or open windows vehicle. It is important to take the time
and doors, carbon monoxide can to get familiar with the vehicle once
rapidly reach dangerous levels. modifications are made to understand
– Never run the vehicle outdoors how to adapt your driving behavior ac-
where engine exhaust can be drawn cordingly.
into a building through openings
such as windows and doors. Do not temper with unauthorized mod-
ifications or install equipment not
specifically certified by BRP for the
2) Avoid Gasoline Fires vehicle. These modifications have not
and Other Hazards been tested by BRP and they may in-
Gasoline is extremely flammable and crease the risk of injury or loss of con-
highly explosive. Fuel vapors can trol, or render the vehicle illegal to ride.
spread and be ignited by a spark or As an example, tempering with tire
flame many feet away from the en- specifications may affect the behavior
gine. To reduce the risk of fire or explo- of the vehicle and increase the risk of a
sion, follow these instructions: loss of control.
– Use only an approved red gasoline Ask your authorized BRP dealer for
container to store fuel. suitable available accessories for your
– Never fill a gasoline container on vehicle.
the vehicle. An electrical static dis- If no such attachment points are fore-
charge may ignite the fuel. seen, the operator' s manual shall
prohibit the installation of a frontend
loader
12 _______ A) SAFETY INFORMATION _______

I GENERAL PRECAUTIONS
This T3 has not attachment points for

frontend loader. Do not install front
loader.
See your authorized Can-Am dealer for
available accessories for your vehicle.

II SPECIAL SAFETY MESSAGES
THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
– This vehicle handles differently from other vehicles including motorcycles
and cars. A collision or rollover can occur quickly, if you fail to take proper
precautions, even during routine maneuvers such as turning and driving on hills
or over obstacles.
SEVERE INJURY OR DEATH can result if you do not comply with the following in-
structions:
– Read this Operator's Guide and all on-product safety labels carefully and follow
the operating procedures described. Watch and pay attention to the SAFETY
VIDEO before operating the vehicle.
– Always follow this age recommendation: A person under 16 years old should
never operate this vehicle.
– Never take place on this vehicle without wearing an approved helmet of the
proper size and other required riding gears. Refer to RIDING GEAR in RIDING
THE VEHICLE for detailed information.
– Never carry a passenger on this vehicle unless you are operating a 2-UP model.
Passenger(s) affect balance and steering and increase risk of losing control.
– On 1-UP models, do not make any modifications to accommodate a passenger
or use racks to carry a passenger.
– Never use this vehicle if you are tired, ill or under with drugs or alcohol. Your re-
action time and judgement is greatly affected under these conditions.
– Never attempt wheelies, jumps, or other stunts.
– Never operate at excessive speeds. Always go at a speed that is proper for the
terrain, visibility, and operating conditions, and your experience.
– Always go slowly and be extra careful when operating on unfamiliar terrain. Al-
ways be alert to changing terrain conditions when operating this vehicle.
– Never operate on excessively rough, slippery or loose terrain until you have
learned and practiced the skills necessary to control this vehicle on such terrain.
Always be especially cautious on these kinds of terrain.
– Always follow proper procedures for turning. Refer to RIDING TECHNIQUES in
RIDING THE VEHICLE.
– Never operate this vehicle on hills too steep for the vehicle or for your abilities.
– Always follow proper procedures for climbing hills as described in RIDING
TECHNIQUES. Check the terrain carefully before you start up any hill. Never
climb hills with excessively slippery or loose surfaces.
– Always follow proper procedures for going down hills and for braking on hills as
described in RIDING TECHNIQUES. Check the terrain carefully before you start
down any hill.
– Always follow proper procedures for crossing the side of a hill as described in
RIDING TECHNIQUES. Avoid hills with excessively slippery or loose surfaces.
– Always use proper procedures if you stall or roll backwards when climbing a
hill. To avoid stalling, use low gear and maintain a steady speed when climbing
a hill. If you stall or roll backwards, follow the driving technique procedures as
described in RIDING TECHNIQUES.
– Always check for obstacles before operating in a new area. Never attempt to
operate over large obstacles, such as large rocks or fallen trees. Always follow
proper procedures when operating over obstacles as described in RIDING
TECHNIQUES.

– Always be careful when skidding or sliding. Learn to safely control skidding or

sliding by practicing at low speeds and on level smooth terrain. On extremely
slippery surfaces, such as ice, go slowly and be very cautious in order to reduce
the chance of skidding out of control. If you are operating a 2-UP model and
have a passenger on-board, never attempt skidding or sliding; overturn or
passenger ejection may occur.
– Never operate this vehicle through deep or fast flowing water. Water should
never exceed footrests. Remember that wet brakes may have reduced stop-
ping ability. Test your brakes after leaving water, mud or snow. If necessary,
apply them several times to let friction dry out the pads.
– Always keep in mind that braking distance is readily affected by but not limited
to; weather and terrain conditions, braking system and tire conditions, vehicle
speed and attitude, and vehicle load including towing. Remember to adjust
your driving accordingly.
– Always be sure there are no obstacles or people behind the vehicle when you
operate in reverse. When it is safe to proceed in reverse, go slowly. Take into
account that on a 2-UP model the passenger can obstruct your view.
– BRP recommends sitting on your ATV when operating in reverse. Avoid stand-
ing up. Your weight could shift forward against throttle lever, causing an unex-
pected acceleration and may lead to a loss of control.
– Never exceed the stated load limits for this vehicle including operator, passen-
ger (2-UP models), all other loads and added accessories. Cargo should be prop-
erly distributed and securely attached. Reduce speed and follow instructions in
this guide for carrying cargo or pulling a trailer. Allow greater distance for brak-
ing.
– Always inspect and confirm the safe operating condition of your vehicle prior to
ride. Refer to PRE-RIDE INSPECTION in RIDING THE VEHICLE. Always follow
the maintenance schedules as described in this Operator's Guide. Refer to
MAINTENANCE.
– Never operate the vehicle if the controls do not function normally.
– Always maintain proper tire pressure. When replacing tires, use only the rec-
ommended tire size and type. For tire information, refer to SPECIFICATIONS.
– Riding your vehicle too fast for the conditions may result in injury. Apply only
enough throttle to proceed safely. Statistics show that mishaps and injury
usually result from high speed turns. Always remember that this vehicle is
heavy! Its pure weight alone may entrap you should it fall resulting in injury.
– This vehicle is not designed for jumping, nor can it fully absorb the high impact
energy generated during manoeuvres such as jumping which, can be passed on
to you, the operator. Performing wheelies can cause the vehicle to flip over onto
you. Both practices have a high risk for you and your passenger (2-UP models)
and should be avoided at all times.
2-UP Models
Driver must:
– Not forget is responsible for the safety of the passenger.
– Inform the passenger concerning the basic rules for a safe ride.
– Instruct the passenger to read the vehicle’s safety labels and to watch the
SAFETY VIDEO.

– Always practice the maneuvers described in this Operator's Guide without and
with a passenger. Greater skills are required with a passenger.
– Always remember that the vehicle handling and stability may be affected when
riding with a passenger. Safely reduce speed. Use proper judgement. If in
doubt, do not attempt and disembark the passenger before executing any
maneuver.
– Always remember that the vehicle braking distance may be longer when riding
with a passenger. Allow greater distance for braking.
– Never carry passenger on a 2-UP model if the passenger seat is not installed.
– Never carry more than one (1) passenger. Do not allow passenger to sit any-
where else than the designated passenger' seat.
– Never carry a passenger if you judge his ability or judgement insufficient to con-
centrate on the terrain conditions and adapt accordingly.
– Never carry a passenger who has used drugs or alcohol, or is tired or ill. These
slow reaction time and impair judgment.
Passenger must:
– Be capable of resting his feet on the footrests and his hands on grab handles
when seated on this vehicle.
– Never take place on this vehicle without wearing an approved helmet (including
a chin guard) that fits properly. The passenger should also wear eye protection
(goggles or face shield), gloves, boots, long sleeved shirt or jacket, and long
pants.
– Be seated on the designated passenger's seat.
– Always keep hands on grab handles and feet on the footrests during operation.
Never hold on to the operator.
– Never get up during vehicle operation. An excessive movement could cause
loss of control.
– Pay attention to vehicle and operator movements.
– Not wait and tell the driver to slow down or stop if you feel uncomfortable or in-
secure for any reason.

1) European Community
On Road Use
The followings warnings applies only in the European Countries where on road us-
age is allowed. SEVERE INJURY OR DEATH can result if you do not comply with
the following instructions.
WARNING
– This vehicle is built for OFF-ROAD purposes only. It may be used for short
distances on paved surfaces at reduced speed, in order to move the vehi-
cle from an off-road location to another.
– Always refrain from speeding and substantially reduce vehicle speed
when turning.
– Always respect the road traffic laws, even on a dirt or gravel road.
– Always use any other equipment as required by traffic law for slow mov-
ing vehicle.
– The front winch hook (if applicable) must be removed and stored.

III OPERATION WARNINGS
The following warning and their format have been requested by the United States
Consumer Product Safety Commission and are required to be in the Operator's
Guide for all ATVs.
NOTE: The following illustrations are general representations only. Your model
may differ.
The list is not exhaustive.
WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does not know
how to operate this vehicle properly in different situations and on different
types of terrain.
HOW TO AVOID THE HAZARD
Beginners and inexperienced operators should complete a training course.
They should then regularly practice the skills learned during the course as
well as the operating techniques described in this Operator's Guide.
For more information about a training course, contact an authorized
Can-Am dealer.

WARNING
V00A1AQ
POTENTIAL HAZARD
Failure to follow the age recommendations for this vehicle.
WHAT CAN HAPPEN
A lack of respect for this age recommendation can lead to severe injury or
death of the child.
Even though a child may be within the age group for which this vehicle is
recommended, he may not have the skills, abilities, or judgment needed to
operate this vehicle safely and may be involved in a serious accident.
No one under 16 should operate this vehicle.

2-UP Models Only
WARNING
vmo2014-005-100
POTENTIAL HAZARD
Failure to respect the physical limitations of the passenger on 2-UP models.
WHAT CAN HAPPEN
A passenger that cannot completely lean his feet on footrests can be ejected
when riding on uneven terrain.
The passenger must be capable of keeping his feet on the footrests and his
hands on grab handles at all times when he is seated on the vehicle.

1-UP Models Only
WARNING
V00A02Q
POTENTIAL HAZARD
Carrying a passenger on this vehicle.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and control this vehicle.
Could cause an accident, resulting in harm to you and/or your passenger.
Never carry passenger. Even with a long seat that provides unrestricted op-
erator movement, it is not designed nor intended to carry passenger(s).

2-UP Models Only
WARNING
V00A1CQ
POTENTIAL HAZARD
Carrying more than one (1) passenger on this vehicle.
WHAT CAN HAPPEN
Carrying more than one (1) passenger reduces your ability to balance and
control this vehicle.
Could cause an accident, resulting in harm to you and/or your passengers.
Never carry more than one (1) passenger. Even with a long seat that pro-
vides unrestricted operator movement, the vehicle is not designed nor
intended to carry more than one (1) operator and one (1) passenger. The
passenger must use the designated passenger's seat when he is seated on
the vehicle with feet firmly planted on footrests and always hold on to the
grab handles.

WARNING
V00A2DQ
POTENTIAL HAZARD
Allowing passenger(s) to sit on front or rear racks on this vehicle.
WHAT CAN HAPPEN
Allowing a passenger could:
– Impair vehicle stability which could lead to a loss of control.
– Result in injury to passenger(s) from impact on hard surfaces.
– Cause an accident, resulting in harm to you and/or your passenger.
Never allow any passenger to sit on front or rear racks on this vehicle.

WARNING
POTENTIAL HAZARD
Operating this vehicle on paved surfaces.
WHAT CAN HAPPEN
Paved surfaces may seriously affect handling and control of the vehicle, and
may cause the vehicle to go out of control.
If a road usage is allowed in your area, operate your vehicle on paved sur-
faces only for short distance and for the only purpose of moving the vehicle
from an off-road usage to another.
Always operate your vehicle at low speed (never exceed 40 km/h (25 MPH))
and reduce the speed before making a turn.
Always respect all road traffic laws when operating your vehicle on public
roads or streets.

WARNING
POTENTIAL HAZARD
Riding this vehicle without wearing an approved helmet, eye protection and
protective gear. On 2-UP models, passenger should also have an approved
helmet with a rigid chin guard.
WHAT CAN HAPPEN
– Riding without an approved helmet increases the chances of a severe
head injury or death in the event of an accident.
– Riding without eye protection can result in an accident and increases the
chances of a severe injury in the event of an accident.
– Riding without protective gear increases the chances of severe injury in
the event of an accident.
Always wear an approved helmet that fits properly. You should also wear:
– Eye protection (goggles or face shield)
– Rigid chin guard
– Gloves and boots
– Long sleeved shirt or jacket
– Long pants.

WARNING
V00A07Q
POTENTIAL HAZARD
Using this vehicle with drugs or alcohol.
WHAT CAN HAPPEN
Could cause the passenger to fall off (2-UP models).
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident or death.
The operator and the passenger (2-UP models) should never use this vehi-
cle with drugs or alcohol.

WARNING
V00A08Q
POTENTIAL HAZARD
Operating this vehicle at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of the vehicle, which can result in
an accident.
Always travel at a speed which is appropriate for the terrain, visibility and
operating conditions, and your experience.
On 2-UP models, the vehicle handling, stability and braking distance may
be affected when riding with a passenger. Safely reduce speed when riding

WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps and other stunts.
WHAT CAN HAPPEN
Increases the chance of an accident, for the operator and the passenger
(2-UP models), including an overturn.
Never attempt stunts, such as wheelies or jumps. Do not try to show off.
WARNING
POTENTIAL HAZARD
Failure to inspect the vehicle before operating.
Failure to properly maintain the vehicle.
WHAT CAN HAPPEN
Increases the possibility of an accident or equipment damage.
Always inspect your vehicle prior to ride to make sure the vehicle is in safe
operating condition.
Always follow the maintenance schedule described in this Operator's
Guide.

WARNING
POTENTIAL HAZARD
Riding on frozen waterways.
WHAT CAN HAPPEN
Breaking through the ice can lead to severe injury or death.
Never ride this vehicle on a frozen surface before you are sure the ice is thick
enough and sound enough to support the vehicle and its load, as well as the
force that is created by a moving vehicle.
WARNING
POTENTIAL HAZARD
Removing hands from handlebars for the opeator and from grab handles
for the passenger (2-UP models), or feet from the footrests during opera-
tion.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce your ability to control the vehi-
cle or could cause you to lose your balance and fall off the vehicle. If you re-
move a foot from the footrests, your foot or leg may come into contact with
the rear wheels, which could injure you or cause an accident.
Operator must always keep both hands on the handlebars and passenger
(2-UP models) on grab handles. Both feet (operator and passenger on 2-UP
models) must rest on the footrests during vehicle operation.

WARNING
POTENTIAL HAZARD
Failure to use extra care when operating this vehicle on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps, or holes, without enough time to
react.
Could result in the vehicle overturning, passenger ejection (2-UP models) or
loss of control.
Go slowly and be extra careful when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating the vehicle.
Do not forget, on 2-UP models, the operator is responsible for the safety of
his passenger. Safely reduce speed when riding with a passenger.

WARNING
POTENTIAL HAZARD
Failure to use extra care when operating on excessively rough, slippery or
loose terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle control, which could result in an acci-
dent, including an overturn or passenger ejection (2-UP models).
Do not operate on excessively rough, slippery or loose terrain until you
have learned and practiced the skills necessary to control this vehicle on
such terrain.
the passenger. In doubt, disembark him before operating on these terrains.

WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
Vehicle could go out of control, causing a collision or an overturn or a pas-
senger ejection (2-UP models).
Always follow proper procedures for turning as described in this Operator's
Guide. Practice turning at low speeds before attempting to turn at faster
speeds.
the passenger. Never perform this maneuver with a passenger. Always re-
member that the vehicle handling, stability and braking distance may be af-
fected when riding with a passenger.
Do not turn at excessive speed.

WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on extremely steep hills than on level
surfaces or small hills.
Never operate this vehicle on hills too steep for the vehicle or for your abili-
ties.
Practice, without and with passenger (2-UP models), on smaller hills before
attempting larger hills.
Always remember that, on 2-UP models, even if this vehicle can climb some
steep hills, it is not recommended to climb such hills with a passenger; al-
ways disembark him before attempting this maneuver. Show good judge-
ment.

WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Could cause loss of control, passenger ejection (2-UP models) or cause ve-
hicle to overturn.
Always follow proper procedures for climbing hills as described in this Op-
erator's Guide.
Always check the terrain carefully before you start up any hill. Do not
forget, on 2-UP models, the operator is responsible for the safety of the
passenger. In doubt, disembark him before climbing hill. Always remem-
ber that the vehicle handling, stability and braking distance may be affected
when riding with a passenger.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward (operator and passenger on (2-UP models).
Never open the throttle suddenly or make sudden gear changes. The vehi-
cle could flip over backwards.
Never go over the top of any hill at high speed. An obstacle, a sharp drop, or
another vehicle or person could be on the other side of the hill.

WARNING
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
hicle to overturn.
Always follow proper procedures for going down hills as described in this
Operator's Guide.
NOTE: A special technique is required when braking as you go down a hill.
Always check the terrain carefully before you start down any hill. Do not
passenger. In doubt, disembark him before going down hill. Always re-
member that the vehicle handling, stability and braking distance may be
affected when riding with a passenger.
Shift your weight backward (operator and passenger on 2-UP models).
Never go down a hill at high speed.
Avoid going down a hill at an angle which would cause the vehicle to lean
sharply to one side. Go straight down the hill where possible.

WARNING
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
WHAT CAN HAPPEN
hicle to overturn.
Never attempt this maneuver on 2-UP models when the passenger is on
board. Always disembark him before executing.
Never attempt to turn the vehicle around on any hill until you have mastered
the turning technique as described in this Operator's Guide on level ground.
Be very careful when turning on any hill.
Avoid crossing the side of a steep hill if possible.
When crossing the side of a hill:
Always follow proper procedures as described further in this Operator's
Guide.
Avoid hills with excessively slippery or loose surfaces.
Operator and passenger (2-UP models) must shift weight to the uphill side
of the vehicle.

WARNING
V00A1PQ
POTENTIAL HAZARD
Stalling, rolling backwards or improperly dismounting while climbing a hill.
WHAT CAN HAPPEN
Could result in vehicle overturning.
Use low gear and maintain steady speed when climbing a hill.
If you lose all forward speed:
Operator and passenger (2-UP models) must keep their weight uphill.
Never open the throttle suddenly or make sudden gear changes. The
vehicle could flip over backwards.
Apply the brakes.
Lock brake lock after you have stopped.
Disembark on uphill side, or to a side if pointed straight uphill (passenger
first on 2-UP models).
If you begin rolling backwards:
Never apply the rear brake while rolling backwards.
Apply the front brake gradually.
When fully stopped, apply rear brake as well and lock brake lock.
Turn the vehicle around and remount, following the procedure described
further in this Operator's Guide.

WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control (passenger ejection on 2-UP models), or a colli-
sion.
Could cause the vehicle to overturn.
Before operating in a new area, check for obstacles.
Never attempt to ride over large obstacles, such as large rocks or fallen
trees.
On 2-UP models, the operator is responsible for the safety of his passenger.
In doubt, disembark him before riding over obstacles. Always remember
that the vehicle handling and stability may be affected when riding with a
passenger.
When you go over obstacles, always follow proper procedures as described
in this Operator's Guide.

WARNING
POTENTIAL HAZARD
Skidding or sliding improperly.
WHAT CAN HAPPEN
You may lose control of this vehicle.
You may also regain traction unexpectedly, which may cause the vehicle to
overturn or passenger ejection (2-UP models).
Learn to safely control skidding or sliding by practicing at low speeds and
on level smooth terrain.
On 2-UP models, never slide or skid with passenger. Always remember that
the vehicle handling and stability may be affected when riding with a pas-
senger.
On extremely slippery surfaces, such as ice, go slowly and be very cautious
in order to reduce the chance of skidding or sliding out of control.

WARNING
POTENTIAL HAZARD
Operating this vehicle through deep or fast flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control, which could lead
to an accident.
Never operate this vehicle in fast flowing water or in deep water.
Check water depth and current before you attempt to cross any water. Wa-
ter should not go above footrests.
Remember that wet brakes may have reduced stopping ability. Test your
brakes after leaving water. If necessary, apply them several times to let
friction dry out the pads.

WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind the vehicle, resulting in serious
injury.
When you select reverse gear, make sure there are no obstacles or people
behind the vehicle. When it is safe to proceed, go slowly. On 2-UP models,
take account that the passenger can obstruct your view.

WARNING
POTENTIAL HAZARD
Operating this vehicle with improper tires, or with improper or uneven tire
pressure.
WHAT CAN HAPPEN
Use of improper tires on this vehicle, or operation of this vehicle with
improper or uneven tire pressure, may cause loss of control, tire blow outs,
tire to move around on its rim, and increases the risk of an accident.
Always use the size and type of tires specified in this Operator's Guide for
this vehicle.
Always maintain proper tire pressure as described in this Operator's Guide.
Always replace wheels or tires that are damaged.

WARNING
POTENTIAL HAZARD
Operating this vehicle with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of this vehicle may
cause changes in handling which in some situations could lead to an acci-
dent.
Never modify this vehicle through improper installation or use of acces-
sories. All parts and accessories added to this vehicle should be approved
by BRP and should be installed and used according to instructions. If you
have questions, consult an authorized Can-Am dealer.
NEVER install a passenger seat (1-UP models) or use the racks to carry a
passenger.
Modification of the vehicle to increase speed and performance may violate
the terms and conditions of your vehicle limited warranty. In addition, cer-
tain modifications including the removal of engine or exhaust components
are illegal under most laws.

WARNING
POTENTIAL HAZARD
Overloading this vehicle, carrying or towing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling which could lead to an accident.
Never exceed the stated load capacity for this vehicle including operator
and passenger (2-UP models) as well as other loads and added accessories.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow greater dis-
tance for braking.
Always follow the instructions in this Operator's Guide for carrying cargo or
pulling a trailer.

WARNING
V03M01Q
POTENTIAL HAZARD
Transporting flammable or dangerous material can lead to explosions.
WHAT CAN HAPPEN
This can cause serious injury or death.
Never transport flammable or dangerous material.

IV RIDING THE VEHICLE
To fully appreciate the pleasures and excitement of riding this vehicle, there are
some basic rules and tips that you MUST follow. Some may be new to you while
others may be common sense or obvious.
Please take the time to study this Operator's Guide and all on-product safety labels
as well as the SAFETY VIDEO that came with this vehicle. They more completely
describe what you should know about this vehicle before riding it.
Whether you are a new user or an experienced rider, it is important for your
personal safety that you know the controls and features of this vehicle. Equally
important is knowing how to properly ride.
This is a high performance ATV. Inexperienced riders may overlook risks and be sur-
prised by the specific behavior of this ATV in any terrain condition.
We recommend following the age recommendation indicated on the safety label
affixed on the unit. Even though a person may be within the age group for which
this vehicle is recommended, he may not have the skills, abilities, or judgment
needed to operate this vehicle safely and may be involved in a serious accident.
Individuals with cognitive or physical impairments or who are high risk takers have
an increased exposure to overturns or collisions which may result in injury includ-
ing death.
Not all vehicles are the same. Each has its own unique performance characteris-
tics, controls and features. Each will ride and handle differently.
Become completely familiar with the operational controls and the general opera-
tion of the vehicle before venturing into off road conditions. Practice driving in a
suitable area free of hazards and feel the response of each control. Drive at low
speeds. Higher speeds require greater experience, knowledge and suitable riding
conditions.
Riding conditions vary from place to place. Each is subject to weather conditions
which may radically change from time to time and from season to season.
Riding on sand is different than riding on snow or through forests or marshes.
Each location may require a greater degree of awareness and skill. Show good
judgement. Always proceed with caution. Please do not take any unnecessary
risks that could leave you stranded or possibly injured.
Never assume that the vehicle will go everywhere safely. Sudden changes in ter-
rain caused by holes, depressions, banks, softer or harder “ground” or other irreg-
ularities may cause the vehicle to topple or become unstable. To avoid this, slow
down and always observe the terrain ahead. If the vehicle does begin to topple or
tip over, the best advice is to immediately get off AWAY from the direction of the tip
over!
If a road usage is allowed in your area, operate your vehicle on paved surface only
for short distance and for the only purpose of moving the vehicle from an off-road
usage to another. Always operate your vehicle at low speed (never exceed
40 km/h (25 MPH)) and reduce the speed before making a turn. This vehicle is
not equipped with a rear differential (rear wheels are always turning at the same
speed). For this reasons, pavement may seriously affect the handling and control
of the vehicle.

Always respect all road traffic laws when operating your vehicle on public roads or
streets. If you have to cross a road, the lead driver should get off his vehicle the ob-
serve and give direction to the other riders. The last person after crossing then as-
sists the lead driver to cross. Do not travel on sidewalks. They are designated for
pedestrian use.
For the users in the European Community, it is mandatory to remove the winch
hook (if so equipped) to operate the vehicle on the roadway. Failure to follow this
requirement could cause additional injuries including the possibility of death if an
accident occurs.
We encourage you to have an Annual Safety Inspection of your vehicle. Please
contact an authorized BRP dealer for further details. Though not required, it is
recommended that an authorized BRP dealer performs the preseason preparation
of your vehicle. Each visit to your authorized BRP dealer is a great opportunity for
your dealer to verify if your vehicle is included in any safety campaign. We also
urge you to visit your authorized BRP dealer in a timely manner if you become
aware of any safety related campaigns.
See an authorized BRP dealer for available accessories you may require.
1) Pre-Ride Inspection
WARNING
Perform a pre-ride inspection before each ride to detect any potential prob-
lem that could occur during operation. The pre-ride inspection can help you
monitor component wear and deterioration before they become a problem.
Correct any problem that you discover to reduce the risk of a breakdown or
crash. See an authorized Can-Am dealer as necessary.
Before using this vehicle, the operator should always perform the following
pre-ride inspection check list.
Correct any problem found before riding the vehicle. See an authorized
Can-Am dealer if necessary.
Pre-Ride Inspection Check List

What to Do Before Starting the Engine (Key OFF)
ITEMS TO BE
INSPECTION TO PERFORM ✔
INSPECTED
Engine oil Check engine oil level.
Coolant Check coolant level.
Fluids Check fuel, engine oil and coolant levels
Brake fluid Check brake fluid level.
Leaks Check for any leaks under vehicle

ITEMS TO BE
INSPECTED
Activate throttle lever several times to ensure it operates
Throttle lever
freely. It must return to idle position when released
Brake lock Apply brake lock and check if it operates properly
Check tire pressure and condition. Refer to
Tires
SPECIFICATIONS and adjust according to load.
Check wheels for damage and for abnormal play, and make
sure that lug nuts are tightened. Tighten wheel beadlock
Wheels
bolts (if equipped). Refer to WHEELS AND TIRES in
MAINTENANCE PROCEDURES for torque specification.
Radiator Check cleanliness of the radiator
Drive shaft boots Check drive shaft boots and protectors condition
Check if operator seat is in place and properly latched
Check if passenger seat is in place and properly latched
Seat(s) (2-UP Models)
Check the passenger backrest and grab handles condition
(2-UP Models)
If you transport a cargo, respect the load
capacity. Refer to LOADING THE CARGO RACKS
Ensure cargo is properly secured to the racks
If you are pulling a trailer or another equipment:
Cargo – Check hitch and trailer ball condition
– Respect the tongue capacity and towing capacity as
indicated on the label affixed to the hitch or refer to
SPECIFICATIONS
– Ensure trailer is properly secured to hitch.
Storage
Check if rear storage compartment is properly latched
compartment
Chassis and Check underneath vehicle for any debris on chassis or
suspension suspension and clean them properly
Engine air filter Inspect and clean engine air filter
CVT air filter Inspect and clean CVT air filter

What to Do Before Starting the Engine (Key ON)

ITEMS TO BE
INSPECTED
Check operation of indicator lamps in multifunction gauge
Multifunction gauge (during first few seconds of key ON)
Check for messages on multifunction gauge
Check operation and cleanliness of headlights and taillight
Check operation of low and high beams
Lights Check operation of brake light
Check operation and cleanliness of turn signal lights
Check operation of hazard warning lights
Horn Check operation of the horn
Fuel level Check the fuel level.
What to Do After the Engine is Started

ITEMS TO BE
INSPECTED
Check if steering operates freely by completely turning it
Steering
from side to side
Shift lever Check operation of shift lever (P, R, N, H and L)
2WD/4WD selector Check operation of 2WD/4WD selector
Drive forward slowly a few feet and apply brake lever
Brakes and brake pedal individually. The brakes must fully apply.
Lever and pedal must fully return when released
Emergency engine Check that the emergency engine stop switch is working
stop switch properly
Check if ignition switch is working properly by restarting
Ignition switch
and stopping the engine
2) Riding Gear
Actual weather conditions should help you decide how to dress. Dress for the
coldest weather expected. Thermal underwear next to the skin also provides a
good insulation. It is important that the operator always wears the appropriate
protective riding gear and apparel, including an approved helmet, eye protection,
boots, gloves, a long sleeved shirt and pants. This type of clothing will provide
you protection from some of the minor hazards you may encounter en route. The
operator must never wear loose clothing such as a scarf that may get entangled in
the vehicle or on tree branches and shrubs. Depending on conditions, anti-fogging

goggles or sunglasses may be required. Different colored lenses available for

goggles or sunglasses help you distinguish terrain variations. Sunglasses should
only be worn during the daytime.
Approved
helmet
Eye protection
Rigid chin
guard
Chest
protector
Long
sleeves
Gloves
Long, sturdy
pants
Boots
V00A0RN
3) Carrying a Passenger
1-UP Models
This vehicle is designed to carry ONE (1) operator only. Do not install passenger
seats or use the racks to carry a passenger.
2-UP Models
This vehicle is designed specifically to carry an operator and ONE (1) passenger
only. The passenger must be seated on the designated passenger's seat and hold
on to the grab handles at all times. NEVER install other passenger's seat other
than the one recommended by BRP. Do not use the racks or their location to carry
passenger(s). Carrying more than one (1) passenger may affect the stability and
your control of the vehicle. When the glove box is installed (in place of rear seat),
the vehicle becomes a ONE-RIDER vehicle (1-UP model) and NO PASSENGER
must be allowed on it.

4) Recreational Riding
Respect the rights and limitations of others. Stay away from areas designated
for other types of off road use. This includes snowmobile trails, equestrian trails,
cross country ski trails, mountain bike trails, etc. Never assume there are no other
users on the trail. Always stay to the complete right of the trail and do not zigzag
to one side of the trail then the other. Be prepared to stop or pull off to the side if
another trail user appears in front of you.
Join a local ATV club. It will provide you with a map and advice or inform you where
you can ride. If a club does not exist in your area, help to start one. Group riding and
club activities provide a pleasurable, social experience.
Always keep a safe distance from other riders. Your judgment of speed, ter-
rain conditions, weather, mechanical condition of your vehicle and the “trust in
judgment” you have in others around you will help you make a better choice of
appropriate safe distance. This vehicle, like any other motorized vehicle, cannot
stop “on a dime”. Allow greater distance for braking. On 2-UP models, the
vehicle handling, stability and braking distance may be affected when riding with
a passenger. Safely reduce speed when riding with a passenger.
Before you ride, tell someone where you are planning to travel and your expected
time of return.
Depending on the length of your ride, carry additional tools , drinking water, food
and emergency equipment. Find out where you can get additional gasoline and oil.
Be prepared for the possible conditions you may encounter.
First aid kit Adjustable wrench
Mobile phone Knife
Friction tape Flashlight
A rope Colored lens goggles
Spare light bulbs Trail map
Provided tool kit Snack
5) Environment
One of the benefits of this vehicle is that it can take you off the beaten path away
from most communities. However, you should always respect nature and the
rights of others to enjoy it. Do not ride in environmentally sensitive areas. Do not
drive over forest crops or shrubs nor cut down trees or take down fencing nor spin
your wheels and destroy the terrain. “Tread Lightly”.
This vehicle can cause OHV wildfires if debris builds up near the exhaust or other
engine hot spots and ignites then falls off into dry grass. Avoid riding in wet areas,
through muskeg or tall grass, where debris can build up. Should you ride in those
areas, inspect and remove all debris from your engine and hot spots.
Chasing wildlife is in many areas illegal. Wildlife can die of exhaustion after being
chased by a motorized vehicle. If you encounter animals on the trail, stop and ob-
serve quietly and with caution. It will be one of the better memories of your life.

Observe the rule “what you take in, carry out”. Do not litter. Do not start camp-
fires unless you have permission to do so and then only away from dry areas. The
hazards you may create on the trail may cause injury to others or yourself, even at
a later date.
Respect farm lands. Always obtain the permission of the landowner before riding
on private land. Respect crops, farm animals and property lines. If you come to a
closed gate, close it again behind you.
Finally, do not pollute streams, lakes or rivers and do not modify the engine or ex-
haust system, or remove any of its components.
6) Design Limitation
Although the vehicle is exceptionally rugged for its class, it is still a light vehicle by
definition and its operation must be restricted to its proper purpose.
The addition of weight to any part of the vehicle changes its gravitational stability
and modifies its performance.
7) Off-Road Operation
The very nature of off-road operation is dangerous. Any terrain, which has not
been specially prepared to carry vehicles, presents an inherent danger where
angularity, terrain substance and exact steepness are unpredictable. The terrain
itself presents a continual element of danger, which must be knowingly accepted
by anyone venturing over it.
An operator who takes a vehicle off-road should always exercise the utmost care in
selecting the safest path and keeping close watch on the terrain ahead of him. On
no account should the vehicle be operated by anyone who is not completely famil-
iar with the driving instructions applicable to the vehicle, nor should it be operated
on steep or treacherous terrain.
8) Riding Techniques
Information in this guide is limited. Increase your knowledge and improve your
skills by following a certified training course.
Care, caution, experience and driving skill are the best precautions against the haz-
ards of vehicle operation.
Respect and follow all posted trail signs. They are there to help you and others.
In off-road operation, power and traction, not speed, are important. Never drive
faster than visibility and your own ability to select a safe route permits.
Constantly watch the terrain ahead for sudden changes in slopes or obstacles,
such as rocks or stumps, that may cause loss of stability, resulting in tip over or
rollover.
It is also wise to know the terrain condition on the other side of a hill or bank. All too
often there exists a sharp drop-off that is impossible to negotiate or descend.
Whenever there is the slightest doubt that the vehicle can safely negotiate an ob-
stacle or a particular piece of terrain, always choose an alternate route.
Always use proper riding techniques to avoid vehicle overturns on hills and rough
terrain and in turns.

Body Position
To maintain proper control, it is strongly advised that you keep your hands on the
handlebar and within easy reach of all controls. The same holds true for your feet
on the foot pegs. To minimize the possibility of a leg or foot injury, keep your feet
on the foot pegs at all times. Do not direct your toes outwards nor extend your
feet out to assist in turning as they can be hit or be snagged on passing obstacles,
or may come into contact with the wheels.
Even though there is a suspension on this vehicle, there are “washboard” or rough
terrain conditions that will make you feel uncomfortable and can even cause a back
injury. “Posting” or riding in a crouched position will often be required. Slow down
and allow your flexed legs to absorb part of the impact energy.
vmo2012-012-520
2-UP Models
The passenger must keep his hands on the grab handles and his feet on footrests
at all times.
The passenger must synchronize his movements with the operator.
Crossing Roads
If you have to cross a road, the lead driver should get off his vehicle, then observe
and give directions to the other riders. The last person after crossing then assists
the lead driver to cross. Do not use sidewalks. They are designated for pedestrian
use.
If road usage is allowed in your area, operate your vehicle on paved surface only for
short distance and for the only purpose of moving the vehicle from an off-road us-
age to another. Always operate your vehicle at low speed (never exceed 40 km/h)
and reduce the speed before making a turn. This vehicle is not equipped with a rear
differential (rear wheels are always turning at the same speed). For this reasons,
pavement may seriously affect the handling and control of the vehicle.

Riding on Roads
Always respect all road traffic laws when operating your vehicle on public roads or
streets. If you have to cross a road, the lead driver should get off his vehicle the ob-
serve and give direction to the other riders. The last person after crossing then as-
sists the lead driver to cross. Do not travel on sidewalks. They are designated for
pedestrian use.
Turning
Practice turning at low speeds before attempting to turn at faster speeds.
Keep both hands on handlebars and feet on foot pegs.
Maintain a constant speed or a slight acceleration during turn.
To reduce the risk of rollovers:
– Use care when turning.
• Do not turn the handlebar too far or too fast for your speed and environment.
Adjust steering inputs accordingly.
• Slow down before entering a turn. Avoid hard braking during a turn.
• Avoid sudden or hard acceleration when turning, even from a stop or low
speed.
– Never attempt donuts, skids, slides, fishtails, jumps, or other stunts. If vehicle
starts to skid or slide, steer in the direction of the skid or slide. Never slam the
brakes and lock the wheels.
– Avoid paved surfaces. This vehicle is not designed to operate on paved surfaces
and is more likely to roll over. If you must drive on pavement, turn gradually, go
slowly, and avoid abrupt acceleration and braking.
Avoid sudden inputs to steering, throttle or brakes while turning.
WARNING
Do not attempt turns at excessive speed.
vmo2012-012-525

If you do get into a slide or skid, it may help to turn the handlebar in the direction of
the skid until you regain control. Never jam the brakes and lock the wheels.
Braking
Always keep both hands on handlebars and feet on foot pegs when braking.
Practice braking to get familiar with the brake response.
– Do it at low speed first, then increase the speed.
– Practice braking in straight line at different speeds and different braking force.
– Practice emergency braking; optimal braking is obtained in straight line, with
high force applied, without locking the wheels.
Remember, braking distance depends on vehicle speed, load and the type of sur-
face. Also, the tires and brakes conditions play a major role.
NOTE: If going forward the vehicle weight is transferred to the front wheels when
braking. To obtain greater stopping efficiency, the brake system distributes more
braking force to the front wheels. This will affect vehicle handling and steering
control when braking vigorously. Take it into account when braking.
Reverse Operation
When operating in reverse, check that the path behind the vehicle is free of people
or obstacles. Proceed slowly and avoid sharp turns.
When riding on a 2-UP model, take into account that the passenger can obstruct
your view. Disembark the passenger if necessary.
We recommend sitting on your ATV when operating in reverse. Avoid standing
up. Your weight could shift forward against throttle lever, causing an unexpected
acceleration.
Obstacles
Obstacles in the “trail” should be traversed with caution. This includes loose
rocks, fallen trees, slippery surfaces, fences, posts, and embankments and
depressions. You should avoid them whenever possible. Remember that some
obstacles are too large or dangerous to cross and should be avoided. Small
rocks or fallen trees may be safely crossed approach at a 90° angle. Stand on
the footrests while keeping your knees flexed. Adjust speed without losing mo-
mentum and do not “gun” the throttle. Hold handlebar (operator) or grab handles
(passenger on 2-UP models) firmly. Place body weight rearwards (operator and
passenger 2-UP models) and proceed. Do not try to lift the vehicle front wheels
off the ground. Be aware that the object may be slippery or may move while
crossing.
When riding on 2-UP models, the operator is responsible for the safety of the pas-
senger; in doubt, disembark the passenger before proceeding.
Uphill Driving
1-UP Models
Before trying to climb a hill, keep these things in mind. Hill Climbing should only
be attempted by experienced operators. Start on shallow slopes. Always drive
straight uphill and keep your body weight forward towards the top of the hill.
Keep your feet on the footrests, shift your ATV into a lower gear and accelerate

before you start to climb. Try to keep a steady speed and go easy on the throttle
to avoid acceleration. Abrupt slope or terrain variation or rolling one wheel over
an obstacle could have a big impact on the stability as it will lift the front of the
vehicle increasing the risk of tipping over. Some hills are too steep to safely stop or
recover from after an unsuccessful climbing attempt. Try to avoid steep inclines.
If you're not careful, you could tip over when going up hills. If the hill is too steep
and you cannot proceed or the vehicle begins to roll backwards, apply the brake,
being careful not to slide. Dismount then use the “K” turn (while walking back,
next to the vehicle on the up hill side and with a hand on the brake lever, slowly
back the rear of the vehicle toward the top of the hill then drive downhill). Always
walk or dismount on the upside of the slope while keeping clear of the vehicle and
its rotating wheels. Do not try to hold on to the vehicle if it begins to topple. Stay
clear. Do not ride over the crest of the hill at high speed. Obstacles, including
sharp drop-offs, may exist.
vmo2012-012-526
2-UP Models
The passenger must synchronize his movements with the operator. The passen-
ger must remain seated at all times.
Do not forget, the operator is responsible for the safety of the passenger. In doubt,
disembark the passenger before climbing a hill.
straight uphill. Operator and passenger must keep their body weight forward,
towards the top of the hill. Keep feet on the footrests, shift the ATV into a lower
gear and accelerate before you start to climb. Try to keep a steady speed and
go easy on the throttle to avoid acceleration. Abrupt slope or terrain variation or
rolling one wheel over an obstacle could have a big impact on the stability as it
will lift the front of the vehicle increasing the risk of tipping over. Some hills are
too steep to safely stop or recover from after an unsuccessful climbing attempt.
Try to avoid steep inclines. If you're not careful, you could tip over when going up
hills. If the hill is too steep and you cannot proceed or the vehicle begins to roll
backwards, apply the brake, being careful not to slide. Dismount, passenger first,
then use the “K” turn (while walking back, next to the vehicle on the up hill side
and with a hand on the brake lever, slowly back the rear of the vehicle toward the
top of the hill then drive downhill). Always walk or dismount on the upside of the

slope while keeping clear of the vehicle and its rotating wheels. Do not try to hold
on to the vehicle if it begins to topple. Stay clear. Do not ride over the crest of the
hill at high speed. Obstacles, including sharp drop-offs, may exist. The passenger
should get on the vehicle only when the vehicle has returned to a safe location.
V00A1XL
Vehicle Behaviors
Due to configuration, this vehicle has excellent climbing ability, so much so that
it is possible to tip over before traction is lost. For example, it is common to
encounter terrain situations where the top of the hill has eroded to a point that
the hill peak rises very sharply. The vehicle can readily negotiate such a condition,
however, in doing so, when the front of the vehicle is driven to a point that the
vehicle's balance moves rearward, a tip over can occur.
The same situation may apply if an embedded object causes the front of the vehi-
cle to climb more than desired. If such a situation occurs take an alternate route.
Be aware of side hilling dangers when doing so. Refer to SIDE HILLING below.
vmo2012-012-526

Downhill Driving
1-UP Models
Keep your body weight rearwards. Stay seated. Apply the brake gradually to pre-
vent skidding. Do not “coast” down the slope using solely engine compression or
in neutral gear.
Decelerating while negotiating a slippery downhill slope could “toboggan” the
vehicle. Maintain steady speed and/or accelerate slightly to regain control. Try
to avoid steep inclines. If you're not careful, you could tip over when going down
hills.
vmo2012-012-523
2-UP Models
The operator is responsible for the safety of the passenger; in doubt, disembark
the passenger before proceeding.
Always remember that the vehicle handling, stability and braking distance may be
Operator and passenger must keep their body weight rearwards. Apply the brake
gradually to prevent skidding. Do not “coast” down the slope using solely engine
compression or in neutral gear. Try to avoid steep inclines. If you're not careful,
you could tip over when going down hills.

V00A1YL
Vehicle Behaviors
This vehicle can climb slopes that are steeper than it can safely descend. There-
fore, it is essential to ensure that a safe route exists to descend a slope before you
climb it.
Side Hilling
This is one of the most risky types of riding since it may drastically change the bal-
ance of the vehicle. It should be avoided whenever possible. However, if it is nec-
essary to do so , it is important that you ALWAYS keep your body weight on the up-
side of the slope and be prepared to dismount on that side should the vehicle begin
to topple
Avoid all objects or depressions that will intensify the raising of one side of the ve-
hicle higher than the other, thus causing rollover.
WARNING
Do not try to stop or save the vehicle from damage.
WARNING
Be careful when loading and transporting liquid reservoirs. They can affect
vehicle stability when side hilling by pulling downhill and increasing the risk
of a roll over.

vmo2012-012-527
2-UP Models
Drop-Offs
This vehicle will “bottom-out” and usually stop if either the front or rear wheels are
driven over a drop-off. If the drop is sharp or deep, the vehicle will nose dive and tip
over.
When riding on a 2-UP model, the operator is responsible for the safety of the pas-
WARNING
Avoid negotiating drop-offs. Reverse and select an alternate route.
Crossing Water
Water can be a unique hazard. If it is too deep the vehicle may “float” and topple.
Check the water depth and current before you attempt to cross any water. Water
should not go above the footrest. Be wary of slippery surfaces such as rocks,
grass, logs, etc., both in the water and on its banks. A loss of traction may occur.
Do not attempt to enter the water at high speed. The water will act as a brake and
could throw you off the vehicle, on the ground.

vmo2012-012-524
Wet brakes will affect the braking ability of your vehicle. Make sure you dry the
brakes by applying them several times after the vehicle leaves the water, mud or
snow. Allow greater distance for braking.
Mud or marsh lands may be encountered near water. Be prepared for sudden
“holes” or changes in depth. Similarly so, be watchful of hazards such as rocks,
logs, etc., partially covered by vegetation.
Riding on Ice
If your route crosses frozen waterways, make sure the ice is thick enough and
sound enough to support the total weight of yourself, your passenger (2-UP mod-
els), the vehicle and its load. Be ever watchful of open water it is a sure indication
that the ice thickness will vary.
On 2-UP models, the operator is responsible for the safety of the passenger; in
doubt, do not attempt to cross.
Ice will also affect the control of the vehicle. Slow down and do not “gun” the
throttle. This will only result in spinning of the tires and possible tip over of the
vehicle or passenger ejection (2-UP models. Avoid rapid braking. This again will
possibly result in an uncontrolled slide and tip over of the vehicle. Slush should be
avoided at all times since it could block the operation or controls of the vehicle.
Riding on Snow Covered Surfaces

When performing the pre-ride inspection, pay special attention to locations on the
vehicle where snow and/or ice accumulations may obstruct visibility of the taillight
and reflectors, clog ventilation openings, block the radiator and fan, and interfere
with the movement of control levers, switches and brake pedal. Before starting
with your ATV check the steering, throttle and brake lever and pedal controls for
interference free operation.
Whenever an ATV is ridden on a snow covered drive path the tire grip is generally
reduced causing the vehicle to react differently to control inputs from the operator.
On low grip surfaces, the steering responses are not as crisp and precise, stopping
distances are lengthened and acceleration becomes sluggish. Slow down and do
not "gun" the throttle. This will only result in spinning of the tires and possibly in an
over steering slide of the vehicle. Avoid hard braking. This will possibly result in a

straight line slide of the vehicle. Again, the best advice is to safely reduce speed in
anticipation of a maneuver so to give yourself time and distance to regain total ve-
hicle control before it spins out of your control.
As you drive your ATV over a loose snow covered surface, snow dust will be
picked up in the wake turbulence of the moving vehicle and transported to contact
and accumulate or melt on some exposed components including rotating parts
like brake discs. Water, snow or ice may affect the response time of the brake
system of your ATV. Even when not required to reduce vehicle speed apply brakes
frequently to prevent ice or snow accumulation and to dry brake pads and discs.
While doing so in low risk driving situations you will test for grip level and keep
yourself alerted to how the vehicle reacts to your control inputs. Always keep
brake pedal, footrests, floor boards, brake and throttle levers free of snow and ice.
Frequently wipe snow off seat, hand grips, headlights, taillights and reflectors.
The depth of the snow cover may hide rocks, tree stumps or other objects and if it
is wet may totally impede the driveability as the vehicle becomes bogged down or
completely looses traction in slushy snow. Look far ahead and always be watchful
of any visible clues that might indicate the presence of such obstacles. In doubt
steer clear. Avoid driving on any frozen body of water before checking that the
ice will safely support the ATV, its riders and its load of cargo. Remember that a
given thickness of ice may be sufficient to support a snowmobile but not an ATV
of an identical weight because of the smaller load bearing surface of the four tire
contact patches as compared to that of a snowmobile track and skis.
To maximize comfort and avoid frostbite, always wear clothing and ATV protective
equipment appropriate for the weather conditions you will be exposed to during
your ride.
At the end of each ride it is a good practice to clean the vehicle body and all moving
components (brakes, steering components, drivelines, controls, radiator fan etc.)
from any snow or ice accumulations. Wet snow will turn to ice during the shut
down period and become more difficult to remove at the next pre-ride inspection.
Riding in snow may reduce the brakes stopping capability. Safely reduce speed
and allow greater distance for braking. Snow projection may cause ice build up or
snow accumulation on brake components and controls. Apply brakes frequently
to prevent ice or snow accumulation.
Riding on Sand
Riding on sand, sand dunes or on snow is another unique experience, but there are
some basic precautions that should be observed. Wet, deep or fine sand/snow
may create a loss of traction and cause the vehicle to slide, drop off or become
“bogged” down. If this occurs look for a firmer base. Again, the best advice is to
slow down and be watchful of the conditions. When you ride with a passenger
(2-UP models), slow down even more.
When riding in sand dunes it is advisable to equip the vehicle with an antenna type
safety flag. This will help make your location more visible to others over the next
sand dune. Proceed carefully should you see another safety flag ahead. Since the
antenna type safety flag can snag and rebound on your body if caught, do not use
it in areas where there are low hanging branches or obstacles. Always remember
when riding on a 2-UP model that the vehicle handling and stability may be affected

Riding on Loose Stones

Riding on loose stones or gravel is very similar to riding on ice. They will affect the
steering of vehicle possibly causing it to slide or tip over especially at high speeds
(resulting in operator and passenger ejection (2-UP models).
Again, the best advice is to slow down and be watchful of the conditions. When
you ride with a passenger (2-UP models), slow down even more.
In addition, braking distance may be affected. Remember that “gunning” the
throttle or sliding may cause loose stones to be ejected rearwards into the path of
another rider. Never do it deliberately.

V MOVING LOADS AND DOING WORK
1) Working with your WARNING
Vehicle The vehicle handling, stability and
Your vehicle can help you perform a braking distance are affected when
number of different LIGHT tasks rang- driving with loaded cargo racks.
ing from snow removal to pulling wood Correct loading and weight dis-
or carrying cargo. A variety of acces- tribution are therefore important.
sories are available from your autho- Never overload, tow or carry cargo
rized Can-Am dealer. To prevent pos- improperly. Always ensure the
sible injury, follow the instructions and cargo is safely secured and prop-
warnings that accompany the acces- erly distributed on the rack(s) be-
sory. Always respect the load limits fore operating the vehicle. Safely
of the vehicle. Overloading the vehi- reduce speed according to terrain
cle can overstress the components conditions when carrying cargo
and cause failure. Avoid overexerting or pulling a trailer, and avoid hills
yourself if you lift or pull heavy loads or and rough terrain. Allow greater
manually push the vehicle. distance for braking, especially on
inclined surfaces and when a pas-
WARNING senger (2-UP models) is on board.
Be careful not to skid or slide. Al-
Mounted machinery must be low- ways secure cargo as low as pos-
ered on the ground before leaving sible on the rack(s) to reduce the
the tractor. effect of a higher center of gravity.
Failure to follow the recommen-
2) Carrying Loads dations could cause changes in
vehicle handling which could lead
Any load carried on the vehicle includ- to an accident.
ing a passenger (2-UP models) and/or
the carrying rack(s) will affect the han-
dling, stability and braking distance of
the vehicle. Do not exceed the total
load allowed for this vehicle, including
the weight of operator and passenger
cargo, accessories and trailer tongue
weight. Always make sure the load is
secured, properly distributed (1/3 of
cargo weight in front and 2/3 of cargo
weight in back) and cannot interfere
with your proper control. Always be
aware that the cargo may slide or fall
vmr2012-002-002_c
off and create an accident. Avoid cargo
that may protrude sideways and get 1. 1/3 of cargo weight
2. 2/3 of cargo weight
snagged or caught in brush or other ob-
stacles. Avoid covering and obstruct-
ing the headlights or taillight with the
cargo.
Always be aware that the “load” may
slide or fall off and cause an accident.

MAXIMUM LOAD TABLE

1-UP 235 kg Includes weight of operator, cargo,
TOTAL MODELS (517 lb) accessories and trailer tongue weight.
LOAD Includes weight of operator, passenger,
ALLOWED 2-UP 272 kg
cargo, accessories and trailer tongue
MODELS (600 lb)
weight.
45 kg
FRONT LOAD Evenly distributed.
(100 lb)
Evenly distributed.
90 kg
REAR LOAD Includes rear rack, rear glove box
(200 lb)
and tongue load.
The following is an example of suitable load distribution:

EXAMPLE OF LOAD DISTRIBUTION
(VEHICLE WITH A TOTAL LOAD ALLOWED OF 235 KG (518 LB))
TOTAL OPERATOR
TONGUE
VEHICLE AND CARGO LOAD ACCESSORIES
WEIGHT
LOAD PASSENGER
100 kg 105 kg
235 kg (518 lb) 10 kg (22 lb) 20 kg (44 lb)
(220.5 lb) (231.5 lb)
3) Loading the Cargo stacles. Avoid covering and obstruct-

Racks ing the brake lights with the cargo.
Ensure no cargo protrudes outside the
NOTICE When loading or unload- cargo rack and that cargo will not inter-
ing, do not exceed the weight limit of fere with your visibility or control of the
90 kg (200 lb) for rear load and 45 kg vehicle.
(100 lb) for front load.
NOTICE Do not exceed the cargo
Load cargo as low as possible – a racks capacity. Refer to SPECIFICA-
higher load can raise the vehicle’s TIONS.
center of gravity, which can reduce
stability. Position cargo on the rack as Never carry gasoline container(s) or
evenly distributed as possible. any dangerous liquids on the cargo
rack.
Secure the load on the cargo rack. Do
not secure cargo to other parts of the
vehicle. If it is not properly secured, a 4) Hauling a Load
load may slide or fall off, possibly strik- Never pull a load by attaching it to the
ing occupants or bystanders; or it may bumper or luggage racks; this can
shift during riding, affecting the han- cause the vehicle to tip over. Use only
dling of the vehicle. the trailer hitch (if installed) to pull a
Objects that are high may affect visibil- load.
ity for the driver and may act as projec- In an emergency situation, use the
tiles in case of an accident. Loads that recovery hooks to recover a stuck ve-
protrude sideways can get snagged or hicle. Refer to RECOVERY HOOKS in
caught in bush, branches or other ob- EQUIPMENT.

When pulling loads with a chain or ca- one on the vehicle. Make sure the
ble, ensure that there is no slack before trailer is horizontal with the vehicle. (In
starting and maintain tension while some instances a special extension
pulling. may have to be installed on the vehicle
When pulling loads with a chain or ca- hitch). Use security chains or cables to
ble, be sure to brake progressively. secure the trailer with the vehicle.
The inertia of the load could lead to an Reduce your speed when pulling a
impact. trailer and turn gradually. Avoid hills
When hauling a load, respect the maxi- and rough terrain. Never attempt
mum hauling capacity. See PULLING steep hills. Allow more distance for
A TRAILER in this section. braking, especially on inclined surfaces
and when a passenger (2-up models)
is on board. Be careful not to skid or
WARNING slide.
A slack in the chain or cable can
If a trailer is used behind the vehicle
cause it to break and snap back.
make sure that its hitch is compatible
with the one on the vehicle. Make sure
When pulling another vehicle, be sure the trailer is horizontal with the vehicle.
that someone is controlling the pulled (In some instances a special extension
vehicle. They must brake and steer to may have to be installed on the vehicle
prevent the vehicle from going out of hitch). Use security chains or cables to
control. secure the trailer with the vehicle. This
Reduce your speed when hauling a vehicle may require additional stopping
load and turn gradually. Avoid hills and distance if hauling heavy loads, espe-
rough terrain. Never attempt steep cially on inclined surfaces and when a
hills. Allow more distance for brak- passenger (2-UP models) is on board.
ing, especially on inclined surfaces and Improperly loading a trailer may cause
when a passenger (2-up models) is on loss of control. Respect the recom-
board. Be careful not to skid or slide. mended maximum hauling capacity
and maximum tongue load (Refer to
5) Pulling a Trailer MAXIMUM HAULING CAPACITY ta-
Check the maximum axle loads of the ble). Make sure there is at least some
vehicle identification plate (statutory weight on the tongue.
plate). Can-am T3 tractor can tow a Always make sure load is evenly dis-
trailer on the road. Check the trailer tributed and safely secured on the
maximum load on its identification trailer; an evenly balanced trailer is
plate. Check the regulations for your easier to control.
area regarding the use of a tractor and Always put the shift lever to L (low
trailer on the road. Connect the trailer range) for hauling a trailer – in addition
lights and set the slow moving vehicle to providing more torque, operating
triangle behind the trailer. in low range helps account for the in-
NOTICE A BRP approved rear creased load on the rear tires.
hitch must be properly installed on When stopped or parked, block the ve-
the vehicle for hauling trailers. hicle and trailer wheels from possible
movement.
Riding this vehicle with a trailer sub-
stantially increases the risk of toppling, Use caution when disconnecting a
especially on inclined slopes. If a trailer loaded trailer; it or its load may topple
is used behind the vehicle make sure on you or others.
that its hitch is compatible with the

Do not exceed the towing capacity and

tongue weight. Refer to SPECIFICA-
TIONS.
WARNING
Stay clear from the area between
tractor and trailed vehicle.
WARNING
Strictly follow the instructions out-
lined in the operator' s manual of
the mounted or trailed machinery
or trailer, and not to operate the
combination tractor - machine or
tractor - trailer unless all instruc-
tions have been followed.

VI IMPORTANT ON-PRODUCT LABELS
1) Hang Tag
This vehicle comes with a hang tag and labels containing important safety informa-
tion.
Any person who rides this vehicle should read and understand this information be-
fore riding.
WARNING
– Locate and read operator's guide. Improper ATV use can result in SE-
VERE INJURY or DEATH. Follow all instructions and warnings.
– Always wear ear protection.
– Always use an approved helmet and protective gear.
– Never carry passengers on 1-up models and NEVER carry more than one
passenger on 2-up models.
– Never use with drugs or alcohol.
G
GENERAL USE MODEL
THIS ATV IS FOR

RECREATIONAL USE OR UTILITY USE
704903931
704903931A
TYPICAL - 1-UP MODELS

G
GENERAL USE MODEL
704903947
704903947

2) Vehicle Safety Labels

Read and understand all the safety la-
bels on your vehicle.
These labels are affixed to the vehicle
for the safety of the operator, passen-
ger or bystanders.
The safety labels on your vehicle
should be considered permanent parts
of the vehicle. If missing or damaged, fvmo2013-002-019_d
they can be replaced free of charge.
See an authorized Can-Am dealer.
NOTE: In the event of any discrep-
ancy between this guide and the ve-
hicle, the safety labels on the vehicle
have precedence over the labels in this
guide.
vmo2012-012-045_e
vmo2012-012-003_a
vmo2012-012-043_b
vmo2012-012-004_a

fvmo2013-002-004_c
Label 1
WARNING
vmo2014-020-003_b
– Locate and read operator's
guide. Improper ATV use can
result in SEVERE INJURY or
DEATH. Follow all instructions
and warnings.
– Always use an approved helmet
and protective gear.
– Never carry a passenger on 1-up
models and NEVER carry more
than one passenger on 2-up
models.
vmo2012-012-001_b
fvmo2015-001-003_a 704903963
704903963B
LABEL 1 - 1-UP MODELS

Label 4
WARNING
– Locate and read operator's
guide.
– NEVER carry a passenger on
1-up models and NEVER carry
more than 1 passenger on 2-up
models.
704903733 – Passenger on 2-up models must
704903733A always use an approved helmet
LABEL 1 - 2-UP MODELS and protective gear.
– Passenger on 2-up models must
Label 2 NEVER ride after using drugs or
alcohol.
WARNING
Operating this ATV if you are under
the age of 16 increases the chance
of SEVERE INJURY or DEATH to
the operator, and to both the oper-
ator and passenger on 2-up mod-
els. NEVER operate this ATV if you
are under age 16.
704903968
704903968
704903964
704903964
LABEL 2
Label 3
704903737
LABEL 4- 2-UP MODELS
•This VEHICLE MUST be stopped before

shifting lever.
•ALWAYS apply foot brake to shift from
Park (P) and Neutral (N). 704905695
EN-704905695-DEC
LABEL 3

Label 5
WARNING
– NEVER carry a passenger on this carrier.
– MAXIMUM FRONT LOAD: 45 kg (100 lb) evenly distributed.
– MAXIMUM REAR LOAD: 90 kg (200 lb) evenly distributed (including
trailer tongue weight if applicable).
< 90 kg (200 lb)
< 45 kg
(100 lb)
704903960
704903960
LABEL 5
Label 6
WARNING
NEVER attach here or on the lug-
gage rack to pull a load This can
cause the vehicle to tip over. AL-
WAYS use the trailer hitch or the
recovery hook to pull a load.
704903955
704903955A
LABEL 6
Label 7
WARNING
– Locate and read operator's guide. Improper tire pressure or overloading
can cause loss of control, resulting in SEVERE INJURY or DEATH.
– ALWAYS maintain proper tire pressure as shown.
– On 1-up models, NEVER exceed the load capacity of 235 kg (517 lb)
including weight of operator, cargo, accessories, and trailer tongue
weight.
weight.
– ALWAYS pull a load using the trailer hitch or recovery hook.

704904333
LABEL 7 1-UP MODELS
>132 kg (290 lb)

< 132 kg (290 lb) <272 kg (600 lb)
= =
48.2 kpa 68.9 kpa
kPa 41.4 kpa
(6 psi)
41.4 kpa
(6 psi)
kPa (7 psi) (10 psi)
704903953
704903953
LABEL 7- 2-UP MODELS
Label 8
This warning applies only in European Countries where

on road usage is allowed.
On Road Use
This quadricycle is built for "OFF ROAD" purposes only. It may be used for short
distances on paved surfaces at reduced speed, in order to move the vehicle from an
off road location to another.
When driving this quadricycle on roads, always refrain from speeding and substantially
reduce vehicle speed when turning. Failure to do so can cause a loss of vehicle control,
possibly resulting in serious injury or death.
Front Winch
The front winch hook of the so equiped quadricycle must be removed and stored
when riding the vehicle on public trails and/or roads.Failure to do so can increase the risk of
injury to bystanders. 704903987
704903987
LABEL 8

Label 9
WARNING; GET FAMILIAR WITH THIS VEHICLE.

INEXPERIENCED RIDERS MAY OVERLOOK RISKS. WARNUNG: MACHEN SIE SICH MIT DIESEM
ADVARSEL: LÆR KØRETØJET GRUNDIGT AT FAHRZEUG VERTRAUT. UNERFAHRENE
KENDE. UERFARNE FØRERE KAN LET OVERSE FAHRER KÖNNEN RISIKEN ÜBERSEHEN.
FARERNE.
ΠΡΟΕΙΔΟΠΟΙΗΣΗ: ΕΞΟΙΚΕΙΩΘΕΙΤΕ ΜΕ ΑΥΤΟ
WAARSCHUWING: MAAK UZELF VERTROUWD ΤΟ ΟΧΗΜΑ. ΟΙ ΧΡΗΣΤΕΣ ΧΩΡΙΣ ΕΜΠΕΙΡΙΑ
MET DIT VOERTUIG. ONERVAREN BESTUURDERS ΜΠΟΡΕΙ ΝΑ ΠΑΡΑΒΛΕΨΟΥΝ ΤΥΧΟΝ
KUNNEN DE RISICO'S OVER HET HOOFD ZIEN. ΚΙΝΔΥΝΟΥΣ.
AVERTISSEMENT : FAMILIARISEZ-VOUS AVEC AVVERTENZA: ACQUISIRE FAMILIARITÀ CON
CE VÉHICULE. LES UTILISATEURS INEXPÉRIMENTÉS QUESTO VEICOLO. I PILOTI INESPERTI
POURRAIENT SOUS ESTIMER LES RISQUES. POTREBBERO SOTTOVALUTARE I RISCHI.
VAROITUS : TUTUSTU HUOLELLISESTI TÄMÄN
AJONEUVON KÄYTTÖÖN. KOKEMATTOMAT ADVERTÊNCIA: FAMILIARIZE-SE COM ESTE
KULJETTAJAT SAATTAVAT ALIARVIOIDA VEÍCULO. PILOTOS INEXPERIENTES PODEM
VAARATILANTEET. SUBESTIMAR OS RISCOS.
ADVERTENCIA: TÓMESE EL TIEMPO NECESARIO VARNING: BEKANTA DIG VÄL MED DETTA
PARA FAMILIARIZARSE CON EL VEHÍCULO. FORDON. OERFARNA FÖRARE KAN FÖRBISE
LA FALTA DE EXPERIENCIA PUEDE DAR LUGAR RISKERNA.
A LA OMISIÓN DE RIESGOS IMPORTANTES.
704905720
EN-FR-704905720-DEC
LABEL 9
Label 10
vmo2010-010-100_a 704903688
LABEL 10
704903688
Label 11 LABEL 11
WARNING
Do not open when hot.

Label 12 3) Compliance Labels

These labels indicate vehicle's compli-
ance.
Always make sure to properly install passenger seat or

glove box in place before riding.
TO INSTALL PASSENGER SEAT
.Ensure that the latch lever is in the open position by pulling it
towards the front of seat.
.Using a forward motion, insert both front tabs of the seat into the
vehicle anchor housings.
.Rotate downwards to engage the rear latch.
.Close the latch lever by pushing it rearwards to secure the seat
in position.
.Check if the seat is firmly secured in position before using it.
TO INSTALL GLOVE BOX
• Open glove box cover and turn handle to the unlock position.
• Align and insert glove box latching system into
this vehicle's “LINQ” opening.
• Turn handle to the lock position.
• Close cover and verify if glove box is locked
in position.
FOR MORE DETAILS REFER TO OPERATOR’S GUIDE
704904442
704904442
LABEL 12 - 2-UP MODELS - LOCATED

UNDER PASSANGER SEAT
fvmo2012-012-002_c
Label 13
605356246 704904067
LABEL 13: TOWING INSTRUCTIONS LOCATION: UNDER SEAT, ON THE UPPER
FRAME MEMBER
605456593
LABEL 1 LOCATION: UNDER SEAT

fvmo2013-002-005
LOCATION: ON TRAILER HITCH
Category 1 - The cab does not offer any

protection against substances which
are harmful to health.
fvmo2013-001-005
CATEGORY 1 704904810
LOCATION: BACK OPERATOR'S BACKREST

4) Technical Information
Labels
707800373
LOCATION: UNDER SEAT
fvmo2012-001-012
TRANSMISSION PARK POSITION

This page is
intentionally blank

B) VEHICLE
INFORMATION
_______________ 79
I CONTROLS
1
9
5
6
vmo2012-012-049_a
1) Throttle Lever
The throttle lever is located on the RH
side of the handlebar.
The throttle lever controls the engine
speed.
To increase or maintain vehicle speed,
press the throttle lever with your right
thumb.
To decrease vehicle speed, release the
throttle lever.
vmo2012-012-006_a
TYPICAL
1. Throttle lever
2. To accelerate
3. To decelerate
80 ______________
I CONTROLS
2) Brake Lever
The brake lever is located on the LH
219001872-001_c
1. Brake lever
2. Lock lever
The brake lock function is to maintain

219001872-001_d brakes to all wheels to prevent the ve-
1. Brake lever
hicle from moving when parked.
The brake lever function is to slow WARNING

down or stop the vehicle. Always use the brake lock and en-
When the brake lever is compressed, gage the PARK position on the shift
the front and rear brakes are applied. lever when the vehicle is not in op-
eration.
To engage the brake lock proceed as

shown:
219001872-001_b
Braking effect is proportional to the

force applied on the lever.
219001872-001_a
3) Brake Lock Step 1: Apply brakes
Step 2: Lock brakes
The brake lock lever is located on the
LH side of the handlebar. NOTE: The lock lever can be set to
several positions.
NOTICE Ensure, when the brake
lock is applied, that the vehicle stays
securely in place.
To unlock the brakes, simply squeeze
the brake lever. It should return to the
rest position.
_______________ 81
I CONTROLS
WARNING
Make sure brake lock is released
before operating the vehicle. If
brake lock is left ON while riding,
it may cause damage to the brake
system and cause loss of braking
capacity and/or fire.
4) Brake Pedal fvmo2013-002-020
SHIFT LEVER LOCATION

The brake pedal is located on the RH
side footrest. The shift lever is used to change the
When pressed down, the front and gearbox position.
rear brakes are applied. The shift lever has 5 positions:
SHIFT LEVER POSITIONS
POSITION GEAR
P Park
R Reverse
N Neutral
H High range (forward)
L Low range (forward)
vmo2012-012-015_a
1. Brake pedal
When released, the brake pedal should

return to its original position.
force applied on the pedal.
NOTE: As on other wheeled vehicles,
the vehicle weight is transferred to the
front wheels when braking. To obtain vmo2012-012-036
greater stopping efficiency, the brake
SHIFT PATTERN
system distributes more braking force
to the front wheels. This will affect The vehicle must be stopped and
vehicle handling and steering control brakes applied prior to selecting any
when braking vigorously. Take it into gear.
account when braking.
Should the brake lever system fail, the NOTICE This gearbox is not de-
rear brake can be used by depressing signed to shift while vehicle is mov-
the brake pedal. ing.
5) Shift Lever P: Park

The shift lever is located on the RH side The park position locks the gearbox to
of the console near steering column. help prevent vehicle movement.
82 ______________
I CONTROLS
WARNING 6) Ignition Switch

Always use the PARK (P) position The ignition switch is located on the LH
when the vehicle is not in oper- side of the central panel below the han-
ation. The vehicle can roll if the dlebar.
shift lever is not set to P (PARK).
R: Reverse
The reverse position allows the vehicle
to go backwards.
NOTE: In reverse operation, the en-
gine's RPM is limited, thus limiting the
vehicle reverse speed.
WARNING
219001735-001_a
When driving downhill in reverse, IGNITION SWITCH POSITIONS
gravity can increase the vehicle 1. OFF
speed above the set limited re- 2. ON “with light”
verse speed.
OFF
Neutral The key can be inserted or removed in
The neutral position disengages the this position only.
gearbox. In OFF position, the electrical system
of the vehicle is disabled.
WARNING The engine is shut down by turning the
Always use the PARK (P) position ignition switch to OFF position.
when the vehicle is not in oper- NOTE: While the engine can be
ation. The vehicle can roll if the stopped by turning the ignition key to
shift lever is set to N (NEUTRAL). OFF position, we recommend the en-
gine be stopped by setting the emer-
High Range (Forward) gency engine stop switch to the STOP
position.
This position selects the high speed
range of the gearbox. It is the normal NOTE: When turning the key to OFF
driving speed range. It allows the vehi- position, the vehicle electrical system
cle to reach its maximum speed. will take a few seconds to shut down.
Low Range (Forward) ON with Lights

This position selects the low speed When the key is turned in this position,
range of the gearbox. It allows the ve- the electrical system of the vehicle is
hicle to move slowly with maximum activated.
torque at the wheels. The gauge should wake-up.
NOTICE Use the low speed range The vehicle lights are turned on.
to pull a trailer, carry heavy cargo, The engine can be started.
go over obstacles or drive uphill and
downhill.
_______________ 83
I CONTROLS
Digitally Encoded Security System

(D.E.S.S.)
The ignition keys contain an electronic
circuit that gives it a unique electronic
serial number.
The D.E.S.S. system reads the key
code and allows engine starting for
keys it recognizes.
7) Multifunction Switch
The multifunction switch is located on
the LH side of the handlebar.
vmo2012-013-001_d
1. Low/high beam headlight switch

2. Low beam
3. High beam
Turn Signal Switch

The turn signal switch is located on the
LH side of handlebar.
vmo2012-013-001_f
TYPICAL - MULTIFUNCTION SWITCH

1. Low/high beam headlight switch
2. Turn signal switch
3. Horn button
4. Engine start button
5. Hazard warning button
6. Emergency engine stop switch
7. Override/DPS button (if applicable)
Low/High Headlight Switch

This switch is used to select either the
headlights low or high beams. vmo2012-013-001_b
1. Turn signal switch
To activate the turn signals, move the

switch button on the right or the left
side, depending on which direction
you picked. Reposition the switch in
the middle when the maneuver is com-
pleted.
84 ______________
I CONTROLS
Horn Button NOTE: To allow engine starting, the ig-

The horn button is located on the LH nition switch must be in the ON or ON
side of handlebar. with lights position and the emergency
engine stop button set to RUN.
Hazard Warning Button

The hazard warning button is located
on the LH side of handlebar.
vmo2012-006-001_d
TYPICAL
1. Horn button
Engine Start Button
vmo2012-013-001_a
1. Hazard warning button
The hazard warning system operates

all the turn signals simultaneously.
Used when the vehicle is stationary
to indicate that the vehicle is temporar-
ily obstructing traffic.
Press the hazard warning button once
to activate the device.
NOTE: Hazard warning lights can be
activated even when the vehicle elec-
vmo2012-013-001_c
trical system is shut down.
TYPICAL
When engine start button is pressed

and held, it starts the engine.
WARNING
injury or death.
_______________ 85
I CONTROLS
Emergency Engine Stop Switch
vmo2012-012-014_b
vmo2012-006-002_a
1. Override/DPS button
1. Emergency engine stop switch Override Function
This switch can be used to stop the en- The override switch main function is to
gine and as an emergency control. bypass the engine speed limiter in re-
verse operation by allowing maximum
To stop engine, set the emergency en-
engine torque.
gine stop switch to the STOP position.
NOTE: While the engine can be WARNING
stopped by turning the ignition key to
OFF position, we recommend the en- Use the "override" mode only if the
gine be stopped by setting the emer- vehicle is caught in mud or other
gency engine stop switch to the STOP soft terrain and the "low range" is
position. not enough. Make sure the area is
secure before using the "override"
Override/DPS Button mode. Do not use the "override"
mode when driving normally in
Depending on the vehicle model, this reverse, this would result in exces-
button can have 2 functions. sive speed.
To engage the override function, pro-

ceed as follows:
While the shift lever is set to REVERSE
position.
1. Ensure that the vehicle is stopped.
2. Press and hold the override switch
then press the throttle lever gradu-
ally.
WARNING
injury or death.
86 ______________
I CONTROLS
NOTE: When using the override func-

tion, the gauge will scroll an OVER-
RIDE message to confirm that the
function is activated.
3. To disengage the override function,
simply release the override switch.
DPS Function (Models with DPS)
This button is also used to change the
DPS mode.
To change DPS mode, refer to TUNE
YOUR RIDE.
8) 2WD/4WD Selector
The 2WD/4WD selector is located on
the RH side of the handlebar.
V07I0DY
4WD MODE - TYPICAL
The 2WD mode is engaged when the

switch is pushed upwards. The vehicle
is then rear wheel drive only.
vmo2012-012-007_a
TYPICAL
1. Selector
2. 2WD position
3. 4WD position
This switch selects 2 wheel drive or 4

wheel drive mode when the vehicle is
stopped and the engine is running.
NOTICE The vehicle must be
stopped to engage or disengage
the 2WD/4WD modes. Mechanical
damage may occur if switch is en-
gaged or disengaged while driving.
switch is pushed downwards.
_______________ 87
I CONTROLS
NOTE: Using the winch intensively

over a long period of time may dis-
charge the battery.
Refer to the winch GUIDE provided
with the vehicle for proper operating
instructions.
10) Shift Lever Lock

The shift lever can be locked when the
vehicle is parked and left unattended.
To unlock shift lever, open protective
cover, insert key and turn it clockwise.
To lock shift lever, turn key counter-
clockwise.
V07I0EY
2WD MODE - TYPICAL
9) Winch Control Switch

(Models with Winch)
This switch controls the winch opera-
tion.
To let out the cable, press the left side
of switch.
To reel in the cable, press the right side
vmo2012-013-702_a
of switch.
SHIFT LEVER LOCKING MECHANISM
1. Protective cover
2. Key lock
3. Turn key clockwise to unlock
4. Turn key counterclockwise to lock
NOTE: The vehicle will not be locked if

the shift lever is not placed in park posi-
tion when the mechanism is engaged.
tmo2012-006-200_a
TYPICAL
1. In
2. Out
WARNING
injury or death.
88 ______________
II MULTIFUNCTION GAUGE (LCD)
WARNING Tachometer
Reading the multifunction gauge Indicates engine speed in revolutions
display can distract from the op- per minute (RPM). Multiply by 1000 to
eration of the vehicle, particularly obtain the actual engine speed.
from constantly scanning the envi- NOTE: RPM can also be displayed via
ronment. Display 2 (mode) display. Refer to DIS-
PLAY 2 (MODE) in this section.
1) Multifunction Gauge
Description
The multifunction gauge is located in
the middle of the handlebar.
vmo2012-012-029_k
1. Tachometer
2. Operating range
3. Tachometer via display 2 (mode)
vmo2012-012-029_a Gearbox Position Display

1. Display 1 This display will show gearbox posi-
2. Display 2 tion.
3. Display 3
4. Display selector button
5. Gearbox position display
7. Indicator lamps
Speedometer
This display will show vehicle speed.
vmo2012-012-029_j
DISPLAY FUNCTION
P Park
R Reverse
vmo2012-012-029_i
1. Vehicle speed (Display 1) N Neutral

H High gear
L Low gear
_______________ 89
NOTE: If the letter “E” is displayed in High Beam Indicator Lamp

the gearbox position display, it means
that there is a electrical communi-
cation error. Contact an authorized
Can-Am dealer.
Fuel Level Display When this indicator is ON, it indicates

that high beam is selected.
Bar gauge that continuously indicates
the fuel level in the fuel tank. Check Engine Indicator Lamp
When this indicator is ON, it indicates

an engine fault code, look for a mes-
sage at the LCD display.
Refer to TROUBLESHOOTING for
more details.
vmo2012-012-029_n Turn Signal Light Indicator Lamp

Low Fuel Level Indicator Lamp

the turn signal lights are in operation.
When this indicator turns ON, it indi- 2) Multifunction Gauge

cates that there is approximately 5 L Features
(1.32 U.S. gal.) of fuel left in fuel tank.
WARNING
4WD Indicator Lamp
Never adjust or set functions on
the multifunction gauge while rid-
ing the vehicle.
The modes can be displayed by press-

When this indicator is ON, it indicates ing the selector button.
the 4WD system is activated.
NOTE: An abbreviation of the mode
Brake Lock Indicator Lamp selected will also be displayed in dis-
play 3 (see abbreviations in parenthe-
sis).

the brake is activated for more than 15
seconds (while riding).
90 ______________
Unit Selection (MPH vs KM/H)

This multifunction gauge is factory pre-
set in Imperial units but it is possible
to change it to Metric units, contact an
authorized Can-Am dealer for unit set-
tings.
NOTE: All features will have their units
changed all together.
vmo2012-012-029_m Language Selection

1. Display 2 (mode) The gauge display language can be
2. Display 3 (mode/message) changed. Refer to authorized Can-Am
dealer for language availability and
Odometer setup the gauge to your preference.
Records the total distance travelled.
Clock Setting
Clock To set current time, proceed as fol-
Displays current time. lows:
Trip Meter
Records the distance travelled since it
has been reset.
Press and HOLD display selection but-
ton to reset.
Hour Meter (Trip Time)

Records the vehicle running time
when the electrical system is activated
since it has been reset.
Press and HOLD display selection but- vmo2012-012-029_o
ton to reset.
1. Time (Display 2)
2. Message (Display 3)
Engine Hour Meter
Records engine running time. 2. Press and HOLD button (SET TIME
will appear on display 3).
Engine RPM 3. Choose the 12-hour (12H) or
Measures engine revolutions per 24-hour (24H) format by pressing
minute (RPM). button.
4. If the 12-hour format was selected,
3) Multifunction Gauge choose Am ("A") or Pm ("P") by press-
Set-Up ing button.
5. Choose hour first digit by pressing
WARNING button.
Never adjust or set functions on 6. Choose hour second digit by press-
the multifunction gauge while riding button.
ing the vehicle. 7. Choose minutes first digit by press-
ing button.
_______________ 91
8. Choose minutes second digit by

pressing button.
9. Press button to enter settings
(CLOCK will appear on display 3).
92 ______________
III MULTIFUNCTION GAUGE (ANALOG/DIGITAL)
1) Multifunction Gauge Description
The Multifunction Gauge (Analog/digital) is located on the steering column.
The Multifunction Gauge (Analog/digital) is comprised of a digital gauge and two
analog gauges (speedometer and tachometer).
The engine temperature and fuel level bar graphs are comprised in the digital
gauge.
The indicators lamps are comprised in both analog gauges.
1 11 2 6 3 7 4
M S
M S
5 10 12 13 9 8 5
vmo2013-008-001_a
WARNING
Do not adjust the display while riding. You could lose control.
_______________ 93
1) Analog Speedometer FUNCTION INFORMATION

Measures vehicle speed in km/h or SEQUENCE DISPLAYED
mph. XX:XX (24:00
time base)
2) MODE (M) Button Clock XX:XX A or P
Pressing the MODE (M) button will (12:00 AM/PM
scroll through the functions of the main time base)
digital display.
Cumulative
FUNCTION distance XXXXX.X km or mi
OPTIONS
SEQUENCE odometer
Press SET (S) to Trip distance
scroll and select — odometer A XXXXX.X km or mi
Numerical Display
desired function (TRIP A)
is flashing
and press MODE
(M) to confirm Trip distance
— odometer B XXXXX.X km or mi
Press SET (S) to (TRIP B)
scroll and select
Multifunction
desired function Engine time
display is flashing XXXXX.X
and press MODE chronometer (Hr)
(M) to confirm
Trip time
chronometer XXXXX.X
3) SET (S) Button (HrTRIP)
Pressing the SET (S) button will scroll
through the functions of the secondary To reset any trip functions, push and
digital display. hold the MODE (M) button for three
seconds.
4) Analog Tachometer (RPM)

Indicates engine speed in revolutions
per minute (RPM). Multiply by 1000 to
obtain actual engine speed.
5) Indicator Lamps
Indicator lamps will inform you of vari-
ous conditions or problems.
An indicator lamp can flash alone or in
combination with another lamp.
94 ______________
INDICATOR If an abnormal engine condition oc-

DESCRIPTION curs, a message can be combined
LAMP(S)
with a pilot lamp. Refer to TROU-
All indicator lamps are BLESHOOTING for details.
All
activated when ignition
indicator On
switch is ON and the 8) Fuel Level Indicator
lamps
engine is not started Bar graph that continuously indicates
the level of fuel left in the fuel tank.
On Low Fuel
9) Gearbox Position Indicator
Displays the selected gearbox posi-
On Check Engine tion.
High Engine 10) Engine Temperature Indicator

On
Temperature Bar graph that continuously indicates
the engine coolant temperature.
Headlights in the HIGH 11) Numerical Display
On
beam position
The vehicle speed or the engine revo-
lutions (RPM) can be displayed. See
Turn signal lights are in MODE (M) BUTTON in this section.
On
operation
12) 2WD/4WD Indicator
Brake is pressed for When this indicator is ON, the 4WD
On more than 15 seconds system is activated.
while riding
13) Secondary Digital Display
6) Main Digital Display Displays useful real time information to
Displays useful real-time information the rider. For display function informa-
to the rider. tions, refer to SET (S) BUTTON.
7) Multifunction Display 2) Gauge Setup
The vehicle speed or the engine revo-
lutions (RPM) can be displayed. See Setting Metric/Imperial Units
MODE (M) BUTTON in this section. See a Can-Am dealer for adjustments.
Important messages can also be dis-
played. Refer to table below. Setting Clock
1. Press SET (S) button to select clock
MESSAGE DESCRIPTION
display.
Message displayed when 2. Push and hold SET (S) button for
BRAKE the brakes are applied three seconds.
continuously for 15 seconds.
3. Press SET (S) button to select 12:00
Override is displayed when AM PM or 24:00 time base.
the override switch is 4. If 12:00 AM PM time base is se-
OVERRIDE
pressed and the shift lever is lected, A or P flashes. Press SET (S)
set to reverse gear. button to select A (AM) or P (PM).
SET (S) button.
_______________ 95
6. Choose hour second digit by press-

ing SET (S) button.
7. Choose minutes first digit by press-
ing SET (S) button.
pressing SET (S) button.
9. Press SET (S) button.
Setting Language
The gauge display language can be
changed. Refer to an authorized
Can-Am dealer for language availability
and setup the gauge to your prefer-
ence.
96 ______________
IV EQUIPMENT
fvmo2016-002-005_b
TYPICAL - 1-UP MODEL
_______________ 97
IV EQUIPMENT
fvmo2016-002-008_b
98 ______________
IV EQUIPMENT
1) Operator's Seat
The seat is designed for an operator
only.
Seat Removal
To remove the operator's seat, push its
latch upward. This latch is located un-
derneath the rear of seat.
fvmo2016-002-001_a
ADJUSTABLE BACK REST

1. Back rest adjustment lever (60 mm)
2. Open
3. Close
4. Adjustment screw to adjust tilting force
Secure that adjustment lever locking

tab is in adjustment hole.
Seat Riser Installation

Seat can be set higher using a riser
vmo2012-012-020_a block.
1. Seat latch
Pull seat upward then rearward. Con-

tinue lifting movement until you can
release the front retaining device, then
completely remove seat.
Seat Installation
Insert front tabs of seat into steel
hooks of frame. When seat rests in
its position, firmly push seat down to
latch.
NOTE: A distinctive snap will be felt. fvmo2016-002-002_a
Double check that the seat is secure by
1. Riser Blocks (30 mm)
giving it a tug to confirm proper latch-
ing. 2-UP Models
1. Remove passenger's seat
WARNING
Confirm that the operator's seat All Models
is properly locked in position by 2. Remove operator's seat.
pulling back and up several times.
3. Remove the riser blocks from their
storage.
Seat Backrest
A seat backrest is provided to ease op-
erator's operation.
_______________ 99
IV EQUIPMENT
fvmo2016-002-006_a
1. Riser Blocks
4. Install the riser blocks to the loca- fvbl2016-001-040

tions shown.
2-UP Models
7. Install passenger's seat.
2) Passenger's Seat
(2-UP Models)
WARNING
Never operate the vehicle without
fvmo2016-002-004_a passenger's seat.
LOCATIONS FOR RISER BLOCKS
INSTALLATION
The passenger's seat is designed for a
5. Install the locking device. passenger only. The integrated back-
rest supports his back during the ride.
fvbl2016-001-039_a
fvmo2016-002-003_a
1. Lock device
1. Passenger's seat
6. Install operator's seat, then push it 2. Integrated backrest
downwards to latch it properly.
100 ______________
IV EQUIPMENT
Passenger's Seat Removal 4. Close the latch lever by pushing it

1. To unlock latch, pull the passenger's rearwards to secure seat in posi-
seat latch lever toward the front of tion.
the seat. 5. Check if the seat is firmly secured in
position before using it.
fvmo2016-002-003_b vmo2015-007-012_a
1. Seat handle 1. Front pins
2. Apply downwards pressure on the

back of latch lever to clear rear latch WARNING
from pin and turn seat towards front It is of the upmost importance for
using backrest. the passenger's safety that you
3. While maintaining latch lever pulled confirm that the passenger's seat
towards the front, apply downward is properly locked in position by
pressure on the back of latch lever pulling back and up several times.
to clear rear latch from pin and tog-
gle seat towards front using back- 3) Grab Handles (2-UP
rest. Models)
4. Pull seat rearward and up out of lo- The grab handles are located on the RH
cation to clear the front tabs. and LH side of the passenger's seat.
Passenger's Seat Installation The grab handles must be used by the
passenger to hold on firmly during vehi-
1. Ensure the latch lever is in the open cle operation.
position by pulling it towards the
front of seat.
WARNING
2. Using a forward motion, insert both
front tabs of the seat into the vehicle The passenger must always hold
anchor housings. on to the passenger grab han-
dles, not the operator. He must
3. Rotate downwards to engage the also have both feet resting firmly
rear latch. against the footrests.
WARNING
injury or death.
______________ 101
IV EQUIPMENT
2-UP Models
fvmo2016-002-003_c
TYPICAL
1. Grab handles
vmo2013-007-010_a
TYPICAL
4) Footpegs 1. Operator's LH footpeg
The footpegs are located on the RH 2. Passenger's LH footpeg
and LH footrests.
WARNING
Passenger must have both feet on
footpegs at all time during vehicle
operation.
5) 12-Volt Power Outlet

Convenient for handheld spotlight or
other portable equipment.
vmo2012-012-019_a
TYPICAL
1. Operator's LH footpeg
WARNING
Operator must have both feet on
footpegs at all time during vehicle
operation.
vmo2012-012-018_a
1. 12 V power outlet
Remove protective cap to use. Always

reinstall it after use to protect against
weather.
6) Rear Storage
Compartment
Convenient location to carry personal
articles.
102 ______________
IV EQUIPMENT
vmo2012-012-023_b vmo2012-012-026_a
1. Rear storage compartment cover 1. Rear storage compartment latch
WARNING To Close Rear Storage

Compartment
Always engage the PARK position
on the shift lever before opening Gently lift and push cover until the latch
cover. Never leave any heavy or clicks two times to ensure the seal is
loose breakable objects in the stor- compressed.
age area. Always latch cover be- Lock the compartment with the sup-
fore riding. plied key.
To Open Rear Storage Storage Box

Compartment Convenient location to carry additional
Unlock the cover with the supplied key. personal articles.
To remove storage box, open cover
and turn knob counterclockwise to un-
lock LinQ attachment.
vmo2013-008-002_a
1. Rear storage compartment 219001770-001_a

2. Keyhole
1. Storage box
Unlatch cover and gently lower cover.
7) Cargo Racks
Cargo racks are convenient for carry-
ing equipment and various other cargo.
They must never be used to carry a
passenger.
______________ 103
IV EQUIPMENT
ufacturer recommendations. Refer to

SPECIFICATIONS or the safety label
for tongue weight and towing capacity.
vmo2012-012-022
FRONT CARGO RACK
219001872-003_a
1. Safety label
2. Trailer Hitch
WARNING
Ensure to install the proper ball
size that matches the equipment
you will tow.
vmo2012-012-021
NOTE: Follow manufacturer's instruc-
tions for proper attachment.
REAR CARGO RACK
WARNING 9) Trailer Connector

Trailer connector to be used if trailer is
– Never carry a passenger on a equipped with lights.
cargo rack.
– Cargo must never interfere with For towing refer to towing instructions
the drivers line of sight or affect label located at trailer hitch.
his ability to properly steer the
vehicle.
– Do not overload the vehicle.
– Always ensure all cargo is prop-
erly secured and does not ex-
tend out pass the racks.
Refer to SPECIFICATIONS for cargo

racks capacity.
8) Trailer Hitch
Convenient hitch to install a ball to tow 219001872-003_b
a trailer or other equipment. Install 1. Trailer connector
the proper ball size as per trailer man-
104 ______________
IV EQUIPMENT
10) Tool Kit

The tool kit is located under the oper-
ator's seat. It contains tools for basic
maintenance.
11) Recovery Hooks

Convenient hook that can be use to re-
cover a stuck ATV.
vmo2012-012-028_a
1. Winch
2. Roller fairlead
3. Winch hook

charge the battery.
The following tips will help to reduce
the risk of discharging the battery:
fvmo2016-001-006_a
Unreel manually: Unlock the cable us-
1. Front recovery hook
ing the handle then pull on the hook
strap to unreel.
Let the engine run while winching.
Do not stop engine immediately after
winching to let battery recharge.
Also, when winching for more than
30 seconds, it is recommended to in-
crease engine speed in the range of
3000 RPM to increase charging power
to the battery.
NOTE: Make sure vehicle is in NEU-
TRAL (N) before increasing engine
speed.
fvmo2016-001-009_a
Refer to the winchGUIDE provided
1. Recovery hook with the vehicle for more information
about the winch.
12) Winch (If equipped)
The winch can be actuated using the Roller Fairlead (Models with Winch)
winch control switch or with the re- The roller fairlead is used to prevent
mote control (sold separately). damages to the vehicle and guide the
cable into the winch.
______________ 105
IV EQUIPMENT
fvmo2013-002-017_b
TYPICAL
1. Front hitch
vmo2012-012-028_a
1. Winch
2. Roller fairlead
3. Winch hook
13) License Plate Light

Convenient lighting for the license
plate.
106 ______________
V FUEL
1) Fuel Requirements NOTICE Never experiment with
other fuels. Engine or fuel system
NOTICE Always use fresh gaso- damages may occur with the use of
line. Gasoline will oxidize; the re- an inadequate fuel.
sult is loss of octane, volatile com-
pounds, and the production of gum 3) Vehicle Fueling
and varnish deposits which can
damage the fuel system. Procedure
Alcohol fuel blending varies by coun- WARNING
try and region. Your vehicle has been
– Fuel is flammable and explosive
designed to operate using the recom-
mended fuels, however, be aware of under certain conditions.
the following: – Never use an open flame to
– Use of fuel containing alcohol above check fuel level.
the percentage specified by gov- – Never smoke or allow flame or
ernment regulations is not recom- spark in vicinity.
mended and can result in the fol- – Always work in a well-ventilated
lowing problems in the fuel system area.
components:
• Starting and operating difficul- 1. Stop engine.
ties.
• Deterioration of rubber or plastic WARNING
parts. Always stop engine before refuel-
• Corrosion of metal parts. ing.
• Damage to internal engine parts.
– Inspect frequently for the presence 2. Have operator get off vehicle.
of fuel leaks or other fuel system
abnormalities if you suspect the
presence of alcohol in gasoline ex- WARNING
ceeds the current government reg- Do not allow anyone to remain on
ulations. the vehicle while fueling. If there is
– Alcohol blended fuels attract and a fire or explosion during fueling, a
hold moisture which may lead to vehicle occupant could be unable
fuel phase separation and can result to quickly leave the area.
in engine performance problems or
engine damage. 3. Slide protective cover away from
fuel tank cap lock.
2) Recommended Fuel 4. Insert key in fuel tank cap lock.
Use regular unleaded gasoline con- 5. Turn key counterclockwise to un-
taining MAXIMUM 10% ethanol . The lock fuel tank cap.
gasoline must have the following mini-
mum octane requirements. 6. Unscrew slowly the fuel reservoir
cap counterclockwise to remove it.
MINIMUM OCTANE RATING
Outside North
95 E10 RON
America
______________ 107
V FUEL
vmo2012-013-701_b
RH REAR FENDER
1. Fuel tank cap
2. Protective cover
3. Fuel tank cap lock
WARNING
If a differential pressure condition
is noticed (whistling sound heard
when loosening fuel reservoir cap)
have vehicle inspected and/or re-
paired before further operation.
7. Insert the spout into the filler neck.

8. Pour fuel slowly so that air can es-
cape from the tank and prevent fuel
flow back. Be careful not to spill
fuel.
9. Stop filling when the fuel reaches
the bottom of filler neck. Do not
overfill.
WARNING
Never top up the fuel tank before
placing the vehicle in a warm area.
As temperature increases, fuel ex-
pands and may overflow.
10. Fully tighten fuel reservoir cap

clockwise.
11. Lock fuel tank cap by turning key
clockwise.
WARNING
Always wipe off any fuel spillage
from the vehicle.
108 ______________
VI BREAK-IN PERIOD
Operation During Break-In
A break-in period of 300 km (200 mi) or
10 operating hours is required for the
vehicle.
Engine
During the break-in period:
– Avoid full throttle operation.
– Maximum throttle should not ex-
ceed 3/4.
– Avoid sustained accelerations.
– Avoid prolonged cruising speeds.
– Avoid engine overheating.
However, brief accelerations and
speed variations contribute to a good
break-in.
NOTE: It is normal that the engine will
not operate at its maximum efficiency
until the break-in period is completed.
Brakes
WARNING
New brakes will not operate at
their maximum efficiency until
their break-in is completed. Use
extra caution.
Drive Belt
A new drive belt requires a break in pe-
riod of 50 km (30 mi).
– Avoid strong acceleration and decel-
eration.
– Avoid pulling a load.
– Avoid high speed cruising.
______________ 109
VII BASIC PROCEDURES
1) Starting the Engine 3) Stopping the Engine
The shift lever must be set to PARK or and Parking the Vehicle
NEUTRAL.
NOTE: For your convenience, an over- WARNING
ride mode allows the engine to be Avoid parking on steep slope as
started with the shift lever in any po- the vehicle may roll away.
sition. Press and hold the brake lever
or the brake pedal while pressing the
engine start button. WARNING
Insert key in ignition switch and turn to Always put the vehicle in PARK
ON position. when stopped or parked to pre-
vent rolling.
Set the emergency engine stop switch
to RUN.
Press the engine start button and hold WARNING
until the engine starts. Avoid parking in places where hot
Release the engine start button imme- parts can start a fire.
diately when the engine has started.
When stopped or parked always bring
NOTICE If engine does not start shift lever to park position. This is es-
after a few seconds, do not hold the pecially important when parking on
engine start button more than 10 a slope. On very steep inclines or
seconds. Refer to TROUBLESHOOT- if the vehicle is carrying a cargo, the
ING. wheels should be blocked using rocks
or bricks.
2) Changing Gear Select the flattest terrain available for
Selection parking.
Apply brakes and immobilize vehicle, Release throttle and use brakes to
then select the desired shift lever posi- completely stop the vehicle.
tion.
Set shift lever in PARK position.
Release brakes.
Turn key in ignition switch to OFF posi-
NOTICE When changing gear se- tion.
lection, always completely stop the Remove key from ignition switch.
vehicle and apply the brakes prior to
moving the shift lever. Otherwise, If you must park on a steep incline or if
damage to the gearbox may occur. the vehicle is carrying cargo, block the
wheels using rocks or bricks.
Gradually press the throttle lever to
increase engine speed and thus en-
gaging the continuously variable trans-
mission (CVT).
At the opposite, when the throttle
lever is released, the engine speed
decreases.
110 ______________
VIII SPECIAL PROCEDURES
1) What to Do if Water
Entered the CVT
The CVT drain plug is located on the
rear portion of the CVT cover. It is ac-
cessible from the rear LH fender.
Inspect the CVT drain plug to validate if
water is present.
vmo2012-012-054_a
TYPICAL
1. Air filter housing
If water is present, press clamp and re-

move reservoir to drain water from air
filter housing.
If one of the following conditions is
met, bring the vehicle to your nearest
authorized Can-Am dealer to have the
vehicle serviced:
– If more than 50 ml (2 U.S. oz) of
water (approximately 5 drain reser-
vmo2013-007-012_a voirs) is found in the air filter hous-
1. Drain plug ing.
2. Spring clamp – If any deposits are present in the
drain reservoir.
NOTICE If water is present in the
CVT, it could result in belt slippage. In such a case, the vehicle must be ser-
The engine will accelerate but the viced for:
vehicle will remain still. – Vents
– CVT air filter cleaning
If water is present, remove CVT drain
plug to expel water. – CVT cleaning
– Fuel tank breather replacement
NOTICE See an authorized – Lubricant inspection and replace-
Can-Am dealer to have the CVT in- ment as required (engine, gearbox
spected and cleaned. and rear final drive).
Reinstall the drain plug and secure it NOTICE Failure to have vehicle
using the spring clamp. serviced may lead to permanent
NOTE: Make sure hose is properly in- damage to the following compo-
serted on CVT cover nipple. nents but not limited to:
– Engine and gearbox
2) What to Do if Water – Fuel pump
Entered the Air Filter – CVT
Housing – Front differential
Remove the LH side panel. – Rear final drive.
Inspect the underneath the air filter
housing to validate if water is present.
______________ 111
VIII SPECIAL PROCEDURES
3) What to Do if Vehicle is NOTICE Immersion of the vehi-

Turned Over cle can cause serious damage if the
correct restart procedure is not fol-
When vehicle is turned over or stays lowed.
tilted on the side, put the vehicle back
on its wheel. Inspect vehicle for dam- As soon as vehicle is pulled out of wa-
ages. ter, carry out the following:
– Drain CVT. See procedure in WHAT
WARNING TO DO IF WATER ENTERED THE
Never operate the vehicle if dam- CVT.
aged. Refer to an authorized – Drain air filter housing. Refer to
Can-Am dealer. WHAT TO DO IF WATER ENTERED
THE AIR FILTER HOUSING in this
If vehicle has no damage, refer to section.
MAINTENANCE PROCEDURES and NOTICE The vehicle should be ser-
inspect the following.
viced as soon as possible by an au-
– Inspect air filter housing for oil accu- thorized Can-Am dealer.
mulation, if any oil is found, clean air
filter and air filter housing.
– Check engine oil level and refill if
necessary.
– Check engine coolant level and refill
if necessary.
– Check gearbox oil level and refill if
necessary.
– Check rear final drive oil level and re-
fill if necessary.
– Start engine. If the oil pressure light
stays on, stop engine immediately.
Whenever the vehicle is turned over, it
should be inspected by an authorized
Can-Am dealer.
4) What to Do if Vehicle is
Immersed in Water
Should the vehicle become immersed,
immediately stop the engine. Do not
use:
– Any electrical equipments
– Winch (if equipped)
It will be necessary to take the vehi-
cle to an authorized Can-Am dealer as
soon as possible. NEVER ATTEMPT
TO START THE ENGINE!
112 ______________
IX TUNE YOUR RIDE
WARNING
Suspension adjustment could af-
fect vehicle handling. Always take
time to familiarize yourself with
the vehicle's behavior after any
suspension adjustment have been
made.
1) Suspension
Adjustment
vmo2013-007-015_a
Suspension adjustment and loading
can have an effect on your vehicle han- TYPICAL
1. Adjustment cam
dling and comfort. 2. Softer adjustment
Choice of suspension adjustments 3. Firmer adjustment
vary with driver's weight, personal
preference, riding speed and field con- XT-P Model
dition. Adjust by turning adjustment cam ac-
cordingly. Use tool from vehicle tool
Spring Preload Adjustment kit.
WARNING
The left and right shock adjust-
ment on front or rear suspension
must always be set to the same
position. Never adjust one only.
Uneven adjustment can cause
poor handling and loss of stability,
which could lead to an accident.
Shorten the springs for a firmer ride

and rough conditions.
Lengthen the springs for a softer ride
and smooth conditions.
All Models Except XT-P
Adjust spring preload by turning adjust-
vmo2012-014-060_a
ment cam.
TYPICAL
Step 1: Loosen top locking ring
Step 2: Turn adjusting ring accordingly
Step 3: Tighten top locking ring
Shock Damping Adjustments (XT-P

Model)
Compression damping controls how
the shock absorber reacts when riding.
______________ 113
IX TUNE YOUR RIDE
RESULT ON ACTION RESULT

POSITION SETTING
BIG BUMPS
Increasing Firmer
Softer compression compression
1 Soft compression damping force damping
damping
Decreasing Softer
Medium compression compression
Medium
2 compression damping force damping
(Factory)
damping
Firmer WARNING
3 Hard compression Make sure compression damping
damping setting is the same on both sides.
2) Dynamic Power
Steering (DPS) Assist
Level Adjustment
The Tri-Mode Dynamic Power Steering
(DPS) offers easy steering assistance
to the rider. The level of assistance
will automatically adapt according to
the vehicle's speed and rider’s de-
219001682-007_a
mand, in order to provide maximum
1. Position 1 steering power at lower speed where
2. Position 2 the demand is normally higher. As
3. Position 3
speed increases, the assistance is pro-
gressively reduced to keep maximum
steering feel and precision to the rider.
It is possible to choose between three
modes of assistance: Minimum,
Medium and Maximum. Each mode
will continue to automatically adapt
to the vehicle’s speed and rider’s de-
mand, so it does not require to be
changed when riding. These modes
are used to set the level of assistance
to match each rider's preferences.
219001727-010_a
The following DPS modes are preset in
COMPRESSION DAMPING the vehicle.
1. Increases damping (stiffer)
DPS MODE
Turn adjuster clockwise to increase DPS
shock damping action (stiffer). Maximum steering assist
MAX.
Turn adjuster counterclockwise to de-
crease shock damping action (softer). DPS
Medium steering assist
MED.
DPS
Minimum steering assist
MIN.
114 ______________
IX TUNE YOUR RIDE
To show the active DPS mode, pro- To change the DPS mode, proceed as
ceed as follows: follows:
1. Press and release Override/DPS 1. Press and hold Override/DPS but-
button. ton for 2 seconds to go to the next
setting.
2. Release Override/DPS button.
3. Repeat until desired setting is se-
lected.
NOTE: The DPS adjustment will not
be possible if the vehicle transmission
is set to REVERSE.
vmo2012-012-014_b
TYPICAL
1. Override/DPS button
2. Check the multifunction gauge to

confirm the active DPS mode.
vmo2012-012-029_p
LCD GAUGE
1. DPS mode (Display 3)
ANALOG/DIGITAL GAUGE
1. DPS mode display
______________ 115
X VEHICLE TRANSPORTATION
When transporting this vehicle, secure WARNING
it to a trailer or in pickup box with suit-
able tie-downs. Use of ordinary ropes Front hitch is only for pulling, do
is not recommended. not lift.
WARNING
Do not tow this vehicle behind a
car or other vehicle. Use a trailer.
Never tip this vehicle on end for
transporting. The vehicle must be
in its normal operating position
(on all four wheels).
fvmo2013-002-017_a
1. Front tie-down point location

2. Front hitch
V00A17Y
Remember to:
– Unload vehicle racks before trans-
portation.
– Set shift lever to PARK position.
– Set the brake lock. vmo2013-007-003_a
– Secure the vehicle by the front and TYPICAL - REAR TIE-DOWN POINT
LOCATION
rear tie-down points.
1. Rear tie-down point location
NOTICE Securing vehicle at other

locations may damage the vehicle.
vmo2013-007-014_a
116 ______________
C) MAINTENANCE
______________ 117
I MAINTENANCE SCHEDULE
Maintenance is very important for keeping your vehicle in safe operating condition.
Proper maintenance is the owner's responsibility. The vehicle should be serviced
as per the maintenance schedule.
WARNING
Failure to properly maintain the vehicle according to the maintenance
schedule and procedures can make it unsafe to operate.
1) SEVERE DUSTY CONDITIONS

Air filter maintenance must be increased in frequency in the following dusty condi-
tions:
NOTE: Riding in a group in these conditions would increase even more the air filter
maintenance.
2) MAINTENANCE SCHEDULE LEGEND

3) MAINTENANCE SCHEDULE
Make sure to perform proper maintenance at recommended intervals as indicated
in the tables. Some items of the maintenance schedule must be performed in
function of the calendar, regardless of the distance or time of operation.
Lubricate front and rear propeller shaft joints
118 ______________

Inspect and clean CVT air filter. Replace as needed. (If equipped)
Tighten wheel beadlock bolts (If equipped)
Lubricate lower shock absorber spherical bearings (Outlander XT-P)

Verify gearbox oil level and look for contamination
PERFORM AT THE FIRST 3 000 KM (2,000 MI) AND AT 6 000 KM (4,000 MI)
THEN FOLLOW THE REGULAR SCHEDULE
Replace gearbox oil
Clean the vehicle speed sensor (VSS)
______________ 119

Replace spark plugs
Replace gearbox oil

120 ______________
II MAINTENANCE PROCEDURES
This section includes instructions for NOTE: An accessory pre-filter for
basic maintenance procedures. If you "dusty conditions" may be used. Con-
have the necessary mechanical skills tact an authorized Can-Am dealer for
and the required tools, you can per- details.
form these procedures. If not, see
your authorized Can-Am dealer. Air Filter Removal
Other important items in the main- NOTICE Never remove or mod-
tenance schedule that are more dif- ify any component in the air filter
ficult and require in-depth technical housing. Otherwise, engine perfor-
knowledge or special tools are best mance degradation or damage can
performed by your authorized Can-Am occur. The engine is calibrated to
dealer. operate specifically with these com-
ponents.
WARNING
Unless otherwise indicated, al- Remove seat.
ways turn ignition switch to OFF Remove console.
position and remove key before
Lift rear portion of console upwards
performing any maintenance. until the studs are released from the
grommets.
WARNING
Should removal of a locking de-
vice be required (e.g. lock tab,
self-locking fastener, etc.), always
replace it with a new one.
1) Air Filter
Air Filter Maintenance Guideline
As with any ATV, air filter maintenance
is critical to ensure proper engine per-
formance and life span.
Air filter maintenance should be ad-
justed according to riding conditions. vmo2014-007-001_a
Air filter maintenance must be in- TYPICAL

creased in frequency and oil must be 1. Console
2. Studs and grommets
added to the foam filter for the follow-
ing dusty conditions: Pull console rearwards.
– Riding on dry sand.
Rotate air filter cover counterclock-
– Riding on dry dirt covered surfaces. wise to remove.
– Riding on dry gravel trails or similar
conditions. NOTE: A socket wrench may be used
to ease removal.
NOTE: Riding in a group in these con-
ditions would increase even more the
air filter maintenance. Refer to AIR
FILTER CLEANING AND OILING in this
section for maintenance procedure.
______________ 121
vmr2012-010-017_a
vmo2012-012-039_a
TYPICAL - SOME PARTS REMOVED FOR
1. Air filter cover CLARITY
1. Air filter housing inlet drain tube
Remove air filter.
3. Check air filter dirty chamber for
cleanliness.
– If any debris or water are found,
clean air filter chamber using a
vacuum cleaner.
NOTICE Do not blow compressed
air into air filter chamber.
4. Check air filter drain tube (clean
chamber).
– If any debris or water are found,
refer to SPECIAL PROCEDURES.
vmo2012-012-038 – Investigate for contamination
AIR FILTER REMOVAL source.
Engine Air Filter Housing Inspection
and Draining
1. Remove LH side panel.
2. Drain air filter housing inlet drain
tube.
vmr2012-010-017_b

CLARITY
1. Air filter drain tube
122 ______________
Air Filter Cleaning and Oiling
CAUTION Always wear ap-

propriate skin and eye protection.
Chemicals can cause a skin rash and
eye injury.
Paper Filter Cleaning
1. Ensure that the foam filter is re-
vbs2009-012-005
moved from paper filter.
TYPICAL - DRY
2. Tap out heavy dust from the paper
filter. NOTE: A second application may be
This will allow dirt and dust to get out of necessary for heavily soiled elements.
the paper filter. Foam Filter Oiling
NOTE: Paper filter have a limited 1. Make sure filter is clean. Refer to
life span; replace filter if too dirty or FOAM FILTER CLEANING.
clogged.
2. Spray AIR FILTER OIL (P/N 219 700
NOTICE It is not recommended to 340) on the foam filter previously
blow compressed air on the paper dried.
filter; this could damage the paper
fibers and reduce its filtration ability
when used in dusty environments.
NOTICE Do not wash the paper fil-
ter with any cleaning solution.
Foam Filter Cleaning
1. Spray the foam filter inside and out
with a good air filter cleaner and fol-
low manufacturer's instructions.
219700340
AIR FILTER OIL (P/N 219 700 340)
vbs2009-012-015_a
TYPICAL - SPRAY THE FOAM FILTER

vbs2009-012-014
TYPICAL - OIL THE FOAM FILTER
3. Let stand for 3 to 5 minutes.
______________ 123
4. Remove any excess of oil that Install console as the reverse of re-
could transfer to the paper filter by moval. However, pay attention to the
wrapping the foam filter into an ab- following.
sorbent cloth and squeezing gently. Align console front tabs with slots,
This will also ensure a full oil cover- then push console forward.
age on foam filter.
Then align and insert studs with grom-
5. Reinstall the foam filter over the pa- mets on rear portion of console until
per filter. studs engage with grommets.
vbs2009-012-001
TYPICAL
6. Slightly grease plastic body of filter

for ease of installation and future re-
moval.
vmo2014-007-001_a
Air Filter Installation TYPICAL

1. Console
Slightly grease O-ring seal and plastic 2. Studs and grommets
body of air filter.
Install air filter as the reverse of re- 2) Engine Oil
moval.
Engine Oil Level
Ensure air filter cover is properly locked
onto the air filter housing. See indica- NOTICE Check level frequently
tions on filter cover and housing. and refill if necessary. Do not over-
fill. Operating the engine/gearbox
with an improper level may severely
damage engine/gearbox. Wipe off
any spillage.
NOTE: While checking the oil level, vi-
sually inspect engine area for leaks.
vmr2012-005-001_a
1. Cover position arrow

2. Locked
3. Unlocked
124 ______________
Recommended Engine Oil

RECOMMENDED ENGINE OIL
(SUMMER)
Finland,
Norway
XPS 4-STROKE SYNTH.
and BLEND OIL (F) (P/N 619
Sweden
590 109)
vmo2006-007-013_a
All other
XPS 4-STROKE SYNTH.
TYPICAL - RH SIDE OF ENGINE BLEND OIL (P/N 293
1. Dipstick countries
600 121)
With vehicle on a level surface and en-
gine cold, not running, check the oil RECOMMENDED ENGINE OIL
level as follows: (ALL SEASON)
1. Unscrew dipstick then remove it Finland,
and wipe clean. Norway
XPS 4-STROKE
2. Reinstall dipstick, screw in it com- and
SYNTHETIC OIL (F)
pletely. Sweden (P/N 619 590 114)
3. Remove and check oil level. It
should be near or equal to the up- All other
XPS 4-STROKE
per mark. countries
SYNTHETIC OIL
(P/N 293 600 112)
NOTE: The XPS oil is specially formu-

lated and tested for the severe require-
ments of this engine.
If not available, use 4-stroke SAE
5W40 engine oil that meets or exceeds
1 the requirements for API service clas-
sification SJ, SL, SM or SN. Always
2 check the API service label certifica-
tion on the oil container it must contain
at least one of the above standards.
V07C02B
Engine Oil Change
TYPICAL Start and warm-up engine. Stop en-
1. Full
2. Add gine.
Ensure vehicle is on a level surface.
To add oil, remove dipstick. Place a
funnel into the dipstick tube to avoid Remove dipstick.
spillage. Clean the oil drain plug area.
Add a small amount of recommended Place a drain pan under the oil drain
oil and recheck oil level. plug area.
Repeat the above procedures until Unscrew oil drain plug.
oil level reaches the dipstick's upper
mark. Do not overfill.
Properly tighten dipstick.
______________ 125
CAUTION The engine oil can – Console

be very hot. In order to avoid poten- – RH side panel
tial burns, do not remove the engine – RH footrest panel.
drain plug if the engine is hot. Wait 1. Clean oil filter area.
until engine oil is warm.
2. Remove oil filter cover screws.
3. Remove oil filter cover.
vmo2012-012-058_a
1. Drain plug
Allow enough time for oil to flow out of

oil filter. tmr2011-010-004_a
Replace the oil filter. Refer to OIL FIL- 1. Oil filter screw
TER in this section. 2. Oil filter cover
3. O-ring
Change gasket on oil drain plug. 4. Oil filter
Clean gasket area on engine and oil
drain plug then reinstall plug. Oil Filter Installation
Refill engine at the proper level with 1. Check and clean the oil filter inlet
the recommended oil. and outlet area of dirt and other con-
taminations.
Refer to SPECIFICATIONS for oil ca-
pacity.
Start engine and let idle for a few min-
utes.
Ensure oil filter area and oil drain plug
areas are not leaking.
Stop engine.
Wait a while to allow oil to flow down to
crankcase then check oil level.
Refill as necessary.
tmr2011-010-005_a
Dispose of oil as per your local environ-
mental regulations. 1. Outlet bore to the engine oil providing
system
2. Inlet bore from the oil pump to the oil filter
3) Oil Filter
2. Install a NEW O-ring on oil filter
Oil Filter Removal cover.
To reach oil filter, remove the following 3. Install the filter into the cover.
parts: 4. Apply engine oil on O-ring and on
– Seat end of filter.
126 ______________
Inspect radiating fins. They must be

clean, free of mud, dirt, leaves and any
other deposit that would prevent the
radiator to cool properly.
Remove as much deposits as you can
with your hands. If water is available in
proximity, try rinsing the radiating fins.
NOTE: Inner fenders can be removed
to ease cleaning.
vmr2006-008-001_a
If available, use a garden hose to rinse
1. Slightly oil
the radiating fins.
2. Slightly oil
CAUTION Never clean radiator
5. Install the cover on the engine. with your hands when it is hot. Let
6. Tighten oil filter cover screws to rec- the radiator cool down before clean-
ommended specification. ing.
TIGHTENING TORQUE NOTICE Be careful not to damage
the radiating fins when cleaning. Do
Oil filter cover 10 N•m ± 1 N•m
not use any object/tool that could
damage the fins. The fins are pur-
posely thin parts to allow efficient
7. Reinstall remaining parts if applica- cooling. WHEN RINSING, USE LOW
ble. PRESSURE ONLY, NEVER USE A
HIGH PRESSURE WASHER.
4) Radiator
See an authorized Can-Am dealer to
Radiator Inspection check the performance of the cooling
Periodically check the radiator area for system.
cleanliness.
5) Engine Coolant
Engine Coolant Level Verification
WARNING
Check coolant level with engine
cold. Never add coolant in cooling
system when engine is hot.
Place vehicle on a level surface.

Remove the gauge support.
vmo2012-012-041
Inspect radiator and hoses for leaks or

any damage.
______________ 127
219001854-001_a 219001854-001_b
Step 1: Pull up Step 1: Hook

Step 2: Slide Step 2: Engage retaining tab
Remove the coolant reservoir cap. NOTE: A cooling system that fre-
quently requires coolant is the indica-
WARNING tion of leaks or engine problems. See
an authorized Can-Am dealer.
Warning: Do not remove the
coolant reservoir cap if engine is NOTICE Do not store any objects
hot. under the gauge support.
With vehicle on a level surface, liquid Recommended Engine Coolant

should be between MIN. and MAX.
level marks of coolant reservoir. RECOMMENDED
COUNTRY
COOLANT
Finland, Norway
LONG LIFE
and Sweden
ANTIFREEZE(F)
(P/N 619 590 204)
All other
LONG LIFE
countries
ANTIFREEZE
(P/N 219 702 685)
Distilled water
and antifreeze
Alternative, or if
solution (50%
not available
vmo2012-012-042_a
distilled water,
50% antifreeze)
1. Engine coolant reservoir
NOTE: When checking level at tem- NOTICE Always use ethylene-gly-

perature lower than 20°C (68°F), it may col antifreeze containing corrosion
be slightly lower than MIN. mark. inhibitors specifically for internal
Add coolant if required. combustion aluminum engines.
Use a funnel to avoid spillage. Do not Engine Coolant Replacement
overfill.
Properly reinstall and tighten reservoir Cooling System Draining
cap. Remove the gauge support.
Reinstall gauge support.
128 ______________
NOTE: Do not unscrew the coolant

drain plug completely.
570/650 Models
Disconnect the lower radiator hose
and drain the remaining coolant into a
suitable container.
NOTE: Take note of hose clamp posi-
tion on the lower radiator hose.
219001854-001_a
Reinstall lower radiator hose.
Step 1: Pull up
Step 2: Slide Position the radiator hose clamp as
noted during removal.
Remove the coolant reservoir cap.
Tighten radiator hose clamp to specifi-
cation.
WARNING
To avoid potential burns, do not All Models
remove the pressure cap if the en- Reinstall cooling system drain plug
gine is hot. with a new sealing ring.
Tighten the coolant drain plug to speci-
fication.
TIGHTENING TORQUE
Cooling drain 9 N•m to 11 N•m
plug (80 lbf•in to 97 lbf•in)
Bleed cooling system, refer to COOL-

ING SYSTEM FILLING AND BLEED-
ING.
Cooling System Filling and Bleeding
1. Unscrew bleed screws on both
vmo2012-012-042_a
front and rear cylinders.
1. Engine coolant reservoir cap
Unscrew the coolant drain plug and

drain the coolant into a suitable con-
tainer.
tmo2011-001-501_a
vmo2012-012-058_b TYPICAL
______________ 129
11. Inspect cooling system for leaks.

12. Check coolant level in the reser-
voir. Add coolant as required.
13. Install pressure cap.
6) Muffler Spark Arrester

Muffler Spark Arrester Cleaning and
Inspection
NOTE: Spark arrester screen replace-
tmo2011-001-502_a ment is required only when damaged.
TYPICAL
1. Rear cylinder bleed screw
CAUTION Let exhaust system
2. Fill the cooling system until coolant cool down before proceeding with
comes out of the bleed screw(s). cleaning and inspection.
570/650 Remove the muffler cover. Discard re-
taining screws.
3. Squeeze the top of the coolant hose
between the radiator and coolant NOTICE Do not use impact tool for
pump several times until all air is any screw removal.
bled from the highest point of the
hose.
All Models
4. Install the bleed screws using NEW
gasket rings and tighten to specifi-
cation.
TIGHTENING TORQUE
5.0 N•m ± 0.6 N•m
Bleed screws
5. Add coolant until system is full up to vmr2012-0005-050_a

the pressure cap seat.
TYPICAL
6. Refill coolant tank up to MAX level 1. Screws
mark. 2. Cover
7. Start engine. Remove and discard the tail pipe retain-

NOTE: Do not install pressure cap. ing screws.
8. Run engine at idle until coolant fan
turns ON.
NOTE: Monitor coolant level during
engine warm-up and add coolant as re-
quired.
9. Depress the throttle lever two or
three times; check coolant level.
10. Stop the engine and let it cool
down.
130 ______________
vmr2012-0005-051_a tmo2011-001-043_a
TYPICAL 1. Clean spark arrester

1. Screws
2. Tail pipe Inspect mesh of spark arrester for any
damage. Replace as required.
Remove exhaust tail pipe, gasket (dis-
card) and spark arrester. NOTE: Spark arrester screen replace-
ment is required only when damaged.
Inspect spark arrester chamber in muf-
fler.
Clean any debris as required.
Install new gasket, tail pipe and new re-
taining screws.
Reinstall muffler cover with new re-
taining screws. Tighten to specifica-
tion.
TIGHTENING TORQUE
tmo2011-001-041_a
Tail pipe screws 11 N•m ± 1 N•m
TYPICAL Cover screws (97 lbf•in ± 9 lbf•in)
1. Spark arrester
2. Gasket
3. Exhaust tail pipe
7) CVT Air Filter (1000)
Remove carbon deposits from the
spark arrester using a brush. CVT Air Filter Removal
1. Remove the gauge support.
NOTICE Use a soft brush and be
careful to avoid damaging spark ar-
rester mesh.
CAUTION Wear eye protection

and gloves.
WARNING
injury or death.
______________ 131
vmo2013-007-019_a
219001854-001_a
1. CVT air filter (clip-on type)
Step 1: Pull up
Step 2: Slide 3. Clean inside the CVT air inlet end.
2. Push on three tabs and remove air CVT Air Filter Installation
filter.
Models with Slip-On Air Filter
Install air filter on CVT inlet by stretch-
ing its sides.
Models with Clip-On Air Filter
Install air filter on CVT by inserting tabs
in their slots and push on air filter until it
clicks.
All Models
Install the gauge support.
vmo2013-007-013_a
1. CVT air filter

2. Tab
CVT Air Filter Cleaning

1. Spray filter inside and out with a
good air filter cleaner and follow
manufacturer's instructions.
2. Dry filter completely.
219001854-001_b
Step 1: Hook
Step 2: Engage retaining tab
8) Gearbox Oil
Gearbox Oil Level Verification
NOTICE Check level and refill if
necessary. Do not overfill. Operat-
ing the gearbox with an improper
vmo2010-004-016_a
level may severely damage gear-
1. CVT air filter (slip-on type) box. Wipe off any spillage.
132 ______________
Place the vehicle on a level surface. Place the vehicle on a level surface.
Select NEUTRAL position. Clean drain plug area.
Apply brake lock. Clean the oil level plug area.
Check the gearbox oil level when en- Under the vehicle, place a drain pan un-
gine cold, not running, by removing the derneath the oil drain plug area.
gearbox oil level plug. Remove the oil level plug.
Remove the gearbox drain plug.
vmo2012-012-056_a
TYPICAL
1. Drain plug vmo2012-012-056_a
2. Oil level plug TYPICAL
1. Drain plug
The oil should be level with the bottom 2. Oil level plug
of the oil level hole.
Let oil completely drain from gearbox.
Refill as required until gearbox oil level
flows through oil level hole. Install the drain plug with a NEW seal-
ing ring and tighten to specification.
Recommended Gearbox Oil
TIGHTENING TORQUE
RECOMMENDED
ENGINE QUANTITY 20 N•m ± 2 N•m
PRODUCT Drain plug
570
XPS SYNTHETIC NOTE: Clean drain plug from any
650
GEAR OIL Approximately
metallic particles prior to installation.
(75W 140)(F) 450 ml
1000 (P/N 619 590 (15.22 U.S. oz) Refill gearbox.
182)
NOTICE Use ONLY the recom-
mended type of oil.
If the recommended oil is not available,
use a 75W140 gearbox oil that meets The oil should be level with the bottom
the API GL-5 specification. of the oil level orifice.
NOTICE Do not use another types NOTICE Do not overfill.
of oil when servicing. Do not mix
with other types of oil. Reinstall oil level plug. Tighten plug to
specification.
Gearbox Oil Change
NOTE: When replacing the gearbox
oil, it is recommended to clean the ve-
hicle speed sensor (VSS) at the same
time.
______________ 133
TIGHTENING TORQUE
5 N•m ± 0.6 N•m
Oil level plug
Wipe off any spillage.
9) Throttle Cable
Throttle Cable Lubrication
The throttle cable must be lubricated
with a silicone based lubricant or an V07I0GY 1 2 3 4
equivalent. 1. Cable protector
WARNING 3. Lock nut
Always use a silicone-based lubri-
cant. Using another lubricant (like Screw in the throttle cable adjuster.
a water-based lubricant) could Remove inner housing protector.
cause the throttle lever/cable to
become sticky and stiff.
V07I0HY 1
Remove the cable from the throttle

V07I0FY lever housing.
1. Remove these screws NOTE: Slide cable in clip slot and re-
move the end of cable from clip.
Separate the housing.
Slide rubber protector back to expose
throttle cable adjuster.
134 ______________
V07I0JY
V07I0IY TYPICAL
NOTE: Place a rag around the throttle

Remove the throttle body side cover. cable adjuster to prevent the lubricant
from splashing.
Add lubricant until it runs out at throttle
body end of the throttle cable.
Reinstall and adjust the cable.
Throttle Cable Adjustment

vmo2006-007-032_a
1. Throttle body
2. Side cover screws
Insert the needle of the lubricant can in

the end of throttle cable adjuster.

Chemicals can cause a skin rash and V07I0GY 1 2 3 4
eye injury. 1. Cable protector
3. Lock nut
Loosen lock nut then turn the adjuster

to obtain correct throttle lever free play.
Measure throttle free play at the tip of
throttle lever.
______________ 135
A
219001737-010_a
RH SIDE — REAR CYLINDER

1. Spark plug
V07I010 1
1. Throttle lever
A. 2 mm (.079 in)
Tighten lock nut and reinstall protector.

With the shift lever on PARK position,
start the engine.
Check if the throttle cable is adjusted
correctly by turning handlebar fully to
the right then fully to the left. If the
engine RPM increases, readjust the
219001737-011_a
throttle lever free play.
LH SIDE — FRONT CYLINDER
1. Spark plug
10) Spark Plugs
Spark Plug Installation
Spark Plug Access
Prior to installation, make sure that
Remove side panels. contact surfaces of cylinder heads and
Unplug spark plug cables. spark plugs are free of grime.
Using a feeler gauge, set the spark plug
Spark Plug Removal gap.
Unscrew spark plugs one turn.
SPARK PLUG GAP
CAUTION Always wear safety 570

0.7 mm to 0.8 mm
goggles when using pressurized air. 650
(.028 in to .031 in)
1000
Clean spark plugs and cylinder heads
with pressurized air if possible.
Apply a copper-based anti-seize lubri-
Unscrew spark plugs completely us- cant over spark plug threads to prevent
ing a spark plug socket, then remove a possible seizure.
them.
Screw spark plugs into cylinder heads
by hand and tighten with a torque
wrench and a proper socket.
CAUTION Do not overtighten

spark plugs, engine damage can oc-
cur.
136 ______________
TIGHTENING TORQUE Remove corrosion from battery cable

terminals and battery posts using a
20 N•m ± 2.4 N•m firm wire brush.
Spark plug
11) Battery Battery installation is the reverse of the
removal procedure.
CAUTION Never charge a bat- NOTICE Always connect RED (+)
tery while installed in vehicle. battery cable first.
These vehicles are equipped with a
VRLA battery (Valve Regulated Lead 12) Fuses
Acid). It is a maintenance-free type
battery, there is no need to add water CAUTION Always turn the ig-
to adjust electrolyte level. nition switch to OFF position before
NOTICE Never remove the battery replacing a defective fuse.
sealing cap.
Fuse Inspection
Battery Removal Check if filament is melted.
Disconnect BLACK (-) cable first then If filament is melted, replace damaged
RED (+) cable. fuse, refer to FRONT FUSE BOX or
REAR FUSE HOLDER AND FUSIBLE
NOTICE Always disconnect LINKS below for proper rating.
BLACK (-) battery cable first.
Remove retaining screws, battery
holder then pull the battery out of 1
frame.
A15E0KY
TYPICAL
1. Fuse
2. Check if melted
vmo2012-012-031_a
NOTICE Do not use a higher rated
1. Battery holder fuse as this can cause severe dam-
2. Retaining screws
age.
Battery Cleaning
Front Fuse Box
Clean battery, battery casing and bat-
tery posts using a solution of baking Remove the gauge support.
soda and water.
______________ 137
FRONT FUSE BOX

NO. DESCRIPTION RATING
F6 ECM 5A
2WD/4WD, Winch
F7 5A
(if equipped)
Key Switch,
F8 5A
Starter Solenoid
219001854-001_a
Step 1: Pull up F9 Cooling Fan 25 A

Step 2: Slide
Euro Control
F10 5A
(CE Models)
F11 Lights 30 A
F12 DC Outlet 15 A
F14 Accessories 2 15 A
F15 Fuel Pump 5A
Rear Fuse Holder and Fusible Links
vmo2012-012-032_a
1. Front fuse box

2. Front fuse box cover
NOTE: Check inside fuse box cover to

know fuses location.
NOTICE Do not store any objects
in the front service compartment.
Front Fuse Box Description
FRONT FUSE BOX vmr2016-132-004_a
1. Fuse links
R1 Fan Relay -
R2 Main Relay -
R3 Accessories Relay -
R4 Fuel Pump Relay -
R5 Lights Relay -
R8 Brake Relay - vmr2015-044-004_a
FUSE BOX 2
F4 Gauge (Speedo) 5A
F5 Injectors/Ignition 5A
138 ______________
Rear Fuse Holder Identification

FUSE LINK IDENTIFICATION
Fusible 1 Main 16 awg

links 2 Fan/accessories 16 awg
FUSE IN FUSE BOX 2
IDENTIFICATION
DPS
Fuse 3 (dynamic power 40 A
steering) vmo2012-012-060_b
Pull out bulb.

13) Lights
Properly reinstall removed parts in the
Always check light operation after re- reverse order of their removal.
placement.
Validate headlights operation.
Headlight Bulb Replacement
Headlight Beam Aiming
NOTICE Never touch glass portion Turn adjustment knobs to adjust beam
of a halogen bulb with bare fingers, height to your convenience.
it shortens its operating life. If glass
is touched, clean it with isopropyl al- NOTE: Adjust headlights evenly.
cohol which will not leave a film on
the bulb.
Unplug connector from bulb.
Rotate light bulb counterclockwise to
release it from light housing.
vmo2012-012-059_b
LOW BEAM ADJUSTMENT

1. Adjustment knobs
vmo2012-012-059_a
______________ 139
Remove bulb socket from taillight.

Installation is the reverse of the re-
moval procedure.
14) Drive Shaft Boot and

Protector
Drive Shaft Boot and Protector
Inspection
Visually inspect drive shaft protectors
vmo2012-012-060_a and boots conditions.
HIGH BEAM ADJUSTMENT Check protectors for damage or rub-
1. Adjustment knobs bing against shafts.
Taillight Bulbs Replacement Check boots for cracks, tears, leaking
grease etc.
Rotate taillight counterclockwise to re-
move it from taillight housing. Repair or replace damaged parts as
necessary.
vmo2012-012-061_a
vmo2012-015-003_a
Pull tail light out of its location. TYPICAL — FRONT OF VEHICLE

1. Drive shaft boots
Unplug connector from bulb. 2. Drive shaft protector
Rotate light bulb counterclockwise to
remove it from taillight.
vmo2012-012-062_a
140 ______________
16) Wheels and Tires

Tire Pressure
WARNING
Tire pressure greatly affects vehi-
cle handling and stability. Insuf-
ficient pressure may cause tire to
deflate and rotate on wheel. Over-
pressure may burst the tire. Al-
ways follow recommended pres-
vmo2012-015-002_a sure. NEVER set tire pressure
TYPICAL — REAR OF VEHICLE below minimum. It could cause
1. Drive shaft boots the tire to dislodge from the rim.
2. Drive shaft protector
Since tires are low-pressure types,
a manual pump should be used.
15) Wheel Bearing
Wheel Bearing Inspection Check pressure when tires are cold
before using the vehicle. Tire pres-
Place vehicle on a level surface. sure changes with temperature and
Apply brake lock. altitude. Recheck pressure if one of
these conditions has changed.
For your convenience, a pressure
Secure vehicle on jack stands. gauge is supplied in tool kit.
Push and pull the wheels from the up- Although the tires are specifically de-
per edge to feel the play. signed for off-road use, a flat may still
See an authorized Can-Am dealer if occur. Therefore, it is recommended
there is any play. to carry a tire pump and a repair kit.
Refer to SPECIFICATIONS for recom-
mended pressure.
tmo2011-001-131_a
TYPICAL
______________ 141
Tire Inspection Carefully tighten lug nuts in a criss-

Check tire for damage and wear. Re- cross sequence then apply final
place if necessary. torque.
Do not rotate tires. The front and rear TIGHTENING TORQUE
tires have a different size. The tires are
directional and their rotation must be 100 N•m ± 10 N•m
Wheel lug nuts
kept in a specific direction for proper (74 lbf•ft ± 7 lbf•ft)
operation.
NOTICE Always use the recom-
Tire Replacement mended wheel nuts according to the
Tires replacement should be per- type of wheel. Using a different lug
formed by an authorized Can-Am nut could cause damage to the rim
dealer. or studs.
WARNING
– Replace tires only with the same
type and size as original tires.
– For unidirectional tread pat-
tern, ensure that the tires are
installed in the correct direction
of rotation.
– Tires should be replaced, by an
experienced person, in accor-
dance with tire industry stan-
dards and tools.
vmo2008-001-002_a
Wheel Removal TYPICAL — ALUMINUM WHEEL

1. Wheel lug nut (closed end type)
Apply brake lock. Wheel Beadlock Inspection (If
equipped)
Loosen lug nuts then lift vehicle.
Secure vehicle on jack stands. Wheel Beadlock Retightening
Remove lug nuts then remove wheel. NOTICE Do not use an impact
wrench for tightening beadlock
Wheel Installation screws in order to avoid to damage
At installation, it is recommended to them.
apply anti-seize lubricant on threads.
1. Retighten all screws to specification
If tires are unidirectional, make sure to and according to the following tight-
install wheel according to tire rotation. ening sequence.
WARNING
injury or death.
142 ______________
TIGHTENING TORQUE
Beadlock 11 N•m ± 1 N•m
219001737-001_a
TYPICAL - FINAL TIGHTENING SEQUENCE

V07I0DY
2. Tighten screws a few turns at a

4WD MODE
time to ensure even pressure on
the beadlock clamp ring. NOTE: 4WD mode is engaged when
NOTE: It is normal that the beadlock engine is running and vehicle has
clamp ring flexes slightly to match the moved about one meter.
tire bead. 2. Place the shift lever in PARK.
Wheel Beadlock Gap Verification NOTE: Make sure the gearbox is en-
1. Verify the gap between tire and gaged in PARK.
beadlock clamp ring, it should be
practically equal all around the ring.
fvmo2013-002-020
SHIFT PATTERN
219001737-002_a 3. Lock the brakes.

TYPICAL
A. Gap between tire and ring
If the gap is not acceptable, see an au-

thorized Can-Am dealer.
Instructions for Vehicle Lifting
1. Engage the 4WD mode.
______________ 143
219001872-001_a
Step 1: Apply brakes

Step 2: Lock brakes
fvmo2013-001-011
4. Lift the front or rear of the vehicle us- TYPICAL — REAR LIFTING POINT
ing a suitable lifting device.
17) Steering
WARNING
Ensure all wheels are locked be- Steering Inspection
fore lifting the vehicle. Do not ex-
ceed the lifting device capacity. WARNING
Use only a device approved for The steering components inspec-
lifting this type of vehicle. Do not tion and repair should be per-
move the vehicle using a lifting formed by an authorized Can-Am
device. Refer to the manufacturer dealer.
warnings and instructions prior to
use. Tie-Rods
Visually inspect tie-rods.
The tie-rods must be replaced if
warpage or any other damage is de-
tected.
WARNING
The tie-rod must be replaced if
damaged.
Tie-Rod Ends
fvmo2013-001-010
Apply parking brake.
TYPICAL — FRONT LIFTING POINT Lift vehicle.
NOTE: Ensure that 4 WD is engaged Secure vehicle on jack stands.
and brake is locked. Inspect inner and outer tie-rod boots
for cracks.
Push and pull the wheels from the front
or rear edge to feel the play.
The tie-rod ends must be replaced if
there is an abnormal play or a boot is
cracked.
144 ______________
WARNING The ball joints must be replaced if there

is an abnormal play or a boot is cracked.
The tie-rod end must be replaced if
the boot is cracked or shows an ab-
normal play.
18) Suspension
Front Suspension Lubrication
Lubricate front suspension arms at
grease fittings.
SUSPENSION GREASE
BRP SUSPENSION
recommended GREASE
product (P/N 293 550 033)
tmo2011-001-131_a
TYPICAL
Rear Suspension Lubrication
Lubricate rear stabilizer bar links and WARNING
pivot bushing at grease fittings. The ball joint must be replaced if
SUSPENSION GREASE the boot is cracked or shows an
abnormal play.
BRP SUSPENSION
recommended GREASE Front Suspension Arms
product (P/N 293 550 033)
Check suspension arms for cracks,
bending or other damage.
Suspension Inspection
See an authorized Can-Am dealer as
Shock Absorbers necessary or it shows an abnormal
play.
Inspect shock absorber for oil leaks or
other damage. Rear Trailing Arms
Check tightness of fasteners. Check trailing arms for distortion,
See an authorized Can-Am dealer as cracks or bending.
necessary. See an authorized Can-Am dealer if any
problem is detected.
Ball Joints
Place vehicle on a level surface. 19) Brakes
Apply parking brake.
Brake Fluid Reservoir Level
Lift vehicle. Verification
Secure vehicle on jack stands. With vehicle on a level surface, check
Inspect ball joint boots for cracks. brake fluid in reservoirs for proper
Push and pull the wheels from the up- level.
per and lower edge to feel the play. NOTE: A low level may indicate leaks
See an authorized Can-Am dealer if or worn brake pads.
there is an abnormal play or the boot is
cracked.
______________ 145
Front Brake Reservoir Level Adding Brake FLuid

Verification Clean filler cap.
Turn steering in the straight-ahead po-
sition to ensure reservoir is level. WARNING
Check the brake fluid level, the reser- Clean filler cap before removing.
voir is full when the fluid reaches of the
top of window.
Remove screws retaining the reservoir
Visually inspect lever boot condition. cap.
Check for cracks, tears, etc. Replace if Remove reservoir cap.
damaged.
Add fluid as required using a clean fun-
nel. Do not overfill.
NOTICE Brake fluid can damage
plastic and painted surface. Wipe
off and clean any spillage.
Reinstall reservoir cap and tighten
screws.
NOTE: Ensure filler cap diaphragm is
pushed inside the cap before closing
the brake fluid reservoir.
vmo2012-012-046_a
TYPICAL Always use brake fluid meeting the
specification DOT 4 only from a sealed
Rear Brake Reservoir Level container.
Verification
Remove the seat. WARNING
With vehicle on a level surface, liquid To avoid damage to the braking
should be between MIN. and MAX. system, do not use other brake
level marks of brake pedal fluid reser- fluid types.
voir.
Brake Inspection
CAUTION The brakes can be

very hot after prolonged use of the
vehicle and can cause burns. Wait
for the brakes to cool down.
The brake inspection, maintenance
and repair should be performed by an
authorized Can-Am dealer.
However, verify the following between
visits to your dealer:
vmo2012-012-035_a
– Brake fluid level
1. Rear brake fluid reservoir – Brake system for fluid leaks
– Brake cleanliness.
146 ______________
WARNING
The brake fluid replacement or
brake system maintenance and
repairs should be performed by an
______________ 147
III VEHICLE CARE
1) Post-Operation Care Non Compatible Cleaning Products
When vehicle is used in salt-water en- NON-COMPATIBLE
vironment (beach area, launching and MATERIAL
CLEANING
loading boats etc.), rinsing the vehi- TYPE
PRODUCTS
cle with fresh water is necessary to
preserve vehicle and its components. ANY PETROLEUM
Metallic parts lubrication is highly rec- BASE CLEANING
ommended. Use XPS LUBE (P/N 293 PRODUCTS
600 016) or an equivalent. This must
be performed at the end of each oper- XP-S ATV
ating day. Finishing Spray
Polypropylene (P/N 219 701 704)
When vehicle is operated in muddy
conditions, rinsing the vehicle is rec- XP-S ATV Cleaning
ommended to preserve vehicle and its Kit (P/N 219 701 713)
components and to keep lights clean. (it contains the above
XP-S ATV Finishing
2) Vehicle Cleaning and Spray)
Protection
NOTICE Never use a high pres-
sure washer to clean the vehicle.
USE LOW PRESSURE ONLY (like a
garden hose).
Pay attention to certain areas where
mud or debris can accumulate and po-
tentially cause wear, interferences or
promote corrosion.
Wash the vehicle with a soapy water
solution.
NOTICE Never clean polypropy-
lene body parts with any petroleum
vbs2012-006-002_a
base cleaning products, as it will al-
ter the glossy finish. DO NOT USE ON POLYPROPYLENE
Compatible Cleaning Products

MATERIAL COMPATIBLE
TYPE CLEANING PRODUCT
XPS ATV Wash
Soapy water
148 ______________
III VEHICLE CARE
vbs2012-006-001
SAFE FOR POLYPROPYLENE
______________ 149
IV STORAGE AND PRESEASON PREPARATION
When a vehicle is not in use for more
than 4 months, proper storage is a ne-
cessity.
When using your vehicle after storage,
a preparation is required.
See an authorized Can-Am dealer to
have your vehicle prepared for either
storage or the preseason.
150 ______________
D) TECHNICAL
INFORMATION
______________ 151
I SPECIFICATIONS
MODEL 570 650 1000
ENGINE
ROTAX® 570 ROTAX ® 650 ROTAX® 1000
Engine type 4-stroke, Single Over Head Camshaft
(SOHC), liquid cooled
Number of cylinders 2
4 valves / cylinder (mechanical adjustment),
Number of valves single over head camshaft (SOHC)
with timing chain
Intake 0.06 mm to 0.14 mm (.0024 in to .0055 in)
Valve clearance
Exhaust 0.11 mm to 0.19 mm (.0043 in to .0075 in)
84 mm 82 mm 91 mm
Bore
(3.31 in) (3.23 in) (3.58 in)
51.4 mm 61.5 mm 75 mm
Stroke
(2.02 in) (2.42 in) (2.95 in)
570 cm³ 650 cm³ 976 cm³
Displacement
(34.8 in³) (39.7 in³) (59.56 in³)
Exhaust system
Forest Service
Engine air filter Synthetic paper filter with foam
LUBRICATION SYSTEM
Type Wet sump. Replaceable cartridge oil filter
Capacity 2.0 L (2.1 qt (U.S. liq.))
Use XPS 4-stroke synth. blend oil
(summer) XPS 4-STROKE SYNTH.
BLEND OIL (F) (P/N 619 590 109).
Engine oil or XPS 4-stroke synthetic oil (All
Recommended climate) XPS 4-STROKE SYNTHETIC
OIL (F) (P/N 619 590 114).
that meets the requirements for API service
classification SJ, SL, SM or SN
COOLING SYSTEM
50% water). Use the Long life antifreeze
Type (P/N 219 702 685) or (P/N 619 590 204)
Coolant (Finland, Norway and Sweden) or coolant
specifically designed for aluminum engines
3.5 L
(.9 U.S. gal.)
152 ______________
I SPECIFICATIONS
MODEL 570 650 1000

CVT TRANSMISSION
CVT (Continuously Variable Transmission),
Type sub-transmission with L/H/N/R/P,
Engagement RPM 1800 RPM ± 100 RPM
GEARBOX
Type Dual range (HI-LO) with PARK, neutral and reverse
High 3.705
Overall gear ratio Low 7.509
Reverse 7.88
XPS SYNTHETIC GEAR OIL
Gearbox oil (75W 140)(F) (P/N 619 590 182)
Recommended oil
synthetic gear oil
ELECTRICAL SYSTEM
Without
400 W @ 6000 RPM
Magneto generator output DPS
Ignition timing Variable
Quantity 2
Spark plug Make and type NGK DCPR8E
Forward 8000 RPM
Voltage 12 volts
Battery
______________ 153
I SPECIFICATIONS
MODEL 570 650 1000

ELECTRICAL SYSTEM (cont'd)
High 2 x 60 W
Headlights
Low 2 x 55 W
Taillights 2 x 5/21 W
Turn signal lights 4 x 10 W
Position lights 2x5W
Licence plate light 1 x 10 W
Fuses Refer to FUSES in MAINTENANCE
FUEL SYSTEM
Electronic fuel injection (EFI), 46 mm throttle
Fuel delivery Type
body, 1 injector per cylinder
Throttle body 46 mm
Fuel pump Type Electric (in fuel tank)
Idle speed 1250 ± 100 RPM (not adjustable)
Fuel Minimum 95 (E10) RON or higher- Refer to FUEL
octane REQUIREMENTS
DRIVE SYSTEM
Drive system type Selectable 2WD/4WD
Front 500 ml (17 U.S. oz)
Capacity
Rear 250 ml (8.5 U.S. oz)
Front differential oil/ Front
(P/N 619 590 097)
rear final drive oil or synthetic oil 75W90 API GL5 (LS)
Type XPS SYNTHETIC GEAR OIL
Rear (75W 140)(F) (P/N 619 590 182)
or a 75W140 API GL-5 synthetic gear oil
Base Visco-lok† auto-locking front differential
Front drive All except
Visco-lok† QE auto-locking front differential
Base
154 ______________
I SPECIFICATIONS
MODEL 570 650 1000

DRIVE SYSTEM (cont'd)
Rear drive Straight bevel gear / final drive
CV joint grease CV joint grease (P/N 293 550 062)
Propeller shaft grease Propeller shaft grease (P/N 293 550 063)
STEERING
2 057 mm - -
1-UP
Turning radius (81 in)
2-UP 2 336.8 mm (92 in)
FRONT SUSPENSION
Double suspension arm with dive-control
Suspension type
geometry
Suspension travel 229 mm (9 in)
Qty 2
All Except
Oil
XT-P
HPG shocks
with
Shock absorber piggyback
Type
- - reservoir.
XT-P
QS3†
compression
and preload
adjustments
All Except
5 position cam
Preload adjustment type XT-P
XT-P - - Threaded
REAR SUSPENSION
Torsional Trailing arm Independent (TTI)
Suspension type
with external stabilizer bar
Suspension travel 236 mm (9.3 in)
______________ 155
I SPECIFICATIONS
MODEL 570 650 1000

REAR SUSPENSION (cont'd)
Qty 2
DPS, XT,
Oil
PRO
HPG shocks
with
Shock absorber piggyback
Type
- - reservoir.
XT-P
QS3†
compression
and preload
adjustments
DPS, XT,
5 position cam
Preload adjustment PRO
XT-P - - Threaded
BRAKES
Dual 214 mm cross drilled disc brakes with
Front brake Type
hydraulic twin-piston calipers
Single 214 mm cross drilled disc brake
Rear brake Type
with hydraulic twin-piston caliper
Brake fluid
Type DOT 4
Minimum brake disc thickness 4.0 mm (.157 in)
156 ______________
I SPECIFICATIONS
MODEL 570 650 1000

TIRES
Loaded up
41.4 kPa - -
to 164 kg
(6 PSI)
(360 lb)
1-UP Loaded
from 164 kg
48.2 kPa - -
(360 lb)
(7 PSI)
TO 235 kg
(517 lb)
Front
Loaded up
to 132 kg 41.4 kPa (6 PSI)
(290 lb)
2-UP Loaded
from 132 kg
(290 lb) 48.2 kPa (7 PSI)
TO 272 kg
(600 lb)
Pressure
Loaded up
41.4 kPa - -
to 164 kg
(6 PSI)
(360 lb)
1-UP Loaded
from 164 kg
68.9 kPa - -
(360 lb)
(10 PSI)
TO 235 kg
(517 lb)
Rear
Loaded up
to 132 kg 41.4 kPa (6 PSI)
(290 lb)
2-UP Loaded
from 132 kg
(290 lb) 68.9 kPa (10 PSI)
TO 272 kg
(600 lb)
______________ 157
I SPECIFICATIONS
MODEL 570 650 1000

WHEELS
DPS
Steel Cast
XT Cast Aluminum
Type Aluminum
PRO
XT-P Aluminium beadlocks
Front 305 x 152 mm (12 x 6 (in))
Rim size
Rear 305 x 191 (12 x 7.5 (in))
Wheel nuts torque 100 N•m ± 10 N•m (74 lbf•ft ± 7 lbf•ft)
DIMENSIONS
218.4 cm - -
1-UP
Overall length (86 in)
2-UP 238.7 cm (94 in)
Overall width 116.8 cm (46 in)
126 cm - -
1-UP
Overall height (49.606 in)
2-UP 135 cm (53.15 in)
129.5 cm - -
1-UP
Wheelbase (51 in)
2-UP 149.9 cm (59 in)
Front 96.5 cm (38 in)
Wheel track
Rear 91.4 cm (36 in)
Ground clearance 27.9 cm (11 in)
158 ______________
I SPECIFICATIONS
MODEL 570 650 1000

LOADING CAPACITY AND WEIGHT
410 kg 412 kg 414 kg
1-UP
(903 lb) (908 lb) (912 lb)
Curb weight
430 kg 435 kg 445 kg
2-UP
(948 lb) (959 lb) (981 lb)
Weight distribution Front/Rear 42 % 58 %
Front rack capacity 45 kg (100 lb)
Rear rack capacity 90 kg (200 lb)
Rear storage compartment loading capacity 10 kg (22 lb)
Total vehicle load allowed (including driver, all 1-UP 235 kg (518 lb) - -
other loads and added accessories) 2-UP 272 kg (600 lb)
Trailer
without 590 kg (1,301 lb)
Towing capacity brakes
Trailer with
750 kg (1,653 lb)
brakes
Trailer
without 59 kg (130 lb)
Tongue weight brakes
Trailer with
75 kg (165 lb)
brakes
______________ 159
I SPECIFICATIONS
MODEL ALL
TIRES
660 x 203 x 305 mm (AT26
Front
x 8 x 12 (in))
Tire size
660 x 254 x 305 mm (AT26
Rear
x 10 x 12 (in))
Tires (dimen- Technically permissible Technically permissible maximum
Axle No
sions) maximum mass per axle mass per tire
1 - Front AT26x8-12 350 kg (771.6 lb) 175 kg (385.8 lb)
2 - Rear AT26x10-12 410 kg (903.9 lb) 205 kg (451.9 lb)
SEAT the vibration level measured according to Directive 78/764/EEC
1-UP 0.69
Light driver aws
2-UP 0.77
1-UP 0.62
Heavy driver aws
2-UP 0.65
160 ______________
I SPECIFICATIONS
MODEL ALL
NOISE AND VIBRATION DECLARATION (570 model)
13.1
according to Annex VI to Directive stationary: 81 dB(A)
Exterior sound level:
2009/63/EC
13.2 .moving: 78 dB(A)
Driver-perceived
according to Directive 2009/76/EC 90 dB(A)
sound level:
13.1
according to Annex VI to Directive stationary: 81dB(A)
2009/63/EC
13.2 moving: 75dB(A)
Driver-perceived
sound level:
13.1
according to Annex VI to Directive stationary: 84 dB(A)
2009/63/EC
13.2 moving: 82 dB(A)
Driver-perceived
sound level:
______________ 161
I SPECIFICATIONS
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intentionally blank
162 ______________
E)
TROUBLESHOOTING
______________ 163
TROUBLESHOOTING GUIDELINES
ENGINE DOES NOT TURN

1. Ignition switch is in the OFF position.
– Place switch to the ON position.
2. Emergency engine stop switch.
– Make sure that emergency engine stop switch is in ON position.
3. Transmission is not set on PARK or NEUTRAL.
– Set transmission either in PARK or in NEUTRAL or press the brake lever.
4. Burnt fuse.
– Check main fuse condition.
5. Weak battery or loose connections.
– Check charging system fuse.
– Check connections and terminals condition.
– Have the battery checked.
– Contact an authorized Can-Am dealer.
6. Wrong ignition key, multifunction gauge display shows INVALID KEY.
– Use the proper key for this vehicle.
7. Weak starter or loose connections.
– Check starter connections.
– Check starter relay.
ENGINE TURNS OVER BUT FAILS TO START

1. Flooded engine (spark plug wet when removed).
– (Drowned mode) If the engine does not start and it is fuel-flooded, this
special mode can be activated to prevent fuel injection and to cut ignition
while cranking. Proceed as follows:
• Insert key in ignition switch and turn to ON position.
• Move shift lever in park position.
• Press completely and HOLD throttle lever.
• Press the engine START button.
The engine should be cranked for 20 seconds. Release engine START but-
ton.
Release throttle lever and start/crank engine again to allow starting.
If it does not work:
• Clean the spark plug caps area then remove them.
• Remove the spark plugs.
• Unplug injector electrical connector.
• Crank engine several times.
• Install new spark plugs if possible or clean and dry spark plugs.
• Start engine as explained above.
If engine continues to flood, see an authorized Can-Am dealer.
NOTE: Make sure to verify that there is no fuel in engine oil, if so, replace
engine oil.
164 ______________
ENGINE TURNS OVER BUT FAILS TO START (cont’d)

2. No fuel to the engine (spark plug dry when removed).
– Check fuel tank level.
– A failure of the fuel pump may have occurred.
– Check fuel pump fuse and relay.
3. Spark plug/ignition (no spark).
– Check main fuse condition.
– Remove spark plug then reconnect to ignition coil.
– Check that ignition switch and/or emergency engine stop switch is/are at the
ON position.
– Start engine with spark plug grounded to the engine away from spark plug
hole. If no spark appears, replace spark plug.
– If trouble persists, contact an authorized Can-Am dealer
4. Multifunction gauge CHECK ENGINE indicator lamp is on and display
shows CHECK ENGINE.
5. Engine is under a protection (limp home) mode.
– Multifunction gauge CHECK ENGINE indicator lamp is on and display shows
CHECK ENGINE, contact an authorized Can-Am dealer.
ENGINE LACKS ACCELERATION OR POWER

1. Fouled or defective spark plug.
– Refer to ENGINE TURNS OVER BUT FAILS TO START.
2. Lack of fuel to engine.
3. Engine is overheating. (CHECK ENGINE indicator light will turn on and HI
TEMP will appear in the multifunction display.)
– Refer to ENGINE OVERHEATS.
4. Air filter/housing clogged or dirty.
– Check air filter and clean if necessary.
– Check deposits in air filter housing drain.
– Check the position of the air intake tube.
5. CVT dirty or worn-out.
– Check multifunction gauge display for messages.
CHECK ENGINE or LIMP HOME, contact an authorized Can-Am dealer.
ENGINE OVERHEATS
1. Low coolant in cooling system.
– Check engine coolant, refer to ENGINE COOLANT in MAINTENANCE PRO-
CEDURES.
______________ 165
ENGINE OVERHEATS (cont’d)

2. Dirty radiator fins.
– Clean radiator fins, refer to RADIATOR in MAINTENANCE PROCEDURES.
3. Cooling fan inoperative.
– Check cooling fan fuse or relay, refer to FUSES in MAINTENANCE PROCE-
DURES. If the fuse is good, contact an authorized Can-Am dealer.
ENGINE BACKFIRE
1. Exhaust system leakage.
2. Engine is running too hot.
– Refer to ENGINE LACKS ACCELERATION OR POWER.
3. Ignition timing is incorrect or there is an ignition system failure.
ENGINE MISFIRE
1. Fouled/defective/worn spark plug.
– Clean/verify spark plug and heat range. Replace as required.
2. Water in fuel.
– Drain fuel system and refill with fresh fuel.
VEHICLE CANNOT REACH FULL SPEED

1. Engine.
2. Brake lock.
– Ensure brake lock is completely removed.
3. Air filter/housing plugged or dirty.
CHECK ENGINE or LIMP HOME, contact an authorized Can-Am dealer.
SHIFT LEVER IS HARD TO MOVE

1. Transmission gears are in a position that prevents the shift lever to work.
– Rock the vehicle back and forth to move the gears in the transmission and al-
low the shift lever to be set.
166 ______________
THE RPM INCREASES BUT THE VEHICLE DOES NOT MOVE

1. The transmission is on PARK or NEUTRAL position.
– Select the R, HI or LO position.
3. Water in the CVT housing.
REDUCED POWER STEERING ASSIST

1. When DPS is subjected to sustained severe steering conditions, the assis-
tance provided by the DPS motor may be reduced to protect the system.
– Once the load is reduced, the normal steering assistance will return.
2. CHECK ENGINE INDICATOR LAMP is ON and display shows CHECK DPS
– Seek service from an authorized Can-Am dealer, repair shop or person of your
own choosing for maintenance, repair or replacement.
______________ 167
II MULTIFUNCTION GAUGE MESSAGES
PILOT
MESSAGE DESCRIPTION
LAMP(S) ON
Indicates that you have used the wrong ignition key, use the
DESS KEY NOT
Check engine proper key for this vehicle. It is also possible that the ignition
RECOGNIZED
key has a bad contact, remove and clean key.
Displayed when brake is applied for more than 15 seconds
PARK BRAKE Brake lock
(while riding).
Low battery voltage, check battery voltage and charging
LO BATT VOLT Check engine
system.
High battery voltage, check battery voltage and charging
HIGH BATT VOLT Check engine
system.
LOW OIL (1) Check engine Engine low oil pressure, stop engine immediately.
Engine is overheating, refer to ENGINE OVERHEATS in
HI TEMP Check engine
TROUBLESHOOTING.
Serious fault on the engine that can change the normal
LIMP HOME Check engine operation of the engine, CHECK ENGINE indicator lamp will
also blink, refer to TROUBLESHOOTING.
Engine fault, CHECK ENGINE indicator lamp will also be ON,
CHECK ENGINE Check engine
refer to TROUBLESHOOTING.
ECM NOT Communication error between speedometer and engine
Check engine
RECOGNIZED control module (ECM), contact an authorized Can-Am dealer.
CHECK DPS (models Indicates that the DPS (Dynamic Power Steering) does not
Check engine
with DPS) work properly. See an authorized Can-Am dealer.
DPS OVERTORQUE Indicates that DPS module is lowering its assist level to
None
(models with DPS) protect itself against extreme torque level.
DPS OVERHEAT Indicates that DPS module is lowering its assist level to
None
(models with DPS) protect itself against extreme temperature.
168 ______________
PILOT
MESSAGE DESCRIPTION
LAMP(S) ON
MAINTENANCE
None Displayed in gauge when vehicle is due for a maintenance
REQUIRED (2)
TPS FAULT PRESS
Throttle position sensor does not work properly. See an
OVERRIDE BUTTON Check engine
TO LIMP HOME
NOTICE (1) If the message and the check engine light stay on after engine
starting, stop engine. Check engine oil level. Refill if necessary. If the oil
level is good, see an authorized Can-Am dealer. Do not use the vehicle until
repaired.
(2) To
erase the MAINTENANCE REQUIRED message, proceed as follows:
1. From main display (vehicle speed), press SET and HOLD.
2. Alternate between LOW beam and HIGH beam 3 times.
NOTE: Step 2 must be completed within 2 seconds.
______________ 169
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intentionally blank
170 ______________
F) SPARE PARTS
______________ 171
I CATALOGS
You will find your Can-Am ATV spare parts on our website at www.epc.brp.com.
172 ______________
G) WARRANTY
______________ 173
I BRP INTERNATIONAL LIMITED WARRANTY: 2018
CAN-AMTM ATV T3
1) SCOPE OF THE LIMITED WARRANTY
Bombardier Recreational Products Inc. ("BRP")* warrants its 2018 Can-Am
ATV sold by Can-Am ATV distributors or dealers authorized by BRP to distribute
Can-Am ATVs ("Can-Am ATV Distributor/Dealer") outside of the fifty United States,
Canada and states that are members of the European Economic Area ("EEA")
(which is comprised of the states members of the European Union plus Norway,
Iceland and Liechtenstein), Turkey, and states members of the Commonwealth of
the Independent States ("CIS") (which is comprised of the Russian Federation and
ex-members states of the USSR), from defects in material or workmanship for the
period and under the conditions described below.
Non-factory installed parts and accessories are not covered under this limited war-
ranty. Please refer to the applicable parts and accessories limited warranty text.
This limited warranty will become null and void if: (1) The ATV was used for racing
or any other competitive activity, at any point, even by a previous owner; or (2)
the ATV has been altered or modified in such a way so as to adversely affect its
operation, performance or durability, or has been altered or modified to change its
intended use.
2) LIMITATIONS OF LIABILITY
TO THE EXTENT PERMITTED BY LAW, THIS WARRANTY IS EXPRESSLY
GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EX-
PRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TO THE
EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES
ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY.
INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM
COVERAGE UNDER THIS WARRANTY. SOME JURISDICTIONS DO NOT AL-
LOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED
ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY
GIVES YOU SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY. (FOR PROD-
UCTS PURCHASED IN AUSTRALIA SEE CLAUSE 4 BELOW).
Neither the Can-Am ATV Distributor/Dealer nor any other person has been autho-
rized to make any affirmation, representation or warranty regarding the product,
other than those contained in this limited warranty, and if made, shall not be
enforceable against BRP.
BRP reserves the right to modify this limited warranty at any time, being under-
stood that such modification will not alter the warranty conditions applicable to
the products sold while this warranty is in effect.
3) EXCLUSIONS – ARE NOT WARRANTED

The following are not warranted under this limited warranty under any circum-
stances:
– Normal wear and tear;
– Routine maintenance items, tune ups, adjustments;
– Damage caused by negligence or failure to provide proper maintenance and/or
storage, as described in the Operator's Guide;
174 ______________
– Damage resulting from removal of parts, improper repairs, service, main-
tenance, modifications or use of parts or accessories not manufactured or
approved by BRP which in its reasonable judgement are either incompatible
with the product or adversely affect its operation, performance and durability,
or resulting from repairs done by a person that is not an authorized servicing
Can-Am ATV Distributor/Dealer;
– Damage caused by abuse, abnormal use, neglect, racing or operation of the
product in a manner inconsistent with the recommended operation described
in the Operator’s Guide;
– Damage resulting from accident, submersion, fire, snow or water ingestion,
theft, vandalism or any act of God;
– Operation with fuels, oils or lubricants which are not suitable for use with the
product (see the Operator’s Guide);
– Damage resulting from rust, corrosion or exposure to the elements;
– Incidental or consequential damages, or damages of any kind including without
limitation towing, storage, transportation expenses, telephone, rental, taxi, in-
convenience, insurance coverage, loan payments, loss of time, loss of income;
or time missed for downtime experience due to service work.
4) WARRANTY COVERAGE PERIOD

This limited warranty will be in effect from (1) the date of delivery to the first retail
consumer or (2) the date the product is first put into use, whichever occurs first and
for a period of:
SIX (6) CONSECUTIVE MONTHS for private use or commercial use.
The repair or replacement of parts or the performance of service under this war-
ranty does not extend the life of this warranty beyond its original expiration date.
Note that the duration and any other modalities of the warranty coverage are sub-
ject to the applicable national or local legislation in the customer's country.
FOR PRODUCTS SOLD IN AUSTRALIA ONLY

Nothing in these Warranty terms and conditions should be taken to exclude,
restrict or modify the application of any condition, warranty, guarantee, right or
remedy conferred or implied under the Competition and Consumer Act 2010
(Cth), including the Australian Consumer Law or any other law, where to do so
would contravene that law, or cause any part of these terms and conditions to be
void. The benefits given to you under this limited warranty are in addition to other
rights and remedies that you have under Australian law.
Our goods come with guarantees that cannot be excluded under the Australian
Consumer Law. You are entitled to a replacement or refund for a major failure
and for compensation for any other reasonably foreseeable loss or damage. You
are also entitled to have the goods repaired or replaced if the goods fail to be of
acceptable quality and the failure does not amount to a major failure.
______________ 175
5) CONDITIONS TO HAVE WARRANTY COVERAGE
This warranty coverage is available only if each of the following conditions has
been fulfilled:
– The 2018 Can-Am ATV must be purchased as new and unused by its first owner
from a Can-Am ATV Distributor/Dealer authorized to distribute Can-Am ATVs in
the country in which the sale occurred;
– The BRP specified pre-delivery inspection process must be completed and doc-
umented;
– The product must have undergone proper registration by an authorized Can-Am
ATV Distributor/Dealer;
– The 2018 Can-Am ATV must be purchased in the country or union of countries in
which the purchaser resides; and
– Routine maintenance outlined in the Operator’s Guide must be timely per-
formed in order to maintain warranty coverage. BRP reserves the right to make
warranty coverage contingent upon proof of proper maintenance.
BRP will not honour this limited warranty to any private use owner or commercial
use owner if one of the preceding conditions has not been met. Such limitations
are necessary in order to allow BRP to preserve both the safety of its products, and
also that of its consumers and the general public.
6) WHAT TO DO TO OBTAIN WARRANTY COVERAGE

The customer must cease using the ATV upon the appearance of an anomaly. The
customer must notify a servicing Can-Am ATV Distributor/Dealer within two (2)
days of the appearance of a defect, and provide it with reasonable access to the
product and reasonable opportunity to repair it. The customer must also present
to the authorized Can-Am ATV Distributor/Dealer proof of purchase of the product
and must sign the repair/work order prior to starting the repair in order to validate
the warranty repair. All parts replaced under this limited warranty become the
property of BRP.
Note that the notification period is subject to the applicable national or local legisla-
tion in customer's country.
7) WHAT BRP WILL DO

To the extent permitted by law, BRP’s obligations under this warranty are lim-
ited to, at its sole discretion, repairing parts found defective under normal use,
maintenance and service, or replacing such parts with new genuine Can-Am ATV
parts without charge for parts and labour, at any authorized Can-Am ATV Distrib-
utor/Dealer during the warranty coverage period under the conditions described
herein. BRP's responsibility is limited to making the required repairs or replace-
ments of parts. No claim of breach of warranty shall be cause for cancellation or
rescission of the sale of the Can-Am ATV to the owner. You may have other legal
rights which may vary from country to country.
In the event that service is required outside of the country of original sale, the
owner will bear responsibility for any additional charges due to local practices
and conditions, such as, but not limited to, freight, insurance, taxes, license fees,
import duties, and any and all other financial charges, including those levied by
governments, states, territories and their respective agencies.
176 ______________
BRP reserves the right to improve or modify products from time to time without as-
suming any obligation to modify products previously manufactured.
8) TRANSFER
If the ownership of a product is transferred during the warranty coverage period,
this warranty shall also be transferred and be valid for the remaining coverage pe-
riod provided BRP or an authorized Can-Am ATV Distributor/Dealer receives a proof
that the former owner agreed to the transfer of ownership, in addition to the co-or-
dinates of the new owner.
9) CONSUMER ASSISTANCE
In the event of a controversy or a dispute in connection with this limited warranty,
BRP suggests that you try to resolve the issue at the dealership level. We recom-
mend discussing the issue with the authorized dealer's service manager or owner.
If the matter still remains unresolved, contact BRP by filling out the customer con-
tact form at www.brp.com or contact BRP by mail at one of the addresses listed
under the CONTACT US section of this guide.
* For the territory covered by this limited warranty, products are distributed and serviced by
Bombardier Recreational Products Inc. or its affiliates.
© 2017 Bombardier Recreational Products Inc. All rights reserved.
TM Trademark of Bombardier Recreational Products Inc. or its affiliates.
______________ 177
II BRP LIMITED WARRANTY FOR THE EUROPEAN
ECONOMIC AREA, THE COMMONWEALTH OF
THE INDEPENDENT STATES AND TURKEY: 2018
CAN-AMTM ATV T3
Bombardier Recreational Products Inc. ("BRP")* warrants its 2018 Can-Am ATVs
sold by distributors or dealers authorized by BRP to distribute Can-Am ATVs
("Can-Am ATV Distributor/Dealer") in member states of the European Economic
Area (which is comprised of the member states of the European Union plus Nor-
way, Iceland and Liechtenstein) ("EEA"), in member states of the Commonwealth
of the Independent States (including Ukraine and Turkmenistan) ("CIS") and Turkey
from defects in material or workmanship for the period and under the conditions
described below.
intended use.
GIVES YOU SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY.
BRP reserves the right to modify this warranty at any time, being understood that
such modification will not alter the warranty conditions applicable to the products
sold while this warranty is in effect.

stances:
178 ______________
limitation towing, transportation expenses, storage, telephone, rental, taxi, in-
convenience, insurance coverage, loan payments, loss of time, loss of income

This warranty will be in effect from (1) the date of delivery to the first retail con-
sumer or (2) the date the product is first put into use, whichever occurs first and
for a period of:
TWENTY-FOUR (24) CONSECUTIVE MONTHS for private use.
SIX (6) CONSECUTIVE MONTHS for commercial use or rental use.
TWENTY-FOUR (24) CONSECUTIVE MONTHS for commercial use provided that
the product is purchased in Finland, Norway or Sweden.
The product is used commercially when it is used in connection with any work or
employment that generates income during any part of the warranty period. The
product is also used commercially when, at any point during the warranty period,
it is licensed for commercial use.

been fulfilled:
umented;
______________ 179
– The 2018 Can-Am ATV must be purchased within the EEA by an EEA resident,
in the CIS for residents of the countries comprised in such area and in Turkey for
residents of Turkey; and

months of the appearance of a defect and provide it with reasonable access to the
to the authorized Can-Am ATV Distributor/Dealer, proof of purchase of the product
property of BRP.
7) WHAT BRP WILL DO

In the event that service is required outside of the EEA, CIS or Turkey, the owner
will bear responsibility for any additional charges due to local practices and
conditions, such as, but not limited to, freight, insurance, taxes, license fees,
180 ______________
8) TRANSFER
BRP suggests that you try to resolve the issue at the Can-Am ATV Distribu-
tor/Dealer level. We recommend discussing the issue with the authorized
Can-Am ATV Distributor/Dealer's service manager or owner.
* In the EEA, products are distributed and serviced by BRP European Distribution S.A. and
other affiliates or subsidiaries of BRP.
™ Trademark of Bombardier Recreational Products Inc. or its affiliates.
______________ 181
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182 ______________
H) CUSTOMER
INFORMATION
______________ 183
184 ______________
______________ 185
186 ______________
______________ 187
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188 ______________
IV MAINTENANCE RECORDS
Send photocopy of maintenance record to BRP if needed.
PREDELIVERY
Serial number: Signature/Print:
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
Refer to vehicle Pre-Delivery Bulletin for detailed installation procedures
______________ 189
FIRST INSPECTION
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
For maintenance schedule refer to Maintenance Information section of this operator's guide
SERVICE
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
SERVICE
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
SERVICE
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
190 ______________
SERVICE
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
SERVICE
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
SERVICE
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
SERVICE
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
______________ 191
SERVICE
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
SERVICE
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
SERVICE
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
SERVICE
Mileage / km:
Hours:
Date:
Dealer no:
Notes:
192 ______________
WARNING
injury or death.
T3 4x4 OUTLANDER / OUTLANDER MAX 570/650/1000 Series


2018
training course.
control if you carry more than one passenger.
if you carry a passenger. Operator’s
SURFACE unless it is for short distances, at reduced
speed and in order to move the vehicule from an
Guide
off-road location to another. Includes
• ALWAYS RESPECT THE ROAD TRAFFIC LAWS Safety, Vehicle
when you operate the vehicule on the roadway, even a
dirt or gravel road. and Maintenance Information
T3 4x4 OUTLANDER TM/

STUNTS.
OUTLANDERTM MAXTM
570/650/1000 Series
WARNING
2018
Read this guide thoroughly. It contains important safety information.

219 001 872
Minimum recommended age: Operator: 16 years old. Driving tractor requires at least a tractor
OPERATOR’S GUIDE T3 4x4 OUTLANDER / MAX Series / ENGLISH driving license. Keep this Operator’s Guide in the vehicle.
GUIDE DU COND. Séries T3 4x4 OUTLANDER / MAX / ANGLAIS
2 1 9 0 0 1 8 7 2 Original Instructions
Original Instructions

OUTLANDER Series / OUTLANDER MAX Series

2018
training course.
• DO NOT EXCEED VEHICLE SEATING CAPACITY
control if you carry more than a passenger.
Operator’s
Guide
if you carry a passenger.
SURFACE. You increase your risk of losing control
if you operate this vehicle on pavement.
• NEVER OPERATE THIS VEHICLE ON PUBLIC
Includes
ROADS. You can collide with another vehicle if you Safety, Vehicle
operate this vehicle on a public road. and Maintenance Information
STUNTS.
OUTLANDER Series/ TM
OUTLANDER MAX Series

TM TM
2018
WARNING
219 001 856 Read this guide thoroughly. It contains important safety information.
OPERATOR’S GUIDE OUTLANDER / MAX Series (GL2) / ENGLISH
GUIDE DU COND. Séries OUTLANDER / MAX (GL2) / ANGLAIS
Minimum recommended age: Operator: 16 years old. Keep this Operator’s Guide in the vehicle.
FAIT AU / MADE IN CANADA U/M:P.C.

©2017 BOMBARDIER RECREATIONAL PRODUCTS INC. ALL RIGHTS RESERVED. PRINTED IN CANADA. 2 1 9 0 0 1 8 5 6 Original Instructions
WARNING
YOUR VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rollover
can occur quickly, if you fail to take proper precautions, even during routine
maneuvers such as turning and driving on hills or over obstacles.
For your safety, understand and follow all the warnings contained in this
Operator's Guide and on the labels on your vehicle. Failure to follow these
warnings can result in SEVERE INJURY OR DEATH!
Keep this Operator's Guide with the vehicle at all times.
WARNING
Disregarding any of the safety precautions and instructions contained in
this Operator’s Guide, SAFETY VIDEO and on-product safety labels could
result in an injury including the possibility of death!
WARNING
This vehicle may exceed the performance of other vehicles you may have
ridden in the past. Take time to familiarize yourself with your new vehicle.
CALIFORNIA PROPOSITION 65 WARNING

WARNING: Operating, servicing and maintaining an off-road
vehicle can expose you to chemicals including engine
exhaust, carbon monoxide, phthalates, and lead, which are
known to the State of California to cause cancer and birth
defects or other reproductive harm. To minimize exposure,
avoid breathing exhaust, do not idle the engine except
as necessary, service your vehicle in a well-ventilated
area and wear gloves or wash your hands frequently
when servicing your vehicle. For more information go to
www.p65warnings.ca.gov/products/passenger-vehicle.
In Canada, products are distributed by Bombardier Recreational Products Inc.
(BRP). In USA, products are distributed by BRP US Inc.
The following trademarks are the property of Bombardier Recreational
Products Inc.:
Can-Am® DPS™ Outlander™ Rotax® TTI™ XPS™
This document contains the trademarks of the following companies:

– Mossy Oak is a trademark of Hass Outdoors, Inc.
– Visco-lok is a trademark of GKN Viscodrive GmbH.
219001856 en KD
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.
©2017 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
FOREWORD
Dieses Handbuch ist möglicherweise in Ihrer Landessprache

Deutsch verfügbar. Bitte wenden Sie sich an Ihren Händler oder besuchen Sie:
This guide may be available in your language. Check with your dealer or
English
go to: www.operatorsguides.brp.com
Es posible que este manual esté disponible en su idioma. Consulte a su
Español
distribuidor o visite: www.operatorsguides.brp.com
Ce guide peut être disponible dans votre langue. Vérifier avec votre
Français
concessionnaire ou aller à: www.operatorsguides.brp.com
本手册可能有您的语种的翻译版本。请向经销商问询，或者登录
中文 www.operatorsguides.brp.com 查询。
このガイドは、言語によって翻訳版が用意されています。.
日本語ディーラーに問い合わせるか、次のアドレスでご確認ください：
Deze handleiding kan beschikbaar zijn in uw taal. Vraag het aan uw dealer
Nederlands
of ga naar: www.operatorsguides.brp.com
Denne boken kan finnes tilgjengelig på ditt eget språk. Kontakt din
Norsk
forhandler eller gå til: www.operatorsguides.brp.com
Este manual pode estar disponível em seu idioma. Fale com sua
Português
concessionária ou visite o site: www.operatorsguides.brp.com
Käyttöohjekirja voi olla saatavissa omalla kielelläsi. Tarkista jälleenmyyjältä
Suomi
tai käy osoitteessa: www.operatorsguides.brp.com
Denna bok kan finnas tillgänglig på ditt språk. Kontakta din återförsäljare
Svenska
eller gå till: www.operatorsguides.brp.com
Congratulations on your purchase of a At delivery, you were also informed of

new Can-Am® ATV. It is backed by the the warranty coverage and signed the
BRP warranty and a network of autho- PREDELIVERY CHECK LIST to ensure
rized Can-Am dealers ready to provide your new vehicle was prepared to your
the parts, service or accessories you entire satisfaction.
may require.
Your dealer is committed to your sat- Know Before you Go
isfaction. He has taken training to per- To learn how to reduce the risk for you
form the initial setup and inspection of or bystanders being injured or killed,
your vehicle as well as completed the read this Operator's Guide before you
final adjustment before you took pos- operate the vehicle.
session. If you need more complete
servicing information, please ask your Also, read all safety labels on your ATV
dealer. and watch attentively your SAFETY
VIDEO.
This vehicle is for off road use only. It is
mainly for general recreational use but
it may also be used for utility purposes.
_______________ 1
FOREWORD
Failure to follow the warnings con- NOTICE Indicates an instruction

tained in this Operator's Guide can which, if not followed, could se-
result in SERIOUS INJURY or DEATH. verely damage vehicle components
or other property.
Age Recommendation
This vehicle is a category G, always fol- About this Operator's
low this age recommendation: Guide
– A person under 16 years old should This Operator's Guide has been pre-
never operate this vehicle. pared to acquaint the owner/operator
– Passenger on 2-UP models must be of a new vehicle with the various ve-
capable of keeping his feet on the hicle controls, maintenance and safe
footrests and his hands on grab han- operating instructions. It is indispens-
dles at all times when seated on this able for the proper use of the product.
vehicle.
WARNING
Training Course
Throughout this Operator's Guide,
Never operate this vehicle without the term “1-UP” refers to vehi-
proper instruction. Take a training cles designed to carry the operator
course. All operators should receive only while the term “2-UP” refers
training from a certified instructor. to vehicles designed to carry also
For more information about ATV safety, a passenger.
contact an authorized Can-Am dealer Make sure to identify and follow
to find out about available training the warnings and instructions
courses nearest you. that are applicable to your specific
model.
In the United States, call the Specialty
Vehicle Institute of America (SVIA)
at 1 800 887–2887 or in Canada, the Note that this guide is available in sev-
Canada Safety Council (CSC) at 1 613 eral languages. In the event of any dis-
739–1535. crepancy, the English version shall pre-
vail.
Safety Messages Keep this Operator's Guide in the vehi-
cle as you can refer to it for things such
The types of safety messages, what as maintenance, troubleshooting and
they look like and how they are used in instructing others.
this guide are explained as follows:
If you want to view and/or print an
The safety alert symbol indicates extra copy of your Operator's Guide,
a potential injury hazard. simply visit the following website
www.operatorsguides.brp.com.
WARNING The information contained in this doc-
ument are correct at the time of publi-
Indicates a potential hazard, if not cation. However, BRP maintains a pol-
avoided, could result in serious in- icy of continuous improvement of its
jury or death. products without imposing upon itself
any obligation to install them on prod-
CAUTION Indicates a hazard ucts previously manufactured. Due
situation which, if not avoided, to late changes, some differences be-
could result in minor or moderate tween the manufactured product and
injury. the descriptions and/or specifications
in this guide may occur. BRP reserves
2 _______________
FOREWORD
the right at any time to discontinue or

change specifications, designs, fea-
tures, models or equipment without
incurring any obligation upon itself.
This Operator's Guide and the SAFETY
DVD should remain with the vehicle
when it is sold.
WARNING
injury or death.
_______________ 3
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Know Before you Go . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
About this Operator's Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY INFORMATION
GENERAL PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Avoid Carbon Monoxide Poisoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Avoid Gasoline Fires and Other Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Avoid Burns from Hot Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accessories and Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL SAFETY MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRE-RIDE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pre-Ride Inspection Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
RIDING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Riding Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Carrying a Passenger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Recreational Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Design Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Off-Road Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Riding Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
MOVING LOADS AND DOING WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Working with your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Carrying Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Loading the Cargo Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Hauling a Load (if Equipped with Hitch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Pulling a Trailer (if Equipped with Hitch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
IMPORTANT ON-PRODUCT LABELS(CANADA/UNITED STATES) . . . . . . . . . 63
Hang Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Vehicle Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Compliance Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Technical Information Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
IMPORTANT ON-PRODUCT LABELS (ALL COUNTRIES EXCEPT
CANADA/UNITED STATES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Hang Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Vehicle Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Compliance Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Technical Information Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4 _______________
TABLE OF CONTENTS
VEHICLE INFORMATION
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1) Throttle Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2) Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3) Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4) Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5) Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6) Ignition Switch and Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7) Multifunction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8) 2WD/4WD Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
MULTIFUNCTION GAUGE (LCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Multifunction Gauge Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Multifunction Gauge Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Navigating in the LCD Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Gauge Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1) Operator's Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2) Passenger's Seat (2-UP Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3) Footpegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4) Grab Handles (2-UP Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5) 12-Volt Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6) Rear Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7) Cargo Racks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8) Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
9) Tool Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10) Recovery Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
ADDITIONAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1) Full Underbody Aluminum Skid Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2) Portable Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3) Gun Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4) Gear Grips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5) Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6) Roller Fairlead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Vehicle Fueling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Operation During Break-In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
BASIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Operating the Shift Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Stopping the Engine and Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
What to Do if Water Entered the CVT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
What to Do if Water Entered the Air Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . 110
_______________ 5
TABLE OF CONTENTS
SPECIAL PROCEDURES (cont’d)

What to Do if Vehicle is Turned Over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
What to Do if Vehicle is Immersed in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
TUNE YOUR RIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Suspension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Dynamic Power Steering (DPS) Assist Level Adjustment . . . . . . . . . . . . . . . . . 112
VEHICLE TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
MAINTENANCE
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

SEVERE DUSTY CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
MAINTENANCE SCHEDULE LEGEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Muffler Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Gearbox Oil (570 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Drive Shaft Boot and Protector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Wheel Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
VEHICLE CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Post-Operation Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Vehicle Cleaning and Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
STORAGE AND PRESEASON PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
TECHNICAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Engine Identification Number (EIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6 _______________
TABLE OF CONTENTS
NOISE EMISSION CONTROL SYSTEM REGULATION (CANADA/UNITED

STATES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
NOISE EMISSION AND VIBRATION VALUES (ALL COUNTRIES EXCEPT
CANADA/UNITED STATES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
EC-DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
TROUBLESHOOTING
TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

MULTIFUNCTION GAUGE MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
WARRANTY
BRP LIMITED WARRANTY USA AND CANADA: 2018 CAN-AM® ATV . . . . 170
US EPA EMISSION-RELATED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
BRP INTERNATIONAL LIMITED WARRANTY: 2018 CAN-AM® ATV. . . . . . . 176
BRP LIMITED WARRANTY FOR THE EUROPEAN ECONOMIC AREA, THE
COMMONWEALTH OF THE INDEPENDENT STATES AND TURKEY: 2018
CAN-AM® ATV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
CUSTOMER INFORMATION
PRIVACY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

CONTACT US. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Oceania . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
South America. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Asia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
CHANGE OF ADDRESS/OWNERSHIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
_______________ 7
TABLE OF CONTENTS
8 _______________
SAFETY
INFORMATION
________ SAFETY INFORMATION ________ 9

GENERAL PRECAUTIONS
Avoid Carbon Monoxide – For refueling, strictly adhere to in-
Poisoning structions in FUEL.
All engine exhaust contains carbon – Never start or operate the engine if
monoxide, a deadly gas. Breathing car- the fuel cap is not properly installed.
bon monoxide can cause headaches, Gasoline is poisonous and can cause
dizziness, drowsiness, nausea, confu- injury or death.
sion and eventually death. – Never siphon gasoline by mouth.
Carbon monoxide is a colorless, odor- – If you swallow gasoline, get any in
less, tasteless gas that may be present your eye(s), or inhale gasoline vapor,
even if you do not see or smell any en- see your doctor immediately.
gine exhaust. Deadly levels of carbon If gasoline spills on you, wash with
monoxide can collect rapidly, and you soap and water and change your
can quickly be overcome and unable clothes.
to save yourself. Also, deadly levels of
carbon monoxide can linger for hours
or days in enclosed or poorly ventilated Avoid Burns from Hot Parts
areas. If you experience any symp- Certain components become hot dur-
toms of carbon monoxide poisoning, ing operation. Avoid contact with
leave the area immediately, get fresh those parts during and shortly after
air and seek medical treatment. operation to avoid burns.
To prevent serious injury or death from
carbon monoxide: Accessories and
– Never run the vehicle in poorly ven- Modifications
tilated or partially enclosed areas Any modifications or addition of acces-
such as garages, carports or barns. sories may affect the handling of your
Even if you try to ventilate engine vehicle. It is important to take the time
exhaust with fans or open windows to get familiar with the vehicle once
and doors, carbon monoxide can modifications are made to understand
rapidly reach dangerous levels. how to adapt your driving behavior ac-
– Never run the vehicle outdoors cordingly.
where engine exhaust can be drawn Do not temper with unauthorized mod-
into a building through openings ifications or install equipment not
such as windows and doors. specifically certified by BRP for the
vehicle. These modifications have not
Avoid Gasoline Fires and been tested by BRP and they may in-
Other Hazards crease the risk of injury or loss of con-
Gasoline is extremely flammable and trol, or render the vehicle illegal to ride.
highly explosive. Fuel vapors can As an example, tempering with tire
spread and be ignited by a spark or specifications may affect the behavior
flame many feet away from the en- of the vehicle and increase the risk of a
gine. To reduce the risk of fire or explo- loss of control.
sion, follow these instructions: Ask your authorized BRP dealer for
– Use only an approved red gasoline suitable available accessories for your
container to store fuel. vehicle.
– - Never fill a gasoline container on
the vehicle. An electrical static dis-
charge may ignite the fuel.
10 _______ SAFETY INFORMATION ________

SPECIAL SAFETY MESSAGES
THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
– This vehicle handles differently from other vehicles including motorcycles
and cars. A collision or rollover can occur quickly, if you fail to take proper
precautions, even during routine maneuvers such as turning and driving on hills
or over obstacles.
SEVERE INJURY OR DEATH can result if you do not comply with the following in-
structions:
– Read this Operator's Guide and all on-product safety labels carefully and follow
the operating procedures described. Watch and pay attention to the SAFETY
VIDEO before operating the vehicle.
– Always follow this age recommendation: A person under 16 years old should
never operate this vehicle.
– Never take place on this vehicle without wearing an approved helmet of the
proper size and other required riding gears. Refer to RIDING GEAR in RIDING
THE VEHICLE for detailed information.
– Never carry a passenger on this vehicle unless you are operating a 2-UP model.
Passenger(s) affect balance and steering and increase risk of losing control.
– On 1-UP models, do not make any modifications to accommodate a passenger
or use racks to carry a passenger.
– This vehicle is not designed to ride on paved surfaces; if you must shortly use
the vehicle on such surfaces, avoid abrupt inputs to steering, accelerator and
brakes. Reduce your speed.
– This vehicle is not designed for riding on roads or highways (in most places it is
an illegal practice). Riding your vehicle on roads or highways could cause a col-
lision with another vehicle.
– Never use this vehicle if you are tired, ill or with drugs or alcohol. Your reaction
time and judgement is greatly affected under these conditions.
– Never attempt wheelies, jumps, or other stunts.
– Never operate at excessive speeds. Always go at a speed that is proper for the
terrain, visibility, operating conditions, and your experience.
– Always go slowly and be extra careful when operating on unfamiliar terrain. Al-
ways be alert to changing terrain conditions when operating this vehicle.
– Never operate on excessively rough, slippery or loose terrain until you have
learned and practiced the skills necessary to control this vehicle on such terrain.
– Always follow proper procedures for turning as described in RIDING TECH-
NIQUES.
– Never operate this vehicle on hills too steep for the vehicle or for your abilities.
– Always follow proper procedures for climbing hills as described in RIDING
TECHNIQUES. Check the terrain carefully before you start up any hill. Never
climb hills with excessively slippery or loose surfaces.
– Always follow proper procedures for going down hills and for braking on hills as
described in RIDING TECHNIQUES. Check the terrain carefully before you start
down any hill.
– Always follow proper procedures for crossing the side of a hill as described in
RIDING TECHNIQUES. Avoid hills with excessively slippery or loose surfaces.

– Always use proper procedures if you stall or roll backwards when climbing a
hill. To avoid stalling, use low gear and maintain a steady speed when climbing
a hill. If you stall or roll backwards, follow the driving technique procedures as
described in RIDING TECHNIQUES.
– Always check for obstacles before operating in a new area. Never attempt to
operate over large obstacles, such as large rocks or fallen trees. Always follow
proper procedures when operating over obstacles as described in RIDING
TECHNIQUES.
– Always be careful when skidding or sliding. Learn to safely control skidding or
sliding by practicing at low speeds and on level smooth terrain. On extremely
slippery surfaces, such as ice, go slowly and be very cautious in order to reduce
the chance of skidding out of control. If you are operating a 2-UP model and
have a passenger on-board, never attempt skidding or sliding; overturn or
passenger ejection may occur.
– Never operate this vehicle through deep or fast flowing water. Water should
never exceed footrests. Remember that wet brakes may have reduced stop-
ping ability. Test your brakes after leaving water, mud or snow. If necessary,
apply them several times to let friction dry out the pads.
– Always keep in mind that braking distance is readily affected by but not limited
to; weather and terrain conditions, braking system and tire conditions, vehicle
speed and attitude, and vehicle load including towing. Remember to adjust
your driving accordingly.
– Always be sure there are no obstacles or people behind the vehicle when you
operate in reverse. When it is safe to proceed in reverse, go slowly. Take into
account that on a 2-UP model the passenger can obstruct your view.
– BRP recommends sitting on your ATV when operating in reverse. Avoid stand-
ing up. Your weight could shift forward against throttle lever, causing an unex-
pected acceleration and may lead to a loss of control.
– Never exceed the stated load limits for this vehicle including operator, passen-
ger (2-UP models), all other loads and added accessories. Cargo should be prop-
erly distributed and securely attached. Reduce speed and follow instructions in
this guide for carrying cargo or pulling a trailer. Allow greater distance for brak-
ing.
– Always inspect and confirm the safe operating condition of your vehicle prior to
ride. Refer to PRE-RIDE INSPECTION. Always follow the maintenance sched-
ules as described in this Operator's Guide. Refer to MAINTENANCE section.
– Never operate the vehicle if the controls do not function normally.
– Always maintain proper tire pressure. When replacing tires, use only the rec-
ommended tire size and type. For tire information, refer to SPECIFICATIONS.
– Riding your vehicle too fast for your skills or the conditions may result in injury.
Apply only enough throttle to proceed safely. Statistics show that mishaps and
injury usually result from high speed turns. Always remember that this vehicle
is heavy! Its pure weight alone may entrap you should it fall, resulting in injury.
– This vehicle is not designed for jumping, nor can it fully absorb the high impact
energy generated during manoeuvres such as jumping which, can be passed on
to you, the operator. Performing wheelies can cause the vehicle to flip over onto
you. Both practices have a high risk for you and your passenger (2-UP models)
and should be avoided at all times.
– The tires of this vehicle are not suited for paved road use.

2-UP Models
Driver must:
– Not forget he is responsible for the safety of the passenger.
– Inform the passenger concerning the basic rules for a safe ride.
– Instruct the passenger to read the vehicle’s safety labels and to watch the
SAFETY VIDEO.
– Always practice the maneuvers described in this Operator's Guide without and
with a passenger. Greater skills are required with a passenger.
– Always remember that the vehicle handling and stability may be affected when
riding with a passenger. Safely reduce speed. Use proper judgement. If in
doubt, do not attempt and disembark the passenger before executing any
maneuver.
– Always remember that the vehicle braking distance may be longer when riding
– Never carry passenger on a 2-UP model if the passenger seat is not properly in-
stalled.
– Never carry more than one (1) passenger. Do not allow passenger to sit any-
where else than the designated passenger seat.
– Never carry a passenger if you judge his ability or judgement insufficient to con-
centrate on the terrain conditions and adapt accordingly.
– Never carry a passenger who has used drugs or alcohol, or is tired or ill. These
slow reaction time and impair judgment.
Passenger must:
– Be capable of resting his feet on the footrests and his hands on grab handles
when seated on this vehicle.
– Never take place on this vehicle without wearing an approved helmet (including
a chin guard) that fits properly. The passenger should also wear eye protection
(goggles or face shield), gloves, boots, long sleeved shirt or jacket, and long
pants.
– Be seated on the designated passenger's seat.
– Always keep hands on grab handles and feet on the footrests during operation.
Never hold on to the operator.
– Never get up during vehicle operation. An excessive movement could cause
loss of control.
– Pay attention to vehicle and operator movements.
– Not wait and tell the driver to slow down or stop if you feel uncomfortable or in-
secure for any reason.

OPERATION WARNINGS
The following warning and their format have been requested by the United States
Consumer Product Safety Commission and are required to be in the Operator's
Guide for all ATVs.
NOTE: The following illustrations are general representations only. Your model
may differ.
WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does not know
how to operate this vehicle properly in different situations and on different
types of terrain.
Beginners and inexperienced operators should complete a training course.
They should then regularly practice the skills learned during the course as
well as the operating techniques described in this Operator's Guide.
For more information about a training course, contact an authorized
Can-Am dealer.

OPERATION WARNINGS
WARNING
V00A1AQ
POTENTIAL HAZARD
Failure to follow the age recommendations for this vehicle.
WHAT CAN HAPPEN
A lack of respect for this age recommendation can lead to severe injury or
death of the child.
Even though a child may be within the age group for which this vehicle is
recommended, he may not have the skills, abilities, or judgment needed to
operate this vehicle safely and may be involved in a serious accident.
No one under 16 should operate this vehicle.

OPERATION WARNINGS
2-UP Models Only
WARNING
vmo2014-005-100
POTENTIAL HAZARD
Failure to respect the physical limitations of the passenger on 2-UP models.
WHAT CAN HAPPEN
A passenger that cannot completely lean his feet on footrests can be ejected
when riding on uneven terrain.
The passenger must be capable of keeping his feet on the footrests and his
hands on grab handles at all times when he is seated on the vehicle.

OPERATION WARNINGS
1-UP Models Only
WARNING
V00A02Q
POTENTIAL HAZARD
Carrying a passenger on this vehicle.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and control this vehicle.
Could cause an accident, resulting in harm to you and/or your passenger.
Never carry passenger. Even with a long seat that provides unrestricted op-
erator movement, it is not designed nor intended to carry passenger(s).

OPERATION WARNINGS
2-UP Models Only
WARNING
V00A1CQ
POTENTIAL HAZARD
Carrying more than one (1) passenger on this vehicle.
WHAT CAN HAPPEN
Carrying more than one (1) passenger reduces your ability to balance and
control this vehicle.
Could cause an accident, resulting in harm to you and/or your passengers.
Never carry more than one (1) passenger. Even with a long seat that pro-
vides unrestricted operator movement, the vehicle is not designed nor
intended to carry more than one (1) operator and one (1) passenger. The
passenger must use the designated passenger's seat when he is seated on
the vehicle with feet firmly planted on footrests and always hold on to the
grab handles.

OPERATION WARNINGS
WARNING
V00A2DQ
POTENTIAL HAZARD
Allowing passenger(s) to sit on front or rear racks on this vehicle.
WHAT CAN HAPPEN
Allowing a passenger could:
– Impair vehicle stability which could lead to a loss of control.
– Result in injury to passenger(s) from impact on hard surfaces.
– Cause an accident, resulting in harm to you and/or your passenger(s).
Never allow any passenger to sit on front or rear racks on this vehicle.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
Never operate this vehicle on any public street, road or highway, even a dirt
or gravel one. In many states it is illegal to operate this vehicle on public
streets, roads and highways.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Riding this vehicle without wearing an approved helmet, eye protection and
protective gear. On 2-UP models, passenger should also have an approved
helmet with a rigid chin guard.
WHAT CAN HAPPEN
– Riding without an approved helmet increases the chances of a severe
head injury or death in the event of an accident.
– Riding without eye protection can result in an accident and increases the
chances of a severe injury in the event of an accident.
– Riding without protective gear increases the chances of severe injury in
the event of an accident.
Always wear an approved helmet that fits properly. You should also wear:
– Eye protection (goggles or face shield)
– Rigid chin guard
– Gloves and boots
– Long sleeved shirt or jacket
– Long pants.

OPERATION WARNINGS
WARNING
V00A07Q
POTENTIAL HAZARD
Using this vehicle with drugs or alcohol.
WHAT CAN HAPPEN
Could cause the passenger to fall off (2-UP models).
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident or death.
The operator and the passenger (2-UP models) should never use this vehi-
cle with drugs or alcohol.

OPERATION WARNINGS
WARNING
V00A08Q
POTENTIAL HAZARD
Operating this vehicle at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of the vehicle, which can result in
an accident.
Always travel at a speed which is appropriate for the terrain, visibility and
operating conditions, and your experience.
On 2-UP models, the vehicle handling, stability and braking distance may
be affected when riding with a passenger. Safely reduce speed when riding

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps and other stunts.
WHAT CAN HAPPEN
Increases the chance of an accident, for the operator and the passenger
(2-UP models), including an overturn.
Never attempt stunts, such as wheelies or jumps. Do not try to show off.
WARNING
POTENTIAL HAZARD
Failure to inspect the vehicle before operating.
Failure to properly maintain the vehicle.
WHAT CAN HAPPEN
Increases the possibility of an accident or equipment damage.
Always inspect your vehicle prior to ride to make sure the vehicle is in safe
operating condition.
Always follow the maintenance schedule described in this Operator's
Guide.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Riding on frozen waterways.
WHAT CAN HAPPEN
Breaking through the ice can lead to severe injury or death.
Never ride this vehicle on a frozen surface before you are sure the ice is thick
enough and sound enough to support the vehicle and its load, as well as the
force that is created by a moving vehicle.
WARNING
POTENTIAL HAZARD
Removing hands from handlebars for the operator and from grab handles
for the passenger (2-UP models), or feet from the footrests during opera-
tion.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce your ability to control the vehi-
cle or could cause you to lose your balance and fall off the vehicle. If you re-
move a foot from the footrests, your foot or leg may come into contact with
the rear wheels, which could injure you or cause an accident.
Operator must always keep both hands on the handlebars and passenger
(2-UP models) on grab handles..Both feet (operator and passenger on 2-UP
models) must rest on the footrests during vehicle operation.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating this vehicle on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps, or holes, without enough time to
react.
Could result in the vehicle overturning, passenger ejection (2-UP models) or
loss of control.
Go slowly and be extra careful when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating the vehicle.
his passenger. Safely reduce speed when riding with a passenger.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating on excessively rough, slippery or
loose terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle control, which could result in an acci-
dent, including an overturn or passenger ejection (2-UP models).
Do not operate on excessively rough, slippery or loose terrain until you
have learned and practiced the skills necessary to control this vehicle on
such terrain.
the passenger. In doubt, disembark him before operating on these terrains.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
Vehicle could go out of control, causing a collision or an overturn or a pas-
senger ejection (2-UP models).
Always follow proper procedures for turning as described in this Operator's
Guide. Practice turning at low speeds before attempting to turn at faster
speeds.
the passenger. Never perform this maneuver with a passenger. Always re-
member that the vehicle handling, stability and braking distance may be af-
fected when riding with a passenger.
Do not turn at excessive speed.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on extremely steep hills than on level
surfaces or small hills.
Never operate this vehicle on hills too steep for the vehicle or for your abili-
ties.
Practice, without and with passenger (2-UP models), on smaller hills before
attempting larger hills.
Always remember that, on 2-UP models, even if this vehicle can climb some
steep hills, it is not recommended to climb such hills with a passenger; al-
ways disembark him before attempting this maneuver. Show good judge-
ment.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
hicle to overturn.
Always follow proper procedures for climbing hills as described in this Op-
erator's Guide.
Always check the terrain carefully before you start up any hill. Do not
passenger. In doubt, disembark him before climbing hill. Always remem-
ber that the vehicle handling, stability and braking distance may be affected
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward (operator and passenger on 2-UP models).
Never open the throttle suddenly or make sudden gear changes. The vehi-
cle could flip over backwards.
Never go over the top of any hill at high speed. An obstacle, a sharp drop, or
another vehicle or person could be on the other side of the hill.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
hicle to overturn.
Always follow proper procedures for going down hills as described in this
Operator's Guide.
NOTE: A special technique is required when braking as you go down a hill.
Always check the terrain carefully before you start down any hill. Do not
passenger. In doubt, disembark him before going down hill. Always re-
member that the vehicle handling, stability and braking distance may be
Shift your weight backward (operator and passenger on 2-UP models).
Never go down a hill at high speed.
Avoid going down a hill at an angle which would cause the vehicle to lean
sharply to one side. Go straight down the hill where possible.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
WHAT CAN HAPPEN
hicle to overturn.
Never attempt this maneuver on 2-UP models when the passenger is on
board. Always disembark him before executing.
Never attempt to turn the vehicle around on any hill until you have mastered
the turning technique as described in this Operator's Guide on level ground.
Be very careful when turning on any hill.
Avoid crossing the side of a steep hill if possible.
When crossing the side of a hill:
Always follow proper procedures as described further in this Operator's
Guide.
Avoid hills with excessively slippery or loose surfaces.
Operator and passenger (2-UP models) must shift weight to the uphill side
of the vehicle.

OPERATION WARNINGS
WARNING
V00A1PQ
POTENTIAL HAZARD
Stalling, rolling backwards or improperly dismounting while climbing a hill.
WHAT CAN HAPPEN
Could result in vehicle overturning.
Use low gear and maintain steady speed when climbing a hill.
If you lose all forward speed:
Apply the brakes.
Lock parking brake after you have stopped.
If you begin rolling backwards:
Never apply the rear brake while rolling backwards.
Apply the front brake gradually.
When fully stopped, apply rear brake as well and lock parking brake.
Turn the vehicle around and remount, following the procedure described
further in this Operator's Guide.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control (passenger ejection on 2-UP models), or a colli-
sion.
Could cause the vehicle to overturn.
Before operating in a new area, check for obstacles.
Never attempt to ride over large obstacles, such as large rocks or fallen
trees.
On 2-UP models, the operator is responsible for the safety of his passenger.
In doubt, disembark him before riding over obstacles. Always remember
that the vehicle handling and stability may be affected when riding with a
passenger.
When you go over obstacles, always follow proper procedures as described
in this Operator's Guide.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Skidding or sliding improperly.
WHAT CAN HAPPEN
You may lose control of this vehicle.
You may also regain traction unexpectedly, which may cause the vehicle to
overturn or passenger ejection (2-UP models).
Learn to safely control skidding or sliding by practicing at low speeds and
on level smooth terrain.
On 2-UP models, never slide or skid with passenger. Always remember that
the vehicle handling and stability may be affected when riding with a pas-
senger.
On extremely slippery surfaces, such as ice, go slowly and be very cautious
in order to reduce the chance of skidding or sliding out of control.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle through deep or fast flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control, which could lead
to an accident.
Never operate this vehicle in fast flowing water or in deep water.
Check water depth and current before you attempt to cross any water. Wa-
ter should not go above footrests.
Remember that wet brakes may have reduced stopping ability. Test your
brakes after leaving water. If necessary, apply them several times to let
friction dry out the pads.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind the vehicle, resulting in serious
injury.
When you select reverse gear, make sure there are no obstacles or people
behind the vehicle. When it is safe to proceed, go slowly. On 2-UP models,
take account that the passenger can obstruct your view.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper tires, or with improper or uneven tire
pressure.
WHAT CAN HAPPEN
Use of improper tires on this vehicle, or operation of this vehicle with
improper or uneven tire pressure, may cause loss of control, tire blow outs,
tire to move around on its rim, and increases the risk of an accident.
Always use the size and type of tires specified in this Operator's Guide for
this vehicle.
Always maintain proper tire pressure as described in this Operator's Guide.
Always replace wheels or tires that are damaged.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of this vehicle may
cause changes in handling which in some situations could lead to an acci-
dent.
Never modify this vehicle through improper installation or use of acces-
sories. All parts and accessories added to this vehicle should be approved
by BRP and should be installed and used according to instructions. If you
have questions, consult an authorized Can-Am dealer.
NEVER install a passenger seat (1-UP models) or use the racks to carry a
passenger.
Modification of the vehicle to increase speed and performance may violate
the terms and conditions of your vehicle limited warranty. In addition, cer-
tain modifications including the removal of engine or exhaust components
are illegal under most laws.

OPERATION WARNINGS
WARNING
POTENTIAL HAZARD
Overloading this vehicle, carrying or towing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling which could lead to an accident.
Never exceed the stated load capacity for this vehicle including operator
and passenger (2-UP models) as well as other loads and added accessories.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow greater dis-
tance for braking.
Always follow the instructions in this Operator's Guide for carrying cargo or
pulling a trailer.

OPERATION WARNINGS
WARNING
V03M01Q
POTENTIAL HAZARD
Transporting flammable or dangerous material can lead to explosions.
WHAT CAN HAPPEN
This can cause serious injury or death.
Never transport flammable or dangerous material.

PRE-RIDE INSPECTION
WARNING
Perform a pre-ride inspection before each ride to detect any potential prob-
lem that could occur during operation. The pre-ride inspection can help you
monitor component wear and deterioration before they become a problem.
Correct any problem that you discover to reduce the risk of a breakdown or
crash.
Before using this vehicle, the operator should always perform the following
pre-ride inspection check list.
Pre-Ride Inspection Check List

What to Do Before Starting the Engine (Key OFF)
ITEMS TO BE
INSPECTED
Engine oil Check engine oil level.
Coolant Check coolant level.
Brake fluid Check brake fluid level
Leaks Check for any leaks under vehicle
Activate throttle lever several times to ensure it operates
Throttle lever
freely. It must return to idle position when released
Parking brake Apply parking brake and check if it operates properly
Check tire pressure and condition. Refer to
Tires
SPECIFICATIONS and adjust according to load.
Check wheels for damage and for abnormal play, and
Make sure that lug nuts are tightened. Refer to WHEELS
Wheels
AND TIRES in MAINTENANCE PROCEDURES for torque
specification.
Radiator Check cleanliness of the radiator
Drive shaft boots Check drive shaft boots and protectors condition
Check if operator seat is in place and properly latched
Check if passenger seat is in place and properly latched
Seat(s) (2-UP Models)
Check the passenger backrest and grab handles condition
(2-UP Models)

PRE-RIDE INSPECTION
ITEMS TO BE
INSPECTED
If you transport a cargo, respect the load
capacity. Refer to LOADING THE CARGO RACKS
Ensure cargo is properly secured to the racks
If you are pulling a trailer or another equipment:
Cargo – Check hitch and trailer ball condition
– Respect the tongue capacity and towing capacity as
indicated on the label affixed to the hitch or refer to
SPECIFICATIONS
– Ensure trailer is properly secured to hitch
Storage
Check if rear storage compartment is properly latched
compartment
Chassis and Check underneath vehicle for any debris on chassis or
suspension suspension and clean them properly
What to Do Before Starting the Engine (Key ON)

ITEMS TO BE
INSPECTED
Check operation of indicator lamps in multifunction gauge
Multifunction gauge (during first few seconds of key ON)
Check for messages on multifunction gauge
Check operation and cleanliness of headlights and taillight
Lights Check operation of low and high beams
Check operation of brake light
Fuel level Check the fuel level.
What to Do After the Engine is Started

ITEMS TO BE
INSPECTED
Check if steering operates freely by completely turning it
Steering
from side to side
Shift lever Check operation of shift lever (P, R, N, H and L)
2WD/4WD selector Check operation of 2WD/4WD selector

PRE-RIDE INSPECTION
ITEMS TO BE
INSPECTED
Drive forward slowly a few feet and apply brake lever
Brakes and brake pedal individually. The brakes must fully apply.
Lever and pedal must fully return when released
Emergency engine Check that the emergency engine stop switch is working
stop switch properly
Check if ignition switch is working properly by restarting
Ignition switch
and stopping the engine

RIDING THE VEHICLE
To fully appreciate the pleasures and excitement of riding this vehicle, there are
some basic rules and tips that you MUST follow. Some may be new to you while
others may be common sense or obvious.
Please take the time to study this Operator's Guide and all on-product safety labels
as well as the SAFETY VIDEO that came with this vehicle. They more completely
describe what you should know about this vehicle before riding it.
Whether you are a new user or an experienced rider, it is important for your
personal safety that you know the controls and features of this vehicle. Equally
important is knowing how to properly ride.
This is a high performance ATV for off-road use only. Inexperienced riders may
overlook risks and be surprised by the specific behavior of this ATV in any terrain
condition.
We recommend following the age recommendation indicated on the safety label
affixed on the unit. Even though a person may be within the age group for which
this vehicle is recommended, he may not have the skills, abilities, or judgment
needed to operate this vehicle safely and may be involved in a serious accident.
Individuals with cognitive or physical impairments or who are high risk takers have
an increased exposure to overturns or collisions which may result in injury includ-
ing death.
Not all vehicles are the same. Each has its own unique performance characteris-
tics, controls and features. Each will ride and handle differently.
Become completely familiar with the operational controls and the general opera-
tion of the vehicle before venturing into off road conditions. Practice driving in a
suitable area free of hazards and feel the response of each control. Drive at low
speeds. Higher speeds require greater experience, knowledge and suitable riding
conditions.
Riding conditions vary from place to place. Each is subject to weather conditions
which may radically change from time to time and from season to season.
Riding on sand is different than riding on snow or through forests or marshes.
Each location may require a greater degree of awareness and skill. Show good
judgement. Always proceed with caution. Please do not take any unnecessary
risks that could leave you stranded or possibly injured.
Never assume that the vehicle will go everywhere safely. Sudden changes in ter-
rain caused by holes, depressions, banks, softer or harder “ground” or other irreg-
ularities may cause the vehicle to topple or become unstable. To avoid this, slow
down and always observe the terrain ahead. If the vehicle does begin to topple or
tip over, the best advice is to immediately get off AWAY from the direction of the tip
over!
We encourage you to have an Annual Safety Inspection of your vehicle. Please
contact an authorized BRP dealer for further details. Though not required, it is
recommended that an authorized BRP dealer performs the preseason preparation
of your vehicle. Each visit to your authorized BRP dealer is a great opportunity for
your dealer to verify if your vehicle is included in any safety campaign. We also
urge you to visit your authorized BRP dealer in a timely manner if you become
aware of any safety related campaigns.
See an authorized BRP dealer for available accessories you may require.

RIDING THE VEHICLE
Riding Gear
Actual weather conditions should help you decide how to dress. Dress for the
coldest weather expected. Thermal underwear next to the skin also provides a
good insulation. It is important that the operator always wears the appropriate
protective riding gear and apparel, including an approved helmet, eye protection,
boots, gloves, a long sleeved shirt and pants. This type of clothing will provide
you protection from some of the minor hazards you may encounter en route. The
operator must never wear loose clothing such as a scarf that may get entangled in
the vehicle or on tree branches and shrubs. Depending on conditions, anti-fogging
goggles or sunglasses may be required. Different colored lenses available for
goggles or sunglasses help you distinguish terrain variations. Sunglasses should
only be worn during the daytime.
Approved
helmet
Eye protection
Rigid chin
guard
Chest
protector
Long
sleeves
Gloves
Long, sturdy
pants
Boots
V00A0RN
Carrying a Passenger
1-UP Models
This vehicle is designed to carry ONE (1) operator only. Do not install passenger
seat or use the racks to carry a passenger.

RIDING THE VEHICLE
2-UP Models
This vehicle is designed specifically to carry an operator and ONE (1) passenger
only. The passenger must be seated on the designated passenger's seat and
hold on to the grab handles at all times. NEVER install other passenger's seat
other than the one recommended by BRP. Do not use the racks or their location to
carry passenger(s). Carrying more than one (1) passenger may affect the stability
and your control of the vehicle. When the passenger seat is not installed,, the
vehicle becomes a ONE-RIDER vehicle (1-UP model) and NO PASSENGER must
be allowed on it.
Recreational Riding
Respect the rights and limitations of others. Stay away from areas designated
for other types of off road use. This includes snowmobile trails, equestrian trails,
cross country ski trails, mountain bike trails, etc. Never assume there are no other
users on the trail. Always stay to the complete right of the trail and do not zigzag
to one side of the trail then the other. Be prepared to stop or pull off to the side if
another trail user appears in front of you.
Join a local ATV club. It will provide you with a map and advice or inform you where
you can ride. If a club does not exist in your area, help to start one. Group riding and
club activities provide a pleasurable, social experience.
Always keep a safe distance from other riders. Your judgment of speed, ter-
rain conditions, weather, mechanical condition of your vehicle and the “trust in
judgment” you have in others around you will help you make a better choice of
appropriate safe distance. This vehicle, like any other motorized vehicle, cannot
stop “on a dime”. Allow greater distance for braking. On 2-UP models, the
vehicle handling, stability and braking distance may be affected when riding with
a passenger. Safely reduce speed when riding with a passenger.
Before you ride, tell someone where you are planning to travel and your expected
time of return.
Depending on the length of your ride, carry additional tools , drinking water, food
and emergency equipment. Find out where you can get additional gasoline and oil.
Be prepared for the possible conditions you may encounter.
First aid kit Adjustable wrench
Mobile phone Knife
Friction tape Flashlight
A rope Colored lens goggles
Spare light bulbs Trail map
Provided tool kit Snack
Environment
One of the benefits of this vehicle is that it can take you off the beaten path away
from most communities. However, you should always respect nature and the
rights of others to enjoy it. Do not ride in environmentally sensitive areas. Do not
drive over forest crops or shrubs nor cut down trees or take down fencing nor spin
your wheels and destroy the terrain. “Tread Lightly”.

RIDING THE VEHICLE
This vehicle can cause OHV wildfires if debris builds up near the exhaust or other
engine hot spots and ignites then falls off into dry grass. Avoid riding in wet areas,
through muskeg or tall grass, where debris can build up. Should you ride in those
areas, inspect and remove all debris from your engine and hot spots.
Chasing wildlife is in many areas illegal. Wildlife can die of exhaustion after being
chased by a motorized vehicle. If you encounter animals on the trail, stop and ob-
serve quietly and with caution. It will be one of the better memories of your life.
Observe the rule “what you take in, carry out”. Do not litter. Do not start camp-
fires unless you have permission to do so and then only away from dry areas. The
hazards you may create on the trail may cause injury to others or yourself, even at
a later date.
Respect farm lands. Always obtain the permission of the landowner before riding
on private land. Respect crops, farm animals and property lines. If you come to a
closed gate, close it again behind you.
Finally, do not pollute streams, lakes or rivers and do not modify the engine or ex-
haust system, or remove any of its components.
Design Limitation
Although the vehicle is exceptionally rugged for its class, it is still a light vehicle by
definition and its operation must be restricted to its proper purpose.
The addition of weight to any part of the vehicle changes its gravitational stability
and modifies its performance.
Off-Road Operation
The very nature of off-road operation is dangerous. Any terrain, which has not
been specially prepared to carry vehicles, presents an inherent danger where
angularity, terrain substance and exact steepness are unpredictable. The terrain
itself presents a continual element of danger, which must be knowingly accepted
by anyone venturing over it.
An operator who takes a vehicle off-road should always exercise the utmost care in
selecting the safest path and keeping close watch on the terrain ahead of him. On
no account should the vehicle be operated by anyone who is not completely famil-
iar with the driving instructions applicable to the vehicle, nor should it be operated
on steep or treacherous terrain.
Riding Techniques
Information in this guide is limited. Increase your knowledge and improve your
skills by following a certified training course.
Care, caution, experience and driving skill are the best precautions against the haz-
ards of vehicle operation.
Respect and follow all posted trail signs. They are there to help you and others.
In off-road operation, power and traction, not speed, are important. Never drive
faster than visibility and your own ability to select a safe route permits.
Constantly watch the terrain ahead for sudden changes in slopes or obstacles,
such as rocks or stumps, that may cause loss of stability, resulting in tip over or
rollover.

RIDING THE VEHICLE
It is also wise to know the terrain condition on the other side of a hill or bank. All too
often there exists a sharp drop-off that is impossible to negotiate or descend.
Whenever there is the slightest doubt that the vehicle can safely negotiate an ob-
stacle or a particular piece of terrain, always choose an alternate route.
Always use proper riding techniques to avoid vehicle overturns on hills and rough
terrain and in turns.
Body Position
To maintain proper control, it is strongly advised that you keep your hands on the
handlebar and within easy reach of all controls. The same holds true for your feet
on the footpegs. To minimize the possibility of a leg or foot injury, keep your feet on
the footpegs at all times. Do not direct your toes outwards nor extend your feet out
to assist in turning as they can be hit or be snagged on passing obstacles, or may
come into contact with the wheels.
Even though there is a suspension on this vehicle, there are “washboard” or rough
terrain conditions that will make you feel uncomfortable and can even cause a back
injury. “Posting” or riding in a crouched position will often be required. Slow down
and allow your flexed legs to absorb part of the impact energy.
vmo2012-012-520
2-UP Models
The passenger must keep his hands on the grab handles and his feet on footrests
at all times.
The passenger must synchronize his movements with the operator.
Crossing Roads
If you have to cross a road, the lead driver should get off his vehicle, then observe
and give directions to the other riders. The last person after crossing then assists
the lead driver to cross. Do not travel on sidewalks. They are designated for
pedestrian use.

RIDING THE VEHICLE
Turning
Practice turning at low speeds before attempting to turn at faster speeds.
Keep both hands on handlebars and feet on footpegs.
Maintain a constant speed or a slight acceleration during turn.
To reduce the risk of rollovers:
– Use care when turning.
• Do not turn the handlebar too far or too fast for your speed and environment.
Adjust steering inputs accordingly.
• Slow down before entering a turn. Avoid hard braking during a turn.
• Avoid sudden or hard acceleration when turning, even from a stop or low
speed.
– Never attempt donuts, skids, slides, fishtails, jumps, or other stunts. If vehicle
starts to skid or slide, steer in the direction of the skid or slide. Never slam the
brakes and lock the wheels.
– Avoid paved surfaces. This vehicle is not designed to operate on paved surfaces
and is more likely to roll over. If you must drive on pavement, turn gradually, go
slowly, and avoid abrupt acceleration and braking.
Avoid sudden inputs to steering, throttle or brakes while turning.
WARNING
Do not attempt turns at excessive speed.
vmo2012-012-525
If you do get into a slide or skid, it may help to turn the handlebar in the direction of
the skid until you regain control. Never jam the brakes and lock the wheels.

RIDING THE VEHICLE
WARNING
The tires of this vehicle are not suited for paved road use. Also this vehicle
is not equipped with a rear differential (rear wheels are always turning at
the same speed). For these reasons, pavement may seriously affect the
handling and control of the vehicle.
Braking
Always keep both hands on handlebars and feet on footpegs when braking.
Practice braking to get familiar with the brake response.
– Do it at low speed first, then increase the speed.
– Practice braking in straight line at different speeds and different braking force.
– Practice emergency braking; optimal braking is obtained in straight line, with
high force applied, without locking the wheels.
Remember, braking distance depends on vehicle speed, load and the type of sur-
face. Also, the tires and brakes conditions play a major role.
NOTE: If going forward the vehicle weight is transferred to the front wheels when
braking. To obtain greater stopping efficiency, the brake system distributes more
braking force to the front wheels. This will affect vehicle handling and steering
control when braking vigorously. Take it into account when braking.
Reverse Operation
When operating in reverse, check that the path behind the vehicle is free of people
or obstacles. Proceed slowly and avoid sharp turns.
When riding on a 2-UP model, take into account that the passenger can obstruct
your view. Disembark the passenger if necessary.
We recommend sitting on your ATV when operating in reverse. Avoid standing
up. Your weight could shift forward against throttle lever, causing an unexpected
acceleration.
Obstacles
Obstacles in the “trail” should be traversed with caution. This includes loose
rocks, fallen trees, slippery surfaces, fences, posts, and embankments and
depressions. You should avoid them whenever possible. Remember that some
obstacles are too large or dangerous to cross and should be avoided. Small
rocks or fallen trees may be safely crossed approach at a 90° angle. Stand on
the footrests while keeping your knees flexed. Adjust speed without losing mo-
mentum and do not “gun” the throttle. Hold handlebar (operator) or grab handles
(passenger on 2-UP models) firmly. Place body weight rearwards (operator and
passenger 2-UP models) and proceed. Do not try to lift the vehicle front wheels
off the ground. Be aware that the object may be slippery or may move while
crossing.
When riding on 2-UP models, the operator is responsible for the safety of the pas-

RIDING THE VEHICLE
Uphill Driving
1-UP Models
straight uphill and keep your body weight forward towards the top of the hill.
Keep your feet on the footrests, shift your ATV into a lower gear and accelerate
before you start to climb. Try to keep a steady speed and go easy on the throttle
to avoid acceleration. Abrupt slope or terrain variation or rolling one wheel over
an obstacle could have a big impact on the stability as it will lift the front of the
vehicle increasing the risk of tipping over. Some hills are too steep to safely stop or
recover from after an unsuccessful climbing attempt. Try to avoid steep inclines.
If you're not careful, you could tip over when going up hills. If the hill is too steep
and you cannot proceed or the vehicle begins to roll backwards, apply the brake,
being careful not to slide. Dismount then use the “K” turn (while walking back,
next to the vehicle on the up hill side and with a hand on the brake lever, slowly
back the rear of the vehicle toward the top of the hill then drive downhill). Always
walk or dismount on the upside of the slope while keeping clear of the vehicle and
its rotating wheels. Do not try to hold on to the vehicle if it begins to topple. Stay
clear. Do not ride over the crest of the hill at high speed. Obstacles, including
sharp drop-offs, may exist.
vmo2012-012-526
2-UP Models
Do not forget, the operator is responsible for the safety of the passenger. In doubt,
disembark the passenger before climbing a hill.
straight uphill. Operator and passenger must keep their body weight forward,
towards the top of the hill. Keep feet on the footrests, shift the ATV into a lower
gear and accelerate before you start to climb. Try to keep a steady speed and
go easy on the throttle to avoid acceleration. Abrupt slope or terrain variation or
rolling one wheel over an obstacle could have a big impact on the stability as it
will lift the front of the vehicle increasing the risk of tipping over. Some hills are

RIDING THE VEHICLE
too steep to safely stop or recover from after an unsuccessful climbing attempt.
Try to avoid steep inclines. If you're not careful, you could tip over when going up
hills. If the hill is too steep and you cannot proceed or the vehicle begins to roll
backwards, apply the brake, being careful not to slide. Dismount, passenger first,
then use the “K” turn (while walking back, next to the vehicle on the up hill side
and with a hand on the brake lever, slowly back the rear of the vehicle toward the
top of the hill then drive downhill). Always walk or dismount on the upside of the
slope while keeping clear of the vehicle and its rotating wheels. Do not try to hold
on to the vehicle if it begins to topple. Stay clear. Do not ride over the crest of the
hill at high speed. Obstacles, including sharp drop-offs, may exist. The passenger
should get on the vehicle only when the vehicle has returned to a safe location.
V00A1XL
Vehicle Behaviors
Due to configuration, this vehicle has excellent climbing ability, so much so that
it is possible to tip over before traction is lost. For example, it is common to
encounter terrain situations where the top of the hill has eroded to a point that
the hill peak rises very sharply. The vehicle can readily negotiate such a condition,
however, in doing so, when the front of the vehicle is driven to a point that the
vehicle's balance moves rearward, a tip over can occur.
The same situation may apply if an embedded object causes the front of the vehi-
cle to climb more than desired. If such a situation occurs take an alternate route.
Be aware of side hilling dangers when doing so. Refer to SIDE HILLING.

RIDING THE VEHICLE
vmo2012-012-526
Downhill Driving
1-UP Models
Keep your body weight rearwards. Stay seated. Apply the brake gradually to pre-
vent skidding. Do not “coast” down the slope using solely engine compression or
in neutral gear.
Decelerating while negotiating a slippery downhill slope could “toboggan” the
vehicle. Maintain steady speed and/or accelerate slightly to regain control. Try
to avoid steep inclines. If you're not careful, you could tip over when going down
hills.
vmo2012-012-523
2-UP Models
Always remember that the vehicle handling, stability and braking distance may be

RIDING THE VEHICLE
Operator and passenger must keep their body weight rearwards. Apply the brake
gradually to prevent skidding. Do not “coast” down the slope using solely engine
compression or in neutral gear. Try to avoid steep inclines. If you're not careful,
you could tip over when going down hills.
V00A1YL
Vehicle Behaviors
This vehicle can climb slopes that are steeper than it can safely descend. There-
fore, it is essential to ensure that a safe route exists to descend a slope before you
climb it.
Side Hilling
This is one of the most risky types of riding since it may drastically change the bal-
ance of the vehicle. It should be avoided whenever possible. However, if it is nec-
essary to do so , it is important that you ALWAYS keep your body weight on the up-
side of the slope and be prepared to dismount on that side should the vehicle begin
to topple.
Avoid all objects or depressions that will intensify the raising of one side of the ve-
hicle higher than the other, thus causing rollover.
WARNING
Do not try to stop or save the vehicle from damage.
WARNING
Be careful when loading and transporting liquid reservoirs. They can affect
vehicle stability when side hilling by pulling downhill and increasing the risk
of a roll over.

RIDING THE VEHICLE
vmo2012-012-527
2-UP Models
Drop-Offs
This vehicle will “bottom-out” and usually stop if either the front or rear wheels are
driven over a drop-off. If the drop is sharp or deep, the vehicle will nose dive and tip
over.
When riding on a 2-UP model, the operator is responsible for the safety of the pas-
WARNING
Avoid negotiating drop-offs. Reverse and select an alternate route.
Crossing Water
Water can be a unique hazard. If it is too deep the vehicle may “float” and topple.
Check the water depth and current before you attempt to cross any water. Water
should not go above the footrest. Be wary of slippery surfaces such as rocks,
grass, logs, etc., both in the water and on its banks. A loss of traction may occur.
Do not attempt to enter the water at high speed. The water will act as a brake and
could throw you off the vehicle, on the ground.

RIDING THE VEHICLE
vmo2012-012-524
Wet brakes will affect the braking ability of your vehicle. Make sure you dry the
brakes by applying them several times after the vehicle leaves the water, mud or
snow. Allow greater distance for braking.
Mud or marsh lands may be encountered near water. Be prepared for sudden
“holes” or changes in depth. Similarly so, be watchful of hazards such as rocks,
logs, etc., partially covered by vegetation.
Riding on Ice
If your route crosses frozen waterways, make sure the ice is thick enough and
sound enough to support the total weight of yourself, your passenger (2-UP mod-
els), the vehicle and its load. Be ever watchful of open water it is a sure indication
that the ice thickness will vary.
On 2-UP models, the operator is responsible for the safety of the passenger; in
doubt, do not attempt to cross.
Ice will also affect the control of the vehicle. Slow down and do not “gun” the
throttle. This will only result in spinning of the tires and possible tip over of the
vehicle or passenger ejection (2-UP models). Avoid rapid braking. This again will
possibly result in an uncontrolled slide and tip over of the vehicle or passenger
ejection (2-UP models). Slush should be avoided at all times since it could block
the operation or controls of the vehicle.
Riding on Snow Covered Surfaces

When performing the pre-ride inspection, pay special attention to locations on the
vehicle where snow and/or ice accumulations may obstruct visibility of the taillight
and reflectors, clog ventilation openings, block the radiator and fan, and interfere
with the movement of control levers, switches and brake pedal. Before starting
with your ATV check the steering, throttle and brake lever and pedal controls for
interference free operation.
Whenever an ATV is ridden on a snow covered drive path the tire grip is generally
reduced causing the vehicle to react differently to control inputs from the operator.
On low grip surfaces, the steering responses are not as crisp and precise, stopping
distances are lengthened and acceleration becomes sluggish. Slow down and do
not "gun" the throttle. This will only result in spinning of the tires and possibly in an

RIDING THE VEHICLE
over steering slide of the vehicle. Avoid hard braking. This will possibly result in a
straight line slide of the vehicle. Again, the best advice is to safely reduce speed in
anticipation of a maneuver so to give yourself time and distance to regain total ve-
hicle control before it spins out of your control.
As you drive your ATV over a loose snow covered surface, snow dust will be
picked up in the wake turbulence of the moving vehicle and transported to contact
and accumulate or melt on some exposed components including rotating parts
like brake discs. Water, snow or ice may affect the response time of the brake
system of your ATV. Even when not required to reduce vehicle speed apply brakes
frequently to prevent ice or snow accumulation and to dry brake pads and discs.
While doing so in low risk driving situations you will test for grip level and keep
yourself alerted to how the vehicle reacts to your control inputs. Always keep
brake pedal, footrests, floor boards, brake and throttle levers free of snow and ice.
Frequently wipe snow off seat, hand grips, headlights, taillights and reflectors.
The depth of the snow cover may hide rocks, tree stumps or other objects and if it
is wet may totally impede the driveability as the vehicle becomes bogged down or
completely looses traction in slushy snow. Look far ahead and always be watchful
of any visible clues that might indicate the presence of such obstacles. In doubt
steer clear. Avoid driving on any frozen body of water before checking that the
ice will safely support the ATV, its riders and its load of cargo. Remember that a
given thickness of ice may be sufficient to support a snowmobile but not an ATV
of an identical weight because of the smaller load bearing surface of the four tire
contact patches as compared to that of a snowmobile track and skis.
To maximize comfort and avoid frostbite, always wear clothing and ATV protective
equipment appropriate for the weather conditions you will be exposed to during
your ride.
At the end of each ride it is a good practice to clean the vehicle body and all moving
components (brakes, steering components, drivelines, controls, radiator fan etc.)
from any snow or ice accumulations. Wet snow will turn to ice during the shut
down period and become more difficult to remove at the next pre-ride inspection.
Riding in snow may reduce the brakes stopping capability. Safely reduce speed
and allow greater distance for braking. Snow projection may cause ice build up or
snow accumulation on brake components and controls. Apply brakes frequently
to prevent ice or snow accumulation.
Riding on Sand
Riding on sand, sand dunes or on snow is another unique experience, but there are
some basic precautions that should be observed. Wet, deep or fine sand/snow
may create a loss of traction and cause the vehicle to slide, drop off or become
“bogged” down. If this occurs look for a firmer base. Again, the best advice is to
slow down and be watchful of the conditions. When you ride with a passenger
(2-UP models), slow down even more.
When riding in sand dunes it is advisable to equip the vehicle with an antenna type
safety flag. This will help make your location more visible to others over the next
sand dune. Proceed carefully should you see another safety flag ahead. Since the
antenna type safety flag can snag and rebound on your body if caught, do not use
it in areas where there are low hanging branches or obstacles. Always remember
when riding on a 2-UP model that the vehicle handling and stability may be affected

RIDING THE VEHICLE
Riding on Loose Stones

Riding on loose stones or gravel is very similar to riding on ice. They will affect the
steering of vehicle possibly causing it to slide or tip over especially at high speeds
(resulting in operator and passenger ejection (2-UP models).
Again, the best advice is to slow down and be watchful of the conditions. When
you ride with a passenger (2-UP models), slow down even more.
In addition, braking distance may be affected. Remember that “gunning” the
throttle or sliding may cause loose stones to be ejected rearwards into the path of
another rider. Never do it deliberately.

MOVING LOADS AND DOING WORK
Working with your Vehicle Always be aware that the “load” may
Your vehicle can help you perform a slide or fall off and cause an accident.
number of different LIGHT tasks rang-
ing from snow removal to pulling wood WARNING
or carrying cargo. A variety of acces- The vehicle handling, stability and
sories are available from your autho- braking distance are affected when
rized Can-Am dealer. To prevent pos- loading racks and using the vehi-
sible injury, follow the instructions and cle. Correct loading and weight
warnings that accompany the acces- distribution are therefore impor-
sory. Always respect the load limits tant. Never overload, tow or carry
of the vehicle. Overloading the vehi- cargo improperly. Always en-
cle can overstress the components sure the cargo is safely secured
and cause failure. Avoid overexerting and properly distributed on the
yourself if you lift or pull heavy loads or rack(s) before operating the vehi-
manually push the vehicle. cle. Safely reduce speed accord-
ing to terrain conditions when car-
Carrying Loads rying cargo or pulling a trailer, and
avoid hills and rough terrain. Al-
WARNING low greater distance for braking,
especially on inclined surfaces and
– On 1-UP models, NEVER exceed when a passenger (2-UP models)
90 km/h (55 MPH) if total load is is on board. Be careful not to skid
more than 164 kg (360 lb). or slide. Always secure cargo as
– On 2-UP models, NEVER exceed low as possible on the rack(s) to
90 km/h (55 MPH) if total load is reduce the effect of a higher center
more than 132 kg (290 lb). of gravity. Failure to follow the rec-
– On 2-UP models, NEVER exceed ommendations here could cause
90 km/h with a passenger. changes in vehicle handling which
could lead to an accident.
Any load carried on the vehicle includ-
ing a passenger (2-UP models) and/or
the carrying rack(s) will affect the han-
dling, stability and braking distance of
the vehicle. Do not exceed the total
load allowed for this vehicle, includ-
ing the weight of operator and pas-
senger cargo, accessories and trailer
tongue weight. Refer to SPECIFICA-
TIONS. Always make sure the cargo
is secured, properly distributed (1/3 of
cargo weight in front and 2/3 of cargo
weight in back) and cannot interfere
with your proper control. Always be
aware that the “cargo” may slide or
fall off and cause an accident. Avoid vmo2015-005-001_a
cargo that may protrude sideways and 1. 1/3 of cargo weight
get snagged or caught in bushes or 2. 2/3 of cargo weight
other obstacles. Avoid covering and
obstructing the headlights or taillight
with the cargo.

MAXIMUM LOAD TABLE

1-UP 235 kg
TOTAL MODELS (518 lb) Includes weight of operator, passenger,
LOAD 2-UP cargo, accessories and trailer tongue
ALLOWED 272 kg weight.
MODELS
(600 lb)
Mossy Oak
54 kg
FRONT LOAD Evenly distributed.
(120 lb)
Evenly distributed.
109 kg
REAR LOAD Includes rear rack, rear glove box
(240 lb)
and tongue load.
EXAMPLE OF SUITABLE VEHICLE TOTAL LOADS (MODELS

WITH235 KG (518 LB) TOTAL LOAD)
OPERATOR TOTAL
TONGUE
AND FRONT RACK REAR RACK VEHICLE
WEIGHT
PASSENGER LOAD
92 kg (203 lb) 40 kg (88 lb) 80 kg (176 lb) 23 kg (51 lb) 235 kg (518 lb)
Loading the Cargo Racks cargo rack and that cargo will not inter-
fere with your visibility or control of the
NOTICE When loading or unload- vehicle.
ing, do not exceed the weight limit
of 109 kg (240 lb) for rear load and Do not overload cargo rack.
54 kg (120 lb) for front load. Never carry gasoline container(s) or
any dangerous liquids on the cargo
Load cargo as low as possible – a rack.
higher load can raise the vehicle’s
center of gravity, which can reduce Hauling a Load
stability. Position cargo on the rack as
evenly distributed as possible. (if Equipped with Hitch)
Secure the load on the cargo rack. Do Never pull a load by attaching it to the
not secure cargo to other parts of the bumper or luggage racks; this can
vehicle. If it is not properly secured, a cause the vehicle to tip over. Use only
load may slide or fall off, possibly strik- the trailer hitch (if installed) to pull a
ing occupants or bystanders; or it may load.
shift during riding, affecting the han- In an emergency situation, use the
dling of the vehicle. recovery hook to recover a stuck ve-
Objects that are high may affect visibil- hicle. Refer to RECOVERY HOOKS in
ity for the driver and may act as projec- EQUIPMENT.
tiles in case of an accident. Loads that When pulling loads with a chain or ca-
protrude sideways can get snagged or ble, ensure that there is no slack before
caught in bush, branches or other ob- starting and maintain tension while
stacles. Avoid covering and obstruct- pulling.
ing the brake lights with the cargo.
Ensure no cargo protrudes outside the

When pulling loads with a chain or ca- and when a passenger (2-up models)
ble, be sure to brake progressively. is on board. Be careful not to skid or
The inertia of the load could lead to an slide.
impact. Improperly loading a trailer may cause
When hauling a load, respect the maxi- a loss of control. Make sure there is at
mum hauling capacity. See PULLING least some weight on the tongue.
A TRAILER. Always make sure load is evenly dis-
tributed and safely secured on the
WARNING trailer; an evenly balanced trailer is
A slack in the chain or cable can easier to control.
cause it to break and snap back. Always put the shift lever to L (low
range) for hauling a trailer – in addition
When pulling another vehicle, be sure to providing more torque, operating
that someone is controlling the pulled in low range helps account for the in-
vehicle. They must brake and steer to creased load on the rear tires.
prevent the vehicle from going out of When stopped or parked, block the ve-
control. hicle and trailer wheels from possible
Reduce your speed when hauling a movement.
load and turn gradually. Avoid hills and Use caution when disconnecting a
rough terrain. Never attempt steep loaded trailer; it or its load may topple
hills. Allow more distance for brak- on you or others.
ing, especially on inclined surfaces and
when a passenger (2-up models) is on When hauling a trailer, respect the ma-
board. Be careful not to skid or slide. ximum hauling capacity indicated on
the label on the hitch and mentioned in
Pulling a Trailer SPECIFICATION.
(if Equipped with Hitch) Make sure there is at least some
weight on the tongue.
NOTICE A BRP approved rear
hitch must be properly installed on
the vehicle for hauling trailers.
Riding this vehicle with a trailer sub-
stantially increases the risk of toppling,
especially on inclined slopes. If a trailer
is used behind the vehicle make sure
that its hitch is compatible with the
one on the vehicle. Make sure the
trailer is horizontal with the vehicle. (In
some instances a special extension
may have to be installed on the vehicle
hitch). Use security chains or cables to
secure the trailer with the vehicle.
Reduce your speed when pulling a
trailer and turn gradually. Avoid hills
and rough terrain. Never attempt
steep hills. Allow more distance for
braking, especially on inclined surfaces

IMPORTANT ON-PRODUCT LABELS
(CANADA/UNITED STATES)
Canada/United States
Hang Tag
tion.
fore riding.
704903310

IMPORTANT ON-PRODUCT LABELS(CANADA/UNITED STATES)
NEVER USE WITH

DRUGS OR
ALCOHOL.
704903314
704903314
WARNING . Operating, servicing and

maintaining an off-road vehicle can expose
you to chemicals including engine exhaust,
carbon monoxide, phthalates, and lead,
which are known to the State of California
to cause cancer and birth defects or other
reproductive harm.
To minimize exposure, avoid breathing 704901107
exhaust, do not idle the engine except as vmo2006-005-009_en
necessary, service your vehicle in a
well-ventilated area and wear gloves or wash TYPICAL
your hands frequently when servicing your
vehicle.
For more information go to

www.P65Warnings.ca.gov/products/
passenger-vehicle
704906872
EN-704906872-DEC

Vehicle Safety Labels

Read and understand all the safety la-
bels on your vehicle.
These labels are affixed to the vehicle
for the safety of the operator, passen-
ger (2-UP) or bystanders.
The safety labels on your vehicle
should be considered permanent parts
of the vehicle. If missing or damaged,
they can be replaced free of charge.
See an authorized Can-Am dealer. vmo2015-005-059_a
NOTE: In the event of any discrep-

ancy between this guide and the ve-
hicle, the safety labels on the vehicle
have precedence over the labels in this
guide.
vmo2015-005-058_a
vmo2015-005-061_a
vmo2015-005-057_a
vmo2015-005-062_a

vmo2015-005-054_b
MAX MODELS ONLY
704903153C
704902787 704902775A
LABEL 1 - 1-UP MODELS LABEL 2 - 1-UP MODELS
704903087A

704902793
704902785
LABEL 3
704903093B
• NEVER carry a passenger on this carrier.

• MAXIMUM FRONT LOAD: 54 kg (120 lb) evenly distributed.
• MAXIMUM REAR LOAD: 109 kg (240 lb) evenly distributed.
(Includes trailer tongue weight if applicable).
704904404
704904440
Improper loading of a trailer may 704904404
cause loss of vehicle control, LABEL 6
resulting in severe injury or death.

• Maximum towing weight
590 kg (1300 lb)
• Maximum tongue weight
23 kg (50 lb) 704904438
704904438
LABEL 5
704902777A
LABEL 7

Improper tire pressure or overloading can cause loss of control, resulting in

SEVERE INJURY or DEATH.
ALWAYS maintain proper tire pressure according to the load on the vehicle. Refer to table.
NEVER underinflate tire as it could cause the tire to disloge from the rim.
NEVER exceed the vehicle load capacity of 235 kg (517 lb),
Mossy Oak configuration 272 kg (598 lb), including weight of operator, cargo,
accessories and trailer tongue weight.
NEVER exceed 90 km/h if total load is more than 164 kg (360 lb),
Mossy Oak configuration 132 kg (290 lb) COLD TIRE PRESSURE
ATV LOADING and TRAILER TOWING FRONT 48.3 kPa (7 psi)
handling. Load must be proprely distributed on racks. REAR 48.3 kPa (7 psi)
- reduce speed.
- allow more distance to stop. 704906970
- avoid hills and rough terrain.
EN-704906970-DEC
Improper tire pressure or overloading can cause loss of control, resulting in

SEVERE INJURY or DEATH.
ALWAYS maintain proper tire pressure according to the load on the vehicle. Refer to table.
NEVER underinflate tire as it could cause the tire to disloge from the rim.
exceed the vehicle load capacity of 272 kg (600 lb), including weight of operator,
cargo, accessories and trailer tongue weight.
exceed 90 km/h if total load is more than 132 kg (290 lb)
exceed 90 km/h with a passenger
COLD TIRE PRESSURE
ATV LOADING and TRAILER TOWING
FRONT 48.3 kPa (7 psi)
• Cargo loading or trailer towing can affect stability and
handling. Load must be proprely distributed on racks. REAR 48.3 kPa (7 psi)
• When loaded with cargo or towing a trailer:
- reduce speed.
- allow more distance to stop. 704906307
- avoid hills and rough terrain.
704906307

Compliance Labels
This vehicle is an all terrain vehicle and is not These labels indicate vehicle's compli-
intended for use on public roads. 704905139 ance.
Ce véhicule est un véhicule tout

terrain qui n’est pas destiné a CAN ICES-2 / NMB-2
être utilisé sur les POWER
704904556
kW
voies publiques. PUISSANCE
WET WEIGHT
POIDS EN ETAT kg
DE MARCHE
704905139
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.
LABEL 9 CE VEHICULE EST UN VEHICULE TOUT TERRAIN QUI N'EST PAS DESTINÉ À ÊTRE UTILISÉ SUR
LES VOIES PUBLIQUES.
704904556
LOCATION: UNDER SEAT, ON THE UPPER

FRAME MEMBER
704902941
LABEL 10
704906388
vmo2010-010-100_a
TYPICAL: ALL MODELS IN CANADA AND
LABEL 11 UNITED STATES EXCLUDING CALIFORNIA
EMISSION CONTROL INFORMATION

THIS VEHICLE IS CERTIFIED TO OPERATE ON UNLEADED
GASOLINE AND CONFORMS TO U.S. EPA AND
Always make sure to properly install passenger seat or CALIFORNIA EMISSION / EVAP REGULATIONS FOR ATV.
ENGINE FAMILY FAMILLE DE MOTEUR
TO INSTALL PASSENGER SEAT PERMEATION FAMILY FAMILLE DE PERMEATION
. Ensure that the latch lever is in the open position by pulling it
towards the front of seat. CERTIFICATION LIMITE DES ÉMISSIONS
. Using a forward motion, insert both front tabs of the seat into STANDARD (FEL) DE LA FAMILLE
the vehicle anchor housings.
. Rotate downwards to engage the rear latch. ENGINE DISPLACEMENT CYLINDRÉE
. Close the latch lever by pushing it rearwards to secure the seat
in position. EXHAUST EMISSION SYSTÈME DE CONTRÔLE
. Check if the seat is firmly secured in position before using it. CONTROL SYSTEM DES ÉMISSIONS
RENSEIGNEMENTS SUR LE DISPOSITIF ANTIPOLLUTION
TO INSTALL GLOVE BOX CE VÉHICULE EST CERTIFIÉ POUR FONCTIONNER À L'ESSENCE SANS PLOMB ET IL
• Open glove box cover and turn handle to the unlock position. EST CONFORME AUX NORMES DE L'EPA ET DE LA CALIFORNIE AU NIVEAU
• Align and insert glove box latching system into DES RÉGLEMENTATIONS DE L’ÉCHAPPEMENT ET DE L’ÉVAPORATION POUR LES VTT.
this vehicle's “LINQ” opening. SEE OPERATOR’S GUIDE FOR MAINTENANCE SCHEDULE
• Turn handle to the lock position. VOIR LE PROGRAMME D’ENTRETIEN DANS LE GUIDE DU CONDUCTEUR
• Close cover and verify if glove box is locked BOMBARDIER RECREATIONAL PRODUCTS INC. 704904648
in position. 704904648
704904358 TYPICAL: CALIFORNIA MODELS
704904358
TYPICAL - LOCATION: UNDER SEAT, ON THE
UPPER FRAME MEMBER

704903327
LOCATION: REAR FENDER
Technical Information
Labels
707800373

FRAME MEMBER

IMPORTANT ON-PRODUCT LABELS (ALL
COUNTRIES EXCEPT CANADA/UNITED STATES)
All Countries Except Canada/United States
Hang Tag
tion.
fore riding.
WARNING
– Locate and read operator's guide. Improper ATV use can result in SE-
VERE INJURY or DEATH. Follow all instructions and warnings.
– Always use an approved helmet and protective gear.
– Never use on public roads.
– Never carry passengers on 1-up models and NEVER carry more than one
passenger on 2-up models.
G
GENERAL USE MODEL
THIS ATV IS FOR

RECREATIONAL USE OR UTILITY USE
704903930
704903930A

IMPORTANT ON-PRODUCT LABELS (ALL COUNTRIES EXCEPT CANADA/UNITED STATES)
G
GENERAL USE MODEL
704903946
704903946
704901107
vmo2006-005-009_en
TYPICAL: APPLICABLE WHEN EQUIVALENT

TO A MODEL CERTIFIED TO US EPA
STANDARDS

Vehicle Safety Labels

Read and understand all the safety labels on your vehicle.
These labels are affixed to the vehicle for the safety of the operator, passenger
(2-UP) or bystanders.
The safety labels on your vehicle should be considered permanent parts of the ve-
hicle. If missing or damaged, they can be replaced free of charge. See an autho-
rized Can-Am dealer.
NOTE: In the event of any discrepancy between this guide and the vehicle, the
safety labels on the vehicle have precedence over the labels in this guide.
vmo2015-006-401_b
vmo2015-005-062_a
vmo2015-005-061_b

704903962
704903962A
vmo2015-005-059_d LABEL 1 - 1-UP MODELS
704903734
vmo2015-005-054_e 704903734A
MAX MODELS ONLY LABEL 1 - 2-UP MODELS
Label 1 Label 2
WARNING WARNING
– Locate and read operator's Operating this ATV if you are under
guide. Improper ATV use can the age of 16 increases the chance
result in SEVERE INJURY or of SEVERE INJURY or DEATH to
DEATH. Follow all instructions the operator, and to both the oper-
and warnings. ator and passenger on 2-up mod-
– Always wear ear protection. els. NEVER operate this ATV if you
are under age 16.
– Always use an approved helmet
– Never use on public roads.
– Never carry a passenger on 1-up
models and NEVER carry more
than one passenger on 2-up
models.
704903964
704903964
LABEL 2

Label 3
•ATV MUST be stopped before shifting lever.

•ALWAYS apply foot brake to shift from
Park (P) and Neutral (N).
704903970
704903737
704903970
LABEL 3 LABEL 4 - 2-UP MODELS
Label 4 Label 5
WARNING WARNING
– Locate and read operator's – NEVER carry a passenger on
guide. this carrier.
– NEVER carry a passenger on – MAXIMUM FRONT LOAD: 54 kg
1-up models and NEVER carry (120 lb) evenly distributed.
more than 1 passenger on 2-up – MAXIMUM REAR LOAD: 109 kg
models. (240 lb) evenly distributed (in-
– Passenger on 2-up models must cluding trailer tongue weight if
always use an approved helmet applicable).
– Passenger on 2-up models must
NEVER ride after using drugs or
< 109 kg (240 lb)
alcohol.
< 54 kg
(120 lb)
704904405
704904405
LABEL 5
704903968
704903968

Label 6
WARNING
NEVER attach here or on the lug-
gage rack to pull a load This can
cause the vehicle to tip over. AL-
WAYS use the trailer hitch or the
recovery hook to pull a load.
704903955
704903955A
LABEL 6
Label 7
WARNING
– Locate and read operator's guide. Improper tire pressure or overloading
can cause loss of control, resulting in SEVERE INJURY or DEATH.
– ALWAYS maintain proper tire pressure as shown.
weight.
weight.
– ALWAYS pull a load using the trailer hitch or recovery hook.
– NEVER exceed the maximum towing weight of 590 kg (1,300 lb).
– NEVER exceed the maximum tongue weight of 23 kg (50 lb).
– On 1-up models, NEVER exceed 90 km/h (55 MPH) if total load is more
than 164 kg (360 lb).
– On 2-up models, NEVER exceed 90 km/h (55 MPH) if total load is more
than 132 kg (290 lb).
– On 2-up models, NEVER exceed 90 km/h with a passenger.

=
< 235 kg (517 lb)
48.3 kpa 48.3 kpa
< 272 kg (598 lb) Mossy Oak kPa (7 psi) (7 psi)
90 km/h
55 mph
590 kg
(1300 lb)
23 kg
> 164 kg (360 lb) (50 lb)
> 132 kg (290 lb) Mossy Oak 704906972
EN-FR-704906972-DEC
=
< 272 kg (600 lb)
48.3 kpa 48.3 kpa
kPa (7 psi) (7 psi)
90 km/h
55 mph
590 kg
(1300 lb)
90 km/h
55 mph
23 kg
(50 lb)
> 132 kg (290 lb) 704906309
704906309

Label 8
WARNING; GET FAMILIAR WITH THIS ATV. WARNUNG: MACHEN SIE SICH MIT DIESEM
INEXPERIENCED RIDERS MAY OVERLOOK ATV VERTRAUT. UNERFAHRENE FAHRER
RISKS. KÖNNEN RISIKEN ÜBERSEHEN.
ADVARSEL: LÆR ATV’EN GRUNDIGT AT KENDE.
UERFARNE FØRERE KAN LET OVERSE FARERNE. ΠΡΟΕΙΔΟΠΟΙΗΣΗ: ΕΞΟΙΚΕΙΩΘΕΙΤΕ ΜΕ ΑΥΤΟ
ΤΟ ΟΧΗΜΑ ΠΑΝΤΟΣ ΕΔΑΦΟΥΣ (ATV). ΟΙ
WAARSCHUWING: MAAK UZELF VERTROUWD ΧΡΗΣΤΕΣ ΧΩΡΙΣ ΕΜΠΕΙΡΙΑ ΜΠΟΡΕΙ ΝΑ
MET DEZE ATV. ONERVAREN BESTUURDERS ΠΑΡΑΒΛΕΨΟΥΝ ΤΥΧΟΝ ΚΙΝΔΥΝΟΥΣ.
KUNNEN DE RISICO'S OVER HET HOOFD ZIEN.
AVERTISSEMENT : FAMILIARISEZ-VOUS AVEC AVVERTENZA: ACQUISIRE FAMILIARITÀ CON
CE VTT. LES UTILISATEURS INEXPÉRIMENTÉS QUESTO ATV. I PILOTI INESPERTI POTREBBERO
POURRAIENT SOUS ESTIMER LES RISQUES. SOTTOVALUTARE I RISCHI.
VAROITUS : TUTUSTU HUOLELLISESTI TÄMÄN ADVERTÊNCIA: FAMILIARIZE-SE COM ESTE
ATV: N KÄYTTÖÖN. KOKEMATTOMAT ATV. PILOTOS INEXPERIENTES PODEM
KULJETTAJAT SAATTAVAT ALIARVIOIDA SUBESTIMAR OS RISCOS.
VAARATILANTEET.
ADVERTENCIA: TÓMESE EL TIEMPO VARNING: BEKANTA DIG VÄL MED DENNA
NECESARIO PARA FAMILIARIZARSE CON EL ATV. OERFARNA FÖRARE KAN FÖRBISE
ATV. LA FALTA DE EXPERIENCIA PUEDE DAR RISKERNA.
LUGAR A LA OMISIÓN DE RIESGOS
IMPORTANTES.
IMPORTANTES 704903895
704903895
LABEL 8
Label 9
vmo2010-010-100_a
LABEL 9

Label 10 Compliance Labels

These labels indicate vehicle's compli-
WARNING ance.
Do not open when hot.
POWER
kW
704904557
PUISSANCE
WET WEIGHT
POIDS EN ETAT kg
EN 15997 DE MARCHE
Representative: BRP Europe N.V., Skaldenstraat 125, Ghent, Belgium, 9042.
704904557

FRAME MEMBER
704903688
704903688
LABEL 10
Label 11
Always make sure to properly install passenger seat or

TO INSTALL PASSENGER SEAT 704906388
.Ensure that the latch lever is in the open position by pulling it
towards the front of seat. TYPICAL : APPLICABLE WHEN EQUIVALENT
.Using a forward motion, insert both front tabs of the seat into the
vehicle anchor housings. TO A MODEL CERTIFIED TO US EPA
.Rotate downwards to engage the rear latch. STANDARDS - LOCATION: UNDER SEAT, ON
.Close the latch lever by pushing it rearwards to secure the seat
in position. THE UPPER FRAME MEMBER
.Check if the seat is firmly secured in position before using it.
TO INSTALL GLOVE BOX
• Open glove box cover and turn handle to the unlock position.
• Align and insert glove box latching system into Technical Information
this vehicle's “LINQ” opening.
• Turn handle to the lock position. Labels
• Close cover and verify if glove box is locked
in position.
704904442
704904442
707800373

FRAME MEMBER

This page is
intentionally blank

VEHICLE
INFORMATION
_______________ 81
CONTROLS
NOTE: Some vehicle safety labels are not shown on illustrations. For information
on vehicle safety labels, refer to IMPORTANT ON-PRODUCT LABELS.
6 5
vmo2015-005-052_b
1) Throttle Lever
The throttle lever is located on the RH
The throttle lever controls the engine
speed.
To increase or maintain vehicle speed,
press the throttle lever with your right
thumb.
To decrease vehicle speed, release the
throttle lever. vmo2015-005-020_a
TYPICAL
1. Throttle lever
2. To accelerate
3. To decelerate
82 ______________
CONTROLS
2) Brake Lever 2 1
The LH brake lever is located on the LH
V07K02Y
V07K01Y
TYPICAL
1. Brake lever lock
TYPICAL 2. Press to apply parking brakes
1. Brake lever
2. To apply brakes NOTE: Locking lever can be adjusted
in several positions.
The brake lever function is to slow
NOTE: The parking brake lever can be
down or stop the vehicle.
set to several positions.
When the brake lever is compressed,
the front and rear brakes are applied. NOTICE When the parking brake is
applied, make sure the vehicle stays
securely in place.
force applied on the lever.
To release the parking brake, simply
3) Parking Brake Lever squeeze the brake lever. It should re-
The parking brake lever is located on turn to the rest position.
the LH side of the handlebar.
The parking brake function is to apply WARNING
brake to all wheels to prevent vehicle Make sure parking brake is re-
from moving when parked. leased before operating the ve-
hicle. If parking brake is left ON
WARNING while riding, it may cause damage
to the brake system and cause loss
Always use the parking brake and of braking capacity and/or fire.
engage the PARK position on the
shift lever when the vehicle is not
in operation. 4) Brake Pedal
The brake pedal is located on the RH
To engage parking brake: Squeeze side of the vehicle near engine.
brake lever and maintain while moving
lever lock. Brake lever is now com-
pressed and applying all brakes.
_______________ 83
CONTROLS
SHIFT LEVER POSITIONS

POSITION GEAR
P Park
R Reverse
N Neutral
H High range (forward)
vmo2015-005-003_a
1. Brake pedal L Low range (forward)
The brake pedal function is to slow

down or stop the vehicle.
When the brake pedal is pressed
down, the rear brake is applied.
When released, the brake pedal should
return to its original position.
force applied on the pedal.
NOTE: The brake will have also an ef- vmo2012-012-036
fect on front wheels through the drive TYPICAL - SHIFT PATTERN

train when 4WD is engaged.
The vehicle must be stopped and
Should the brake lever system fail, the brakes applied prior to selecting any
rear brake can be used by depressing gear.
the brake pedal.
NOTICE This gearbox is not de-
5) Shift Lever signed to shift while vehicle is mov-
ing.
The shift lever is located on the RH side
of the vehicle near steering column. P: Park
The park position locks the gearbox to
help prevent vehicle movement.
WARNING
Always use the PARK (P) position
when the vehicle is not in oper-
ation. The vehicle can roll if the
shift lever is not set to P (PARK).
R: Reverse
vmo2015-005-005_a
SHIFT LEVER LOCATION The reverse position allows the vehicle

to go backwards.
The shift lever is used to change the NOTE: In reverse operation, the en-
gearbox position. gine's RPM is limited, thus limiting the
The shift lever has 5 positions: vehicle reverse speed.
84 ______________
CONTROLS
WARNING
When driving downhill in reverse,
gravity can increase the vehicle
speed above the set limited re-
verse speed.
Neutral
The neutral position disengages the
gearbox. 219001735-001_a
IGNITION SWITCH POSITIONS

WARNING 1. OFF
2. ON “with light”
Always use the PARK (P) position
when the vehicle is not in oper- OFF
ation. The vehicle can roll if the
shift lever is set to N (NEUTRAL). The key can be inserted or removed in
this position only.
High Range (Forward) In OFF position, the electrical system
of the vehicle is disabled.
This position selects the high speed
range of the gearbox. It is the normal The engine is shut down by turning the
driving speed range. It allows the vehi- ignition switch to OFF position.
cle to reach its maximum speed. NOTE: While the engine can be
Low Range (Forward) OFF position, we recommend the en-
This position selects the low speed gine be stopped by setting the emer-
range of the gearbox. It allows the ve- gency engine stop switch to the STOP
hicle to move slowly with maximum position.
torque at the wheels. NOTE: When turning the key to OFF
NOTICE Use the low speed range position, the vehicle electrical system
will take a few seconds to shut down.
to pull a trailer, carry heavy cargo,
go over obstacles or drive uphill and ON with Lights
downhill.
When the key is turned in this position,
6) Ignition Switch and the electrical system of the vehicle is
activated.
Keys
The gauge should wake-up.
The ignition switch is located on the LH
side of the central panel below the han- The vehicle lights are turned on.
dlebar. The engine can be started.
Keys
Basic Key (All Models Except Pro
Models)
The vehicle is delivered with a basic ig-
nition key.
_______________ 85
CONTROLS
Digitally Encoded Security System Performance Key

(D.E.S.S.) (Pro Models) The vehicle is delivered with a perfor-
The ignition keys contain an electronic mance key, which allows the user to
circuit that gives it a unique electronic access the full torque of the engine as
serial number. well as the top speed of the vehicle.
The D.E.S.S. system reads the key This may be useful for riders who pre-
code and allows engine starting for fer crisper throttle response, and for
keys it recognizes. environments where higher speeds
and greater acceleration are appro-
Types of Keys priate. For example, in wide-open
This vehicle can be operated using 2 straight trails, operators may prefer
different types of keys: the performance key.
– Normal key (grey)
– Performance key (black) 7) Multifunction Switch
The key type is differentiated by its The multifunction switch is located on
color. the LH side of the handlebar.
The controls located on this multifunc-
WARNING tion switch are:
Rollovers, tipovers, collisions and
loss of control resulting in serious
injury or death are possible with
the performance or normal. Using
the normal key is not a substitute
for the operator being prepared,
qualified, and operating with care.
Normal Key
The vehicle is delivered with a normal
key. 219001733-001_a
The normal key limits the vehicle TYPICAL — MULTIFUNCTION SWITCH

speed to 70 km/h (44 MPH). 1. Headlight switch
WARNING 4. Override/DPS button (if applicable)
On steep downhills, the engine Low/High/OFF Headlight Switch

speed limiter may not prevent the
vehicle from accelerating beyond This switch is used to select either the
this speed. headlights low or high beams or to turn
them OFF.
This key may be useful for riders who
prefer more gradual acceleration, or
for riding in environments where full
speed and high acceleration are not
desirable. For example, in narrow,
winding trails, operators may prefer
the normal key.
86 ______________
CONTROLS
Engine Start Button
219001733-003_a
HEADLIGHT SWITCH FUNCTIONS

219001733-00_g
1. Lights OFF
2. Low beam and taillight TYPICAL
3. High beam and taillight 1. Engine start button
Emergency Engine Stop Switch
When engine start button is pressed
and held, it starts the engine.
NOTE: To allow engine starting, the
ignition switch must be in the ON po-
sition and the emergency engine stop
button set to RUN.
Override/DPS Button
Depending on the vehicle model, this
button has up to 2 functions.
219001733-001_b
TYPICAL
This switch can be used to stop the en-

gine and as an emergency control.
To stop engine, set the emergency en-
gine stop switch to the STOP position.
NOTE: While the engine can be
OFF position, we recommend the en- 219001733-001_e
gine be stopped by setting the emer- TYPICAL

gency engine stop switch to the STOP 1. Override/DPS button
position.
WARNING
injury or death.
_______________ 87
CONTROLS
Override Function
The override switch main function is to
bypass the engine speed limiter in re-
verse operation by allowing maximum
engine torque.
WARNING
Only use the override to help get
the vehicle unstuck from mud or
other soft terrain. Do not use the
override for normal operation in vmo2012-012-007_a
reverse. This would allow driving TYPICAL
in reverse at excessive speeds and 1. Selector
can increase the risk of losing con- 2. 2WD position
trol. 3. 4WD position
This switch selects 2 wheel drive or 4

To engage the override function, pro- wheel drive mode when the vehicle is
ceed as follows: stopped and the engine is running.
While the shift lever is set to REVERSE
position. NOTICE The vehicle must be
stopped to engage or disengage
1. Ensure that the vehicle is stopped. 2WD/4WD switch. Mechanical dam-
2. Press and hold the override switch age may occur if switch is engaged
then press the throttle lever gradu- or disengaged while driving.
ally.
NOTE: When using the override func- switch is pushed downwards.
tion, the gauge will scroll an OVER-
RIDE message to confirm that the
function is activated.
3. To disengage the override function,
simply release the override switch.
DPS Function (Models with DPS)
This button is also used to change the
Dynamic Power Steering (DPS) mode.
To change DPS mode, refer to TUNE
YOUR RIDE.
8) 2WD/4WD Selector
The 2WD/4WD selector is located on
the RH side of the handlebar.
V07I0DY
4WD MODE - TYPICAL
88 ______________
CONTROLS

switch is pushed upwards. The vehicle
is then rear wheel drive only.
V07I0EY
2WD MODE - TYPICAL
WARNING
injury or death.
_______________ 89
MULTIFUNCTION GAUGE (LCD)
The multifunction gauge is located in
the gauge support.
WARNING
Reading the multifunction gauge
display can distract from the op-
eration of the vehicle, particularly
from constantly scanning the envi- vmr2007-050-002_d
ronment. 1. Gearbox position
DISPLAY FUNCTION
Multifunction Gauge
Description P Park
R Reverse
N Neutral
H High range
L Low range
3) Main Screen
The main screen is used to display nu-
merous functions of the multifunction
vmo2013-010-001_a
gauge.
1. Selector button
2. Gearbox position display Refer to MULTIFUNCTION GAUGE
3. Main screen MODES for the different available
4. Fuel level display modes:
5. 4WD indicator lamp
6. Low fuel level indicator lamp
7. Check engine indicator lamp 4) Fuel Level Display
8. High beam indicator lamp Bar gauge continuously indicates the
9. MPH, Km/h indicator lamp
level of fuel in the fuel tank while riding.
1) Selector Button
The selector button is used to navigate
or change settings in the multifunction
gauge.
2) Gearbox Position Display

This display will show gearbox posi-
tion.
vmo2013-010-001_b
90 ______________
5) 4WD Indicator Lamp Multifunction Gauge

Modes
Speed Mode
When this indicator is ON, it indicates In this mode, the main screen shows
the 4WD mode is selected. the speed of the vehicle either in km/h
or in mph.
6) Low Fuel Level Indicator Lamp
When this indicator is ON, it indi-

cates that there is approximately 5 L
(1.3 U.S. gal.) of fuel left in fuel tank.
vdd2008-001-084
7) Check Engine Indicator Lamp
RPM Mode
In this mode, the main screen shows
the engine RPM.
an engine fault code, look for a mes-
sage at the LCD display.
When this indicator blinks, it indicates
that the LIMP HOME mode is acti-
vated.
Refer to TROUBLESHOOTING section
for more details.
vdd2008-001-089
8) High Beam Indicator Lamp

Combined Mode
In this mode, the main screen shows
the speed of the vehicle and the engine
When this indicator is ON, it indicates RPM.
that high beam is selected on the
headlights and that ignition key is in
ON with lights position.
9) KM/H or MPH Indicator Lamp
vdd2008-001-085_a
The proper lamp turns on to indicate
1. Vehicle speed
the unit the speedometer uses. 2. Engine RPM
Odometer (OD)
Odometer records the total distance
travelled either in miles or kilometers.
_______________ 91
vsi2009-018-030
vsi2009-018-032
Clock Press and HOLD the selector button

Displays current time. for 2 seconds to reset the hour meter.
Engine Hour Meter (EH)

The engine hour meter records engine
running time.
vmo2011-008-001
Refer to GAUGE SETUP to set current vsi2009-018-033

time.
Message Display Mode
Trip Meter (TP)
If an abnormal engine condition oc-
The trip meter records the travelled
curs, a message may scroll across the
distance since it has been reset. Dis-
main screen in conjunction with a pilot
tance travelled is displayed either in
lamp. Refer to TROUBLESHOOTING
kilometers or miles.
section for details.
Fault Code Mode

Switch to HI beam and select engine
hour meter display. Press and hold se-
lector button while switching high and
low beam (three cycles) to access di-
agnostic fault codes.
vsi2009-018-031
Navigating in the LCD
Press and HOLD the selector button Gauge
for 2 seconds to reset the trip meter.
Default Display Mode
Trip Hour Meter (TH)
After vehicle startup, the default dis-
The trip hour meter records vehicle play mode is either:
running time when the electrical sys- – Vehicle speed
tem is activated. It can be used to
establish traveling time between 2
places.
92 ______________
– Engine revolutions per minute

(RPM)
– Both parameters simultaneously
(combined mode).
To change from one display to the
other, proceed as follows.
1. Turn ignition key to ON to power-up vmr2007-050-002_c
the system.
1. Selector button
2. Wait until the “greeting message”
has been displayed. The gauge will display the selected
3. Press and release selector button mode for 10 seconds then will return
once to display OD (odometer). to the normal display mode.
4. Press and HOLD selector button for While in a resettable mode, push and
2 seconds. HOLD selector button for 2 seconds to
reset it.
This will change the Mode to either
Speed, RPM or Combined. Gauge Setup
Clock Setting Using Gauge Selector
Button
To set current time, proceed as fol-
lows:
vdd2008-001-083
5. To select another mode, repeat

steps 3 and 4 until the desired mode
is displayed.
Temporary Display Mode

In the temporary display mode, the fol-
lowing functions are available:
– Odometer vmo2011-008-001_a
– Clock 1. Selector button

2. Time
– Trip meter (resettable)
– Trip Hour meter (resettable) 2. Press and HOLD selector button.
– Engine hour meter. NOTE: The display will flash.
Press and release selector button to 3. Choose the 12-hour (12H) or
change the default display mode to the 24-hour (24H) format by pressing
temporary mode. button.
4. If the 12-hour format was selected,
choose Am (A) or Pm (P) by pressing
button.
button.
_______________ 93
6. Choose hour second digit by press-

ing button.
7. Choose minutes first digit by press-
ing button.
pressing button.
NOTE: The gauge will display the cur-
rent time for 10 seconds then will re-
turn to the normal display mode.
Unit Selection (km/h vs mph)

The speedometer, odometer and trip
meter are factory preset in miles but
it is possible to change them to kilo-
meter reading. Contact an authorized
Can-Am dealer.
Language Selection
The gauge display language can be
changed. Refer to an authorized
Can-Am dealer for language availability
and setup the gauge to your prefer-
ence.
WARNING
injury or death.
94 ______________
EQUIPMENT
NOTE: Some vehicle safety labels are not shown on illustrations. For information
on vehicle safety labels, refer to IMPORTANT ON-PRODUCT LABELS.
7
6
9
8,10
5
3
7
10
vmo2015-005-035_a
_______________ 95
EQUIPMENT
4
2 6
1
7
4
8,10
9
3
5
10
vmo2015-005-036_a
96 ______________
EQUIPMENT
1) Operator's Seat WARNING

The seat is designed for an operator Confirm that the operator's seat
only. is properly locked in position by
WARNING
Never allow anyone to seat as a 2) Passenger's Seat (2-UP
passenger on this vehicle. Models)
Seat Removal WARNING
To remove the operator's seat, push its Never operate the vehicle without
latch upward. This latch is located un- passenger's seat or glove box in-
derneath the rear of seat. stalled.
The passenger's seat is designed for a

passenger only. The integrated back-
rest supports his back during the ride.
vmo2015-005-007_a
1. Seat latch
Pull seat rearward. Continue lifting

movement until you can release the vmo2015-005-054_a
front retaining device then completely 1. Passenger's seat

remove seat. 2. Integrated backrest
Seat Installation WARNING

Insert front tabs of seat on U-rod Without its passenger's seat, the
welded to frame. When seat rests vehicle becomes a ONE RIDER ve-
in its position, firmly push seat down hicle (1-UP model) and NO PAS-
to latch. SENGER must be allowed on vehi-
NOTE: A distinctive snap will be felt. cle.
Double check that the seat is secure by
giving it a tug to confirm proper latch-
ing.
WARNING
injury or death.
_______________ 97
EQUIPMENT
Passenger's Seat Removal 3) Footpegs

1. To unlock latch, pull the passenger's The operator footpegs are located on
seat latch lever toward the front of the RH and LH side of the vehicle.
the seat.
vmo2015-005-029_a
TYPICAL - 1-UP SHOWN

1. Operator's LH footpeg
vmo2015-005-054_c
1. Seat handle WARNING

Operator must have both feet on
2. While maintaining latch lever pulled footpegs at all time during vehicle
towards the front, apply downward operation.
pressure on the back of latch lever
to clear rear latch from pin and tog-
gle seat towards front using back- 2-UP Models
rest. The passenger footpegs are located on
3. Pull seat rearward and up out of lo- the RH and LH side of the vehicle be-
cation to clear the front tabs. hind the operator footpegs.
Passenger's Seat Installation

1. Ensure the latch lever is in the open
position by pulling it towards the
front of seat.
2. Using a forward motion, insert both
front tabs of the seat into the vehicle
anchor housings.
3. Rotate downwards to engage the
rear latch.
4. Close the latch lever by pushing it vmo2015-005-008_a
rearwards to secure seat in posi- TYPICAL
tion. 1. Operator's LH footpeg
5. Check if the seat is firmly secured in 2. Passenger's LH footpeg
position before using it.
WARNING
WARNING Passenger must have both feet on
It is of the upmost importance for footpegs at all time during vehicle
the passenger's safety that you operation.
confirm that the passenger's seat
is properly locked in position by
98 ______________
EQUIPMENT
4) Grab Handles (2-UP Remove protective cap to use. Always

Models) reinstall it after use to protect against
weather.
The grab handles are located on the RH
and LH side of the passenger's seat. Do not exceed the rating capacity. Re-
fer to FUSES in MAINTENANCE.
The grab handles must be used by the
passenger to hold on firmly during vehi-
cle operation. 6) Rear Storage
Compartment
WARNING Convenient location to carry personal
The passenger must always hold articles.
on to the passenger grab han-
dles, not the operator. He must
also have both feet resting firmly
against the footrests.
vmo2015-005-009_a
1. Rear storage compartment cover
WARNING
Always engage the PARK position
on the shift lever before opening
vmo2015-005-054_d
cover. Never leave any heavy or
TYPICAL loose breakable objects in the stor-
1. Grab handles
2. Passenger's seat age area. Always latch cover be-
fore riding.
5) 12-Volt Power Outlet
To Open Rear Storage
Convenient for handheld spotlight or Compartment
other portable equipment.
Unlatch cover and gently lift cover.
vmo2015-005-009_a
vmo2012-012-018_a 1. Rear storage compartment latch
1. 12 V power outlet
_______________ 99
EQUIPMENT
To Close Rear Storage ufacturer recommendations. Refer to

Compartment SPECIFICATIONS for carrying loads
Gently lower and latch cover. and towing recommendations.
7) Cargo Racks
Cargo racks are convenient for carry-
ing equipment and various other cargo.
They must never be used to carry a
passenger.
vmo2015-005-038_a
TYPICAL
1. Trailer hitch
WARNING
Ensure to install the proper ball
size that matches the equipment
you will tow.
vmo2015-005-002_a
NOTE: Follow manufacturer's instruc-
tions for proper attachment.
TYPICAL
1. Front cargo rack
2. Rear cargo rack 9) Tool Kit
The tool kit is located under seat. It
WARNING contains tools for basic maintenance.
– Never carry a passenger on a
cargo rack.
– Cargo must never interfere with
the drivers line of sight or affect
his ability to properly steer the
vehicle.
– Do not overload the vehicle.
– Always ensure all cargo is prop-
erly secured and does not ex-
tend out pass the racks. vmo2015-005-026_a
1. Tool kit
Refer to SPECIFICATIONS for cargo
weight recommendations. 10) Recovery Hooks
Convenient hook that can be use to re-
8) Trailer Hitch cover a stuck ATV.
Convenient hitch to install a ball to tow
a trailer or other equipment. Install
the proper ball size as per trailer man-
100 ______________
EQUIPMENT
vmo2015-005-012_a
1. Front recovery hook
vmo2015-005-010_a
1. Recovery hook
______________ 101
ADDITIONAL ACCESSORIES
Some models are equipped with factory installed accessories.
vmo2016-029-006_b
1) Full Underbody WARNING

Aluminum Skid Plate Never drive vehicle with portable
Aluminum plates provide essential pro- light on.
tection.
NOTE: In some regions, restrictions
may apply to the usage of portable
light when gun boot is installed on ve-
hicle. Refer to local laws before using
spotlight.
vmo2016-029-004_a
1. Full underbody skid plate
2) Portable Light
A convenient 12 V powered spotlight
that can easily be moved around to pro- vmo2016-029-002_a
vided additional lighting on the spot. 1. Portable light
2. 12V power outlet
102 ______________
NOTICE Remove portable light Installing Gun Boot Into Gun Boot
and store when transporting vehi- Mount
cle. Install gun boot into gun boot mount.
WARNING Insert pin into gun boot support and
gun boot.
Do not operate the vehicle with
the spotlight or coil cable obstruct-
ing or interfering with the driver
and/or the operation of the vehicle
control devices. Do not use this
light while the vehicle is in mo-
tion, as it may blind other vehicles
drivers.
3) Gun Boot
vsi2012-105-040_a
This easy access gun boot is designed 1. Bent plate of gun boot support
to accommodate a variety of rifle and
shotguns along with their mods. Install lock onto pin.
NOTE: In some regions, gun boot
should be removed from vehicle out-
side of hunting season. Refer to local
laws.
vsi2012-105-039_a
1. Locked pin
Secure rear section of gun boot using

vmo2016-029-005_a locking pin.
GUN BOOT IN POSSIBLE INSTALLATION Insert pin into rear section of gun boot.
LOCATIONS
Install lock onto pin.
NOTICE Remove gun booth when
transporting vehicle.
WARNING
Reduce your speed while firearm
case is installed on vehicle.
NOTICE Avoid areas with a lot of

branches. If avoiding such areas is
impossible, make sure branches do
not hit the firearm case.
______________ 103
tsi2012-076-004_a
1. Rear section of Gun Boot

2. Pin
3. Lock
4) Gear Grips
These durable and flexible grips allow
for easy transportation of tools, bows,
and other implements.
vmo2016-029-001_a
TYPICAL
1. Close grips to hold item.
2. Press button to release grips.
Rotating the Gear Grips

NOTE: Gear grip can be rotated to
360°. To do so, simply remove the
U-clip by pushing on the plastic tabs
toward exterior side and pulling on
the U-clip. Rotate the gear grip into its
vmo2016-029-003_a mounting base.
1. Gear grips
NOTICE Failure to apply small
Using the Gear Grips pressure toward exterior side to the
plastic tabs may result in damage to
Close grip to hold item and press but- the U-clip.
ton to release grip.
104 ______________
The following tips will help to reduce

the risk of discharging the battery:
Always unreel manually: Unlock the
cable using the handle then pull on the
hook strap to unreel.
It is recommended to let the vehicle
run while winching. Do not stop vehi-
cle immediately after winching to let
battery recharge.
Also, when winching for more than
tsi2012-078-006_a 30 seconds, it is recommended to in-
TYPICAL crease engine RPM in the range of
1. Plastic tabs 3000 RPM to increase charging power
to the battery.
WARNING NOTE: Make sure vehicle is in NEU-
Use gear grips in pair. Gear grips TRAL (N) before increasing engine
should always be installed so the RPM.
dual arms are facing toward driver.
Do not use gear grip to support or 6) Roller Fairlead
hold heavy objects. Objects can The roller fairlead is used to prevent
dislodge from the grip when riding damages to the vehicle and guide the
fast or in a bumpy trail. Reduce wire rope into the winch.
your speed and often verify if gear
remains in place. Ensure objects
loaded do not extend wider than
the vehicle width.
5) Winch
The winch can be actuated using the
winch control switch or with the re-
mote control (sold separately).
219001733-002_a
1. Winch
2. Roller fairlead
3. Winch hook
4. Hook strap
219001733-002_a
1. Winch
2. Roller fairlead
3. Winch hook
4. Hook strap

charge the battery.
______________ 105
FUEL
Fuel Requirements Use of fuel labeled E15 is prohibited by
U.S. EPA Regulations.
NOTICE Always use fresh gaso-
line. Gasoline will oxidize; the re- Vehicle Fueling Procedure
sult is loss of octane, volatile com-
pounds, and the production of gum
and varnish deposits which can WARNING
damage the fuel system. – Fuel is flammable and explosive
Alcohol fuel blending varies by coun- under certain conditions.
try and region. Your vehicle has been – Never use an open flame to
designed to operate using the recom- check fuel level.
mended fuels, however, be aware of – Never smoke or allow flame or
the following: spark in vicinity.
– Use of fuel containing alcohol above – Always work in a well-ventilated
the percentage specified by gov- area.
ernment regulations is not recom-
mended and can result in the fol- 1. Stop engine.
lowing problems in the fuel system
components: WARNING
• Starting and operating difficul-
ties. Always stop engine before refuel-
ing.
• Deterioration of rubber or plastic
parts.
• Corrosion of metal parts. 2. Have operator get off vehicle.
• Damage to internal engine parts.
– Inspect frequently for the presence WARNING
of fuel leaks or other fuel system Do not allow anyone to remain on
abnormalities if you suspect the the vehicle while fueling. If there is
presence of alcohol in gasoline ex- a fire or explosion during fueling, a
ceeds the current government reg- vehicle occupant could be unable
ulations. to quickly leave the area.
– Alcohol blended fuels attract and
hold moisture which may lead to 3. Unscrew slowly the fuel reservoir
fuel phase separation and can result cap counterclockwise to remove it.
in engine performance problems or
engine damage.
Recommended Fuel
Use common unleaded gasoline with
an AKI (R+M)/2 octane rating of 87, or
an RON octane rating of 92.
NOTICE Never experiment with
other fuels. Engine or fuel system
damages may occur with the use of
an inadequate fuel.
NOTICE Do NOT use fuel from fuel vmo2015-005-027_a
pumps labeled E85. 1. Fuel reservoir cap
106 ______________
FUEL
WARNING
If a differential pressure condition
is noticed (whistling sound heard
when loosening fuel reservoir cap)
have vehicle inspected and/or re-
paired before further operation.
4. Insert the spout into the filler neck.

5. Pour fuel slowly so that air can es-
cape from the tank and prevent fuel
flow back. Be careful not to spill
fuel.
6. Stop filling when the fuel reaches
the bottom of filler neck. Do not
overfill.
WARNING
Never top up the fuel tank before
placing the vehicle in a warm area.
As temperature increases, fuel ex-
pands and may overflow.
7. Fully tighten fuel reservoir cap clock-

wise.
WARNING
Always wipe off any fuel spillage
from the vehicle.
______________ 107
BREAK-IN PERIOD
Operation During Break-In
A break-in period of 10 operating hours
or 300 km (200 mi) is required for the
vehicle.
Engine
– Avoid full throttle operation
– Maximum throttle should not ex-
ceed 3/4
– Avoid sustained accelerations
– Avoid prolonged cruising speeds
– Avoid engine overheating.
However, brief accelerations and
speed variations contribute to a good
break-in.
NOTE: It is normal that the engine will
not operate at its maximum efficiency
until the break-in period is completed.
Brakes
WARNING
New brakes will not operate at
their maximum efficiency until
their break-in is completed. Use
extra caution.
Drive Belt
A new drive belt requires a break in pe-
riod of 50 km (30 mi).
– Avoid strong acceleration and decel-
eration
– Avoid pulling a load
– Avoid high speed cruising.
108 ______________
BASIC PROCEDURES
Starting the Engine Stopping the Engine and
The shift lever must be set to PARK or Parking the Vehicle
NEUTRAL.
NOTE: For your convenience, an over- WARNING
ride mode allows the engine to be Avoid parking on steep slope as
started with the shift lever in any po- the vehicle may roll away.
sition. Press and hold the brake lever
or the brake pedal while pressing the
engine start button. WARNING
Insert key in ignition switch and turn to Always put the vehicle in PARK
ON position. when stopped or parked to pre-
vent rolling.
Set the emergency engine stop switch
to RUN.
Press the engine start button and hold WARNING
until the engine starts. Avoid parking in places where hot
Release the engine start button imme- parts can start a fire.
diately when the engine has started.
When stopped or parked always bring
NOTICE If engine does not start shift lever to park position. This is es-
after a few seconds, do not hold the pecially important when parking on
engine start button more than 10 a slope. On very steep inclines or
seconds. Refer to TROUBLESHOOT- if the vehicle is carrying a cargo, the
ING section. wheels should be blocked using rocks
or bricks.
Operating the Shift Lever Select the flattest terrain available for
Apply brakes and immobilize vehicle, parking.
then select the desired shift lever posi-
Release throttle and use brakes to
tion.
completely stop the vehicle.
Release brakes.
Set shift lever in PARK position.
NOTICE When changing gear se- Turn key in ignition switch to OFF posi-
lection, always completely stop the tion.
vehicle and apply the brakes prior
Remove key from ignition switch.
to moving the shift lever. Otherwise
damage to the gearbox may occur. If you must park on a steep incline or if
the vehicle is carrying cargo, block the
Gradually press the throttle lever to wheels using rocks or bricks.
increase engine speed and thus en-
gaging the continuously variable trans-
mission (CVT).
At the opposite, when the throttle
lever is released, the engine speed
decreases.
______________ 109
SPECIAL PROCEDURES
What to Do if Water Entered 450 Models
the CVT Reinstall slotted hexagonal 15 mm
The CVT drain plug is located on the (19/32 in) drain plug.
CVT cover. It is accessible from the
rear LH fender.
570 Models
Reinstall the drain plug and secure it
450 Models using the spring clamp.
Remove the CVT drain plug to validate NOTE: Make sure hose is properly in-
if water is present. serted on CVT cover nipple.
NOTICE See an authorized
Can-Am dealer to have the CVT in-
spected and cleaned.
What to Do if Water Entered

the Air Filter Housing
Remove the LH side panel.
Inspect the drain reservoir underneath
the air filter housing to validate if water
is present.
vmo2015-005-301_a
450 MODELS
1. CVT drain plug
570 Models
Inspect the CVT drain plug to validate if
water is present.
If water is present, remove CVT drain
plug to expel water.
vmo2012-012-054_a
TYPICAL
1. Air filter housing drain reservoir
If water is present, press clamp and re-

move reservoir to drain water from air
filter housing.
If one of the following conditions is
met, bring the vehicle to your nearest
authorized Can-Am dealer to have the
vmo2015-005-303_a
vehicle serviced:
570 MODELS
– If more than 50 ml (2 U.S. oz) of
1. CVT drain plug water (approximately 5 drain reser-
voirs) is found in the air filter hous-
All Models ing.
– If any deposits are present in the
NOTICE If water is present in the drain reservoir.
CVT, it could result in belt slippage.
The engine will accelerate but the
vehicle will remain still.
110 ______________
SPECIAL PROCEDURES
In such a case, the vehicle must be ser- Whenever the vehicle is turned over, it
viced for: should be inspected by an authorized
– Vents Can-Am dealer.
– CVT cleaning
– Fuel tank breather replacement What to Do if Vehicle is
– Lubricant inspection and replace- Immersed in Water
ment as required (engine, gearbox Should the vehicle become immersed,
and rear final drive). immediately stop the engine. Do not
use:
NOTICE Failure to have vehicle
– Any electrical equipments
serviced may lead to permanent
damage to the following compo- – Winch (if equipped)
nents but not limited to: It will be necessary to take the vehi-
– Engine and gearbox cle to an authorized Can-Am dealer as
– Fuel pump soon as possible. NEVER ATTEMPT
TO START THE ENGINE!
– CVT
– Front differential NOTICE Immersion of the vehi-
– Rear final drive. cle can cause serious damage if the
correct restart procedure is not fol-
What to Do if Vehicle is lowed.
Turned Over As soon as vehicle is pulled out of wa-
When vehicle is turned over or stays ter, carry out the following:
tilted on the side, put the vehicle back – Drain CVT. See procedure in WHAT
on its wheel. Inspect vehicle for dam- TO DO IF WATER IS IN THE CVT.
ages. – Drain air filter housing. Refer to
WHAT TO DO IF WATER ENTERED
WARNING THE AIR FILTER HOUSING in this
Never operate the vehicle if dam- section.
aged. Refer to an authorized NOTICE The vehicle should be ser-
Can-Am dealer. viced as soon as possible by an au-
thorized Can-Am dealer.
If vehicle has no damage, refer to
MAINTENANCE PROCEDURES sec-
tion and inspect the following.
– Inspect air filter housing for oil accu-
mulation, if any oil is found, clean air
filter and air filter housing.
– Check engine oil level and refill if
necessary.
– Check engine coolant level and refill
if necessary.
– Check gearbox oil level and refill if
necessary. (570 Models)
– Check rear final drive oil level and re-
fill if necessary.
– Start engine. If the oil pressure light
stays on, stop engine immediately.
______________ 111
TUNE YOUR RIDE
WARNING
Suspension adjustment could af-
fect vehicle handling. Always take
time to familiarize yourself with
the vehicle's behavior after any
suspension adjustment have been
made.
Suspension Adjustment
Suspension adjustment and loading vmo2015-005-040_a
can have an effect on your vehicle han- 1. Adjustment cam
dling and comfort. 2. Softer adjustment
3. Firmer adjustment
Choice of suspension adjustments
vary with driver's weight, personal
preference, riding speed and field con- Dynamic Power Steering
dition. (DPS) Assist Level
Adjustment
Spring Preload Adjustment
All Models Except Base Models
WARNING The Tri-Mode Dynamic Power Steering
(DPS) offers easy steering assistance
The left and right shock adjust- to the rider. The level of assistance
ment on front or rear suspension will automatically adapt according to
must always be set to the same the vehicle's speed and rider’s de-
position. Never adjust one only. mand, in order to provide maximum
Uneven adjustment can cause steering power at lower speed where
poor handling and loss of stability, the demand is normally higher. As
which could lead to an accident. speed increases, the assistance is pro-
gressively reduced to keep maximum
Shorten the springs for a firmer ride steering feel and precision to the rider.
and rough conditions.
It is possible to choose between three
Lengthen the springs for a softer ride modes of assistance: Minimum,
and smooth conditions. Medium and Maximum. Each mode
Adjust spring preload by turning adjust- will continue to automatically adapt
ment cam. Use tool from vehicle tool to the vehicle’s speed and rider’s de-
kit. mand, so it does not require to be
changed when riding. These modes
are used to set the level of assistance
to match each rider's preferences.
The following DPS modes are preset in
the vehicle.
112 ______________
TUNE YOUR RIDE
DPS MODE NOTE: The DPS adjustment will not

be possible if the vehicle gearbox is set
DPS to REVERSE.
Maximum steering assist
MAX.
DPS
Medium steering assist
MED.
DPS
Minimum steering assist
MIN.
To show the active DPS mode, pro-

ceed as follows:
1. Press and release DPS button.
vmo2010-004-003_a
1. DPS button
2. Check the multifunction gauge to

confirm the active DPS mode.
1. DPS mode display
To change the DPS mode, proceed as

follows:
1. Press and hold DPS button for 2 sec-
onds to go to the next setting.
2. Release DPS button.
3. Repeat until desired setting is se-
lected.
______________ 113
VEHICLE TRANSPORTATION
When transporting this vehicle, secure
it to a trailer or in pickup box with suit-
able tie-downs. Use of ordinary ropes
is not recommended.
WARNING
Do not tow this vehicle behind a
car or other vehicle. Use a trailer.
Never tip this vehicle on end for
transporting. The vehicle must be
in its normal operating position
vmo2015-005-013_a
(on all four wheels).
1. Rear tie-down point location
NOTICE Securing vehicle at other

locations may damage the vehicle.
V00A17Y
Remember to:
– Unload vehicle racks before trans-
portation.
– Set shift lever to PARK position.
– Set the parking brake.
– Secure the vehicle by the front and
rear tie-down points.
vmo2015-005-012_a
114 ______________
MAINTENANCE
______________ 115
Maintenance is very important for keeping your vehicle in safe operating condition.
The vehicle should be serviced as per the maintenance schedule.
A repair shop or person of the owner's choosing may maintain, replace, or repair
emission control devices and systems. These instructions do not require compo-
nents or service by BRP or authorized Can-Am dealers. Although an authorized
Can-Am dealer has an in-depth technical knowledge and tools to service the
Can-Am ATV, the emission-related warranty is not conditioned on the use of
an authorized Can-Am dealer or any other establishment with which BRP has a
commercial relationship. For emission-related warranty claims, BRP is limiting
the diagnosis and repair of emission-related parts to the authorized Can-Am
dealers. For more information, please refer to the US EPA EMISSION-RELATED
WARRANTY contained herein. Proper maintenance is the owner’s responsibility.
A warranty claim may be denied if, among other things, the owner or operator
caused the problem through improper maintenance or use.
You must follow the instructions for fuel requirements in the fueling section of
this manual. Even if gasoline containing greater than ten volume percent ethanol
is readily available, the US EPA issued a prohibition against the use of gasoline
containing greater than 10 vol% ethanol that applies to this vehicle. The use of
gasoline containing greater than 10 vol% ethanol with this engine may harm the
emission control system.
The following message appears in the gauge after every 50 hours of operation, to
remind you of maintenance requirements: MAINTENANCE REQUIRED. To erase
message, refer to the appropriate MULTIFUNCTION GAUGE section.
WARNING
Failure to properly maintain the vehicle according to the maintenance
schedule and procedures can make it unsafe to operate.
SEVERE DUSTY CONDITIONS

Air filter maintenance must be increased in frequency in the following dusty condi-
tions:
NOTE: Riding in a group in these conditions would increase even more the air filter
maintenance.
MAINTENANCE SCHEDULE LEGEND

116 ______________
Make sure to perform proper maintenance at recommended intervals as indicated
in the tables. Some items of the maintenance schedule must be performed in
function of the calendar, regardless of the distance or time of operation.
Lubricate rear propeller shaft joint

Verify gearbox oil level and look for contamination (570)
______________ 117
PERFORM AT THE FIRST 3 000 KM (2,000 MI)AND AT 6 000 KM (4,000 MI)

Replace gearbox oil (570)
Clean the vehicle speed sensor (VSS) (570)

Replace spark plugs
Replace gearbox oil (570 only)

118 ______________
MAINTENANCE PROCEDURES
This section includes instructions for Air Filter Removal
basic maintenance procedures. I
NOTICE Never remove or mod-
ify any component in the air filter
WARNING housing. Otherwise, engine perfor-
Unless otherwise indicated, al- mance degradation or damage can
ways turn ignition switch to OFF occur. The engine is calibrated to
position and remove key before operate specifically with these com-
performing any maintenance. ponents.
Remove seat.
WARNING Lift rear portion of console upwards
Should removal of a locking de- until the studs are released from the
vice be required (e.g. lock tab, grommets.
self-locking fastener, etc.), always
replace it with a new one.
Air Filter
Air Filter Maintenance Guideline
As with any ATV, air filter maintenance
is critical to ensure proper engine per-
formance and life span.
Air filter maintenance should be ad-
justed according to riding conditions. vmo2015-005-021_a
Air filter maintenance must be in- TYPICAL

creased in frequency and oil must be 1. Console
added to the foam filter for the follow- 2. Studs and grommets
ing dusty conditions: Pull console rearwards.
– Riding on dry sand.
Rotate air filter cover counterclock-
– Riding on dry dirt covered surfaces. wise to remove.
– Riding on dry gravel trails or similar
conditions. NOTE: A socket wrench may be used
to ease removal.
NOTE: Riding in a group in these con-
ditions would increase even more the
air filter maintenance. Refer to AIR FIL-
TER CLEANING AND OILING for main-
tenance procedure.
NOTE: An accessory pre-filter for
"dusty conditions" may be used. Con-
tact an authorized Can-Am dealer for
details.
vmo2015-005-014_a
1. Air filter cover
Remove air filter.
______________ 119
vmo2015-005-015_a vmr2012-010-017_b
AIR FILTER REMOVAL TYPICAL - SOME PARTS REMOVED FOR

CLARITY
Engine Air Filter Housing Inspection 1. Air filter drain tube
and Draining
Air Filter Cleaning and Oiling
1. Remove LH side panel.
2. Drain air filter housing inlet drain
tube. CAUTION Always wear ap-
Chemicals can cause a skin rash and
eye injury.
Paper Filter Cleaning
1. Ensure that the foam filter is re-
moved from paper filter.
2. Tap out heavy dust from the paper
filter.
This will allow dirt and dust to get out of
the paper filter.
vmr2012-010-017_a
NOTE: Paper filter have a limited
life span; replace filter if too dirty or
CLARITY clogged.
1. Air filter housing inlet drain tube
NOTICE It is not recommended to
3. Check air filter dirty chamber for blow compressed air on the paper
cleanliness. filter; this could damage the paper
– If any debris or water are found, fibers and reduce its filtration ability
clean air filter chamber using a when used in dusty environments.
vacuum cleaner. NOTICE Do not wash the paper fil-
NOTICE Do not blow compressed ter with any cleaning solution.
air into air filter chamber. Foam Filter Cleaning
4. Check air filter drain tube (clean 1. Spray the foam filter inside and out
chamber). with a good air filter cleaner and fol-
– If any debris or water are found, low manufacturer's instructions.
refer to SPECIAL PROCEDURES.
– Investigate for contamination
source.
120 ______________
vbs2009-012-015_a
219700340
TYPICAL - SPRAY THE FOAM FILTER
AIR FILTER OIL (P/N 219 700 340)
vbs2009-012-014
vbs2009-012-005
TYPICAL - DRY TYPICAL - OIL THE FOAM FILTER
NOTE: A second application may be 3. Let stand for 3 to 5 minutes.

necessary for heavily soiled elements. 4. Remove any excess of oil that
could transfer to the paper filter by
Foam Filter Oiling wrapping the foam filter into an ab-
1. Make sure filter is clean. Refer to sorbent cloth and squeezing gently.
FOAM FILTER CLEANING. This will also ensure a full oil cover-
age on foam filter.
2. Spray AIR FILTER OIL (P/N 219 700
340) or equivalent on the foam filter 5. Reinstall the foam filter over the pa-
previously dried. per filter.
vbs2009-012-001
TYPICAL
______________ 121
Air Filter Installation Engine Oil

Slightly grease O-ring seal and plastic
body of air filter. Engine Oil Level
Install air filter as the reverse of re- NOTICE Check level frequently
moval. and refill if necessary. Do not over-
Ensure air filter cover is properly locked fill. Operating the engine/gearbox
onto the air filter housing. See indica- with an improper level may severely
tions on filter cover and housing. damage engine/gearbox. Wipe off
any spillage.
NOTE: While checking the oil level, vi-
sually inspect engine area for leaks.
vmo2015-005-014_b
1. Cover position arrow

2. Locked
3. Unlocked
Install console as the reverse of re- vmr2015-008-100_a

moval. However, pay attention to the 450 MODEL - RH SIDE OF ENGINE
following. 1. Dipstick
Align console front tabs with slots,
then push console forward.
Then align and insert studs with grom-
mets on rear portion of console until
studs engage with grommets.
vmr2015-063-100_a
570 MODEL - RH SIDE OF ENGINE

1. Dipstick
NOTE: Do not lose the O-ring placed

vmo2015-005-021_a
on the dipstick.
TYPICAL With vehicle on a level surface and en-
1. Console gine cold, not running, check the oil
2. Studs and grommets level as follows:
1. Unscrew dipstick then remove it
and wipe clean.
122 ______________
2. Reinstall dipstick, screw in it com- RECOMMENDED ENGINE OIL

pletely. (ALL SEASON)
3. Remove and check oil level. It
should be near or equal to the up- Finland,
Norway
XPS 4-STROKE
per mark. SYNTHETIC OIL (F)
and
Sweden (P/N 619 590 114)
All other
XPS 4-STROKE
countries
SYNTHETIC OIL
(P/N 293 600 112)
NOTE: The XPS oil is specially formu-

lated and tested for the severe require-
ments of this engine. BRP recom-
1 mends the use of its XPS 4-stroke oil.
3 If XPS engine oil is not available, use
2 a 4-stroke SAE 5W40 engine oil that
meets or exceeds the requirements
for API service classification SJ, SL,
SM or SN. Always check the API ser-
vice label certification on the oil con-
V07C02Y
tainer it must contain at least one of
TYPICAL the above standards.
1. Full
2. Add NOTICE Damages caused by the
3. Operating range use of oil not suitable for this engine
may not be covered by the BRP lim-
To add oil, remove dipstick. Place a ited warranty.
funnel into the dipstick tube to avoid
spillage. Engine Oil Change
Add a small amount of recommended Start and warm-up engine. Stop en-
oil and recheck oil level. gine.
Repeat the above procedures until Ensure vehicle is on a level surface.
oil level reaches the dipstick's upper
mark. Do not overfill. Remove dipstick.
Properly tighten dipstick. Clean the oil drain plug area.
Place a drain pan under the oil drain
Recommended Engine Oil plug area.
RECOMMENDED ENGINE OIL Unscrew oil drain plug.
(SUMMER)
Finland, CAUTION The engine oil can
Norway XPS 4-STROKE SYNTH. be very hot. In order to avoid poten-
and
BLEND OIL (F) (P/N 619 tial burns, do not remove the engine
Sweden
590 109) drain plug if the engine is hot. Wait
until engine oil is warm.
All other
XPS 4-STROKE SYNTH.
countries
BLEND OIL (P/N 293
600 121)
______________ 123

1. Clean oil filter area.
2. Remove oil filter cover.
vmr2015-063-101_a

CLARITY
1. Drain plug
2. Access through frame
Allow enough time for oil to flow out of

oil filter.
Replace the oil filter. Refer to OIL FIL-
TER. 1. Oil filter screw
2. Oil filter cover
Change gasket on oil drain plug. 3. O-ring
Clean gasket area on engine and oil 4. Oil filter
drain plug then reinstall plug.
Oil Filter Installation
Refill engine at the proper level with
the recommended oil. 1. Check and clean the oil filter inlet
and outlet area of dirt and other con-
Refer to SPECIFICATIONS for oil ca- taminations.
pacity.
Start engine and let idle for a few min-
utes.
Ensure oil filter area and oil drain plug
areas are not leaking.
Stop engine.
Wait a while to allow oil to flow down to
crankcase then check oil level.
Refill as necessary.
Dispose of oil as per your local environ-
mental regulations. vmr2015-063-003_a
1. Inlet bore from the oil pump to the oil filter

Oil Filter 2. Outlet bore to the engine oil providing
system
Oil Filter Removal
2. Install a NEW O-ring on oil filter
To reach oil filter, remove the following cover.
parts:
3. Install the filter into the cover.
– Seat
– Console 4. Apply engine oil on O-ring and on
end of filter.
124 ______________
Inspect radiating fins. They must be

clean, free of mud, dirt, leaves and any
other deposit that would prevent the
radiator to cool properly.
Remove as much deposits as you can
with your hands. If water is available in
proximity, try rinsing the radiating fins.
If available, use a garden hose to rinse
the radiating fins.
vmr2006-008-001_a
1. Slightly oil CAUTION Never clean radiator

2. Slightly oil with your hands when it is hot. Let
the radiator cool down before clean-
5. Install the cover on the engine. ing.
6. Tighten oil filter cover screws to rec- NOTICE Be careful not to damage
ommended specification. the radiating fins when cleaning. Do
TIGHTENING TORQUE not use any object/tool that could
damage the fins. The fins are pur-
Oil filter cover 10 N•m ± 1 N•m posely thin parts to allow efficient
screws (89 lbf•in ± 9 lbf•in) cooling. WHEN HOSING, USE LOW
PRESSURE ONLY, NEVER USE A
7. Reinstall remaining parts if applica- HIGH PRESSURE WASHER.
ble.
See an authorized Can-Am dealer, re-
Radiator pair shop or person of your own choos-
ing to check the performance of the
Radiator Inspection cooling system.
Periodically check the radiator area for Engine Coolant
cleanliness.
Engine Coolant Level Verification
WARNING
Check coolant level with engine
cold. Never add coolant in cooling
system when engine is hot.

Remove the gauge support.
vmo2012-012-041
Inspect radiator and hoses for leaks or

any damage.
219001850-700
______________ 125
Remove engine coolant reservoir cap. Recommended Engine Coolant

With vehicle on a level surface, liquid NOTICE Always use ethylene-gly-
should be between MIN. and MAX. col antifreeze containing corrosion
level marks of coolant reservoir. inhibitors specifically for internal
combustion aluminum engines.
RECOMMENDED
COUNTRY
COOLANT
Finland, Norway
LONG LIFE
and Sweden
ANTIFREEZE
(P/N 219 702 685)
All other
LONG LIFE
countries
ANTIFREEZE(F)
(P/N 619 590 204)
vmo2015-005-017_a
Distilled water
and antifreeze
1. Engine coolant reservoir Alternative, or if
solution (50%
not available
NOTE: When checking level at tem- distilled water,
perature lower than 20°C (68°F), it may 50% antifreeze)
be slightly lower than MIN. mark.
Add coolant if required. Engine Coolant Replacement
Cooling System Draining
WARNING Remove the gauge support.
Warning: Do not remove the
coolant reservoir cap if engine is Remove the coolant reservoir cap.
hot.
WARNING
Use a funnel to avoid spillage. Do not Warning: To avoid potential burns,
overfill. do not remove the pressure cap if
Properly reinstall and tighten reservoir the engine is hot.
cap.
WARNING
In order to avoid potential burns,
do not remove the radiator cap if
the engine is hot.
NOTE: A cooling system that fre-

quently requires coolant is the indica-
tion of leaks or engine problems. See
an authorized Can-Am dealer.
vmo2015-005-017_a
1. Engine coolant reservoir cap
126 ______________
Unscrew the coolant drain plug and

drain the coolant into a suitable con-
tainer.
vmr2015-008-103_a
TYPICAL
vmr2015-016-105_a

CLARITY
NOTE: Do not unscrew the coolant

drain plug completely.
Disconnect the lower radiator hose
and drain the remaining coolant into a
suitable container.
NOTE: Take note of the position of the
hose clamp on the lower radiator hose tmo2011-001-502_a
at the radiator.
TYPICAL - 570 MODELS ONLY
Reinstall radiator hose as noted prior to 1. Rear cylinder bleed screw
removal.
2. Fill the cooling system until coolant
Reinstall cooling system drain plug comes out of the bleed screw.
with a new gasket ring.
3. Squeeze the top of the coolant hose
Tighten the coolant drain plug. between the radiator and coolant
TIGHTENING TORQUE pump several times until all air is
bled from the highest point of the
Cooling hose.
9 N•m to 11 N•m
system drain 4. Install the bleed screw using a NEW
(80 lbf•in to 97 lbf•in)
plug gasket ring and tighten to specifica-
tion.
Bleed cooling system, refer to COOL-
ING SYSTEM FILLING AND BLEED- TIGHTENING TORQUE
ING.
5.0 N•m ± 0.6 N•m
Bleed screws
Cooling System Filling and Bleeding (44 lbf•in ± 5 lbf•in)
1. Unscrew bleed screws above both 5. Continue adding coolant until sys-
front and rear cylinders. tem is full up to the pressure cap.
6. Refill coolant tank up to MAX level
mark.
______________ 127
7. Run engine at idle with the radiator

cap off. Slowly add coolant if neces-
sary.
8. At this point, wait until engine
reaches normal operating tempera-
ture.
9. Depress the throttle lever two or
three times; then add coolant if re- vmo2015-005-037_a
quired.
TYPICAL
10. Stop the engine and let it cool 1. Muffler
down. 2. Clean out plug
11. Install coolant reservoir cap. Block the end of the muffler with a
12. Inspect all connections for leaks shop rag and start engine.
and check coolant level in the Momentarily increase engine RPM
reservoir. several times to purge accumulated
carbon out of the muffler.
Muffler Spark Arrester Stop engine and allow muffler to cool.
The muffler must be periodically Reinstall the clean out plug.
purged of accumulated carbon.
Gearbox Oil (570 Models)
WARNING
Never run engine in an enclosed Recommended Gearbox Oil
area. Never perform this opera-
tion immediately after the engine RECOMMENDED
QUANTITY
has been run because exhaust sys- PRODUCT
tem is very hot. Make sure that XPS SYNTHETIC
there are no combustible mate- Approximately
GEAR OIL 450 ml
rials in the area. Wear eye pro- (75W 140)
tection and gloves. Never stand (15 U.S. oz)
(P/N 293 600 140)
behind the vehicle while purging
exhaust system. Respect all appli- If the recommended oil is not available,
cable laws and regulations. use a 75W140 gearbox oil that meets
the API GL-5 specification.
Select a well-ventilated area and make
sure the muffler is cool. Gearbox Oil Level Verification
Place gearbox on PARK position. NOTE: Prior checking the gearbox oil
Remove the clean out plug of the muf- level, ensure vehicle is on a level sur-
fler. face.
1. To access gearbox oil level plug, re-
– Seat
– Console
128 ______________
5. Remove magnetic drain plug and

sealing ring. Discard sealing ring.
WARNING
The gearbox oil can be very hot.
6. Remove oil level plug and its O-ring.

NOTE: Allow oil to completely flow
out of gearbox.
vmr2015-063-102_a
1. Oil level plug
2. Remove the gearbox oil level plug.
vmo2012-012-056_a

2. Oil level plug
7. Clean magnetic drain plug and pay

vmo2012-012-056_a
attention to any debris present on
drain plug.
1. Drain plug
2. Oil level plug NOTE: Presence of excessive debris
provides an indication of a gearbox
3. Check oil level. problem.
The oil should be level with the bottom 8. Reinstall magnetic drain plug with
of the oil level hole. a NEW sealing ring and tighten to
specification.
NOTICE Operating the gearbox
with an improper oil level may se- TIGHTENING TORQUE
verely damage gearbox.
20 N•m ± 2 N•m
Drain plug
Gearbox Oil Replacement (15 lbf•ft ± 1 lbf•ft)
Gearbox Oil Draining Procedure 9. Dispose gearbox oil as per your local
1. Start engine and operate vehicle to environmental regulations.
warm-up the gearbox oil. Gearbox Oil Filling Procedure
NOTE: Running engine at idle is not 1. Fill the gearbox through the oil level
sufficient, vehicle gearbox must be op- hole until the oil reaches the bottom
erated. of the oil level hole.
2. Position vehicle on a level surface. 2. Install the oil level plug with its
3. Place a drain pan under the gearbox O-ring. Tighten plug to specifica-
drain plug area. tion.
4. Clean drain plug area.
______________ 129
TIGHTENING TORQUE
5 N•m ± 0.6 N•m
Oil level plug
Throttle Cable
Throttle Cable Lubrication
The throttle cable must be lubricated
with silicone based lubricant or an
equivalent. V07I0GY 1 2 3 4
WARNING 1. Cable protector

Always use a silicone-based lubri- 3. Lock nut
cant. Using another lubricant (like 4. Throttle lever housing
a water-based lubricant) could Screw in the throttle cable adjuster.
cause the throttle lever/cable to
become sticky and stiff. Remove inner housing protector.
V07I0HY 1
V07I0FY
Remove the cable from the throttle
1. Remove these screws lever housing.
NOTE: Slide cable in clip slot and re-
Separate the housing. move the end of cable from clip.
130 ______________
V07I0JY
V07I0IY TYPICAL
NOTE: Place a rag around the throttle

Remove the throttle body side cover. cable adjuster to prevent the lubricant
from splashing.
Add lubricant until it runs out at throttle
body end of the throttle cable.
Reinstall and adjust the cable.
Throttle Cable Adjustment

vmo2006-007-032_a
1. Throttle body
2. Side cover screws
Insert the needle of the lubricant can in

the end of throttle cable adjuster.

Chemicals can cause a skin rash and V07I0GY 1 2 3 4
eye injury. 1. Cable protector
3. Lock nut
Loosen lock nut then turn the adjuster

to obtain correct throttle lever free play.
Measure throttle free play at the tip of
throttle lever.
______________ 131
570 Models Only
vmo2015-005-020_b
A. 2 mm (.079 in) 219001737-010_a
Tighten lock nut and reinstall protector. RH SIDE — REAR CYLINDER

1. Spark plug
With the shift lever on PARK position,
start the engine. All Models
Check if the throttle cable is adjusted
correctly by turning handlebar fully to
the right then fully to the left. If the
engine RPM increases, readjust the
throttle lever free play.
Spark Plugs
Spark Plug Access
Remove side panels.
Unplug spark plug cable(s). 219001737-011_a
LH SIDE — FRONT CYLINDER

Spark Plug Removal 1. Spark plug
Unscrew spark plugs one turn. Spark Plug Installation

Prior to installation, make sure that
CAUTION Always wear safety contact surfaces of cylinder heads and
goggles when using pressurized air. spark plugs are free of grime.
Clean spark plugs and cylinder heads Using a feeler gauge, set the spark plug
with pressurized air if possible. gap.
Unscrew spark plugs completely us-
ing a spark plug socket, then remove SPARK PLUG GAP
them. 0.7 mm - 0.9 mm
450
(.028 in - .035 in)
0.7 mm to 0.8 mm
570
(.028 in to .031 in)
Apply a small amount of copper-based

anti-seize lubricant over spark plug
threads to prevent a possible seizure.
132 ______________
Screw spark plugs into cylinder heads

by hand and tighten with a torque
wrench and a proper socket.
CAUTION Do not overtighten

spark plugs, engine damage can oc-
cur.
TIGHTENING TORQUE
20 N•m ± 2.4 N•m
Spark plug
(15 lbf•ft ± 2 lbf•ft) vmo2015-005-018_a
1. Battery holder
2. Retaining screws
Battery
Battery Cleaning
CAUTION Never charge a bat- Clean battery, battery casing and bat-
tery while installed in vehicle. tery posts using a solution of baking
soda and water.
These vehicles are equipped with a
VRLA battery (Valve Regulated Lead Remove corrosion from battery cable
Acid). It is a maintenance-free type terminals and battery posts using a
battery, there is no need to add water firm wire brush.
to adjust electrolyte level.
NOTICE Never remove the battery
Battery installation is the reverse of the
sealing cap. removal procedure.
Battery Removal NOTICE Always connect RED (+)
Disconnect BLACK (-) cable first then battery cable first.
RED (+) cable.
Fuses
NOTICE Always disconnect
BLACK (-) battery cable first.
CAUTION Always turn the ig-
Remove retaining screws, battery nition switch to OFF position before
holder then pull the battery out of replacing a defective fuse.
frame.
Fuse Inspection
Check if filament is melted.
If filament is melted, replace damaged
fuse, refer to FRONT FUSE BOX for lo-
cation and proper rating.
______________ 133
NOTE: Check inside fuse box cover to

1 know fuses location.
NOTICE Do not store any objects
in the front service compartment.
2
Front Fuse Box Description
FRONT FUSE BOX
R1 Fan Relay -
A15E0KY
R2 Main Relay -
TYPICAL
1. Fuse R3 Accessories Relay -
2. Check if melted
R4 Fuel Pump Relay -
NOTICE Do not use a higher rated
R8 Brake Relay -
fuse as this can cause severe dam-
age. F4 Gauge (Speedo) 10 A
Front Fuse Box Location Injectors/Ignition,

ECM,
Pull upwards and front to remove the F5
Fuel Pump,
10 A
gauge support from its location. VSS
Key Switch,
F8 Starter Solenoid, 10 A
Clock
F9 Cooling Fan 20 A
DC
Outlet/Light/Accessories,
F12 20 A
Euro Control (CE),
2WD/4WD
vmo2015-005-019_a
Fuse Links and Fuse Box 2
1. Gauge support The fuse links and fuse box 2 are lo-
cated behind the RH side panel
vmo2015-005-022_a
1. Front fuse box

2. Front fuse box cover
134 ______________
Headlight Bulb Replacement

NOTICE Never touch glass portion
of a halogen bulb with bare fingers,
it shortens its operating life. If glass
is touched, clean it with isopropyl al-
cohol which will not leave a film on
the bulb.
1. Remove cover.
2. Unplug connector.
vmr2016-132-004_a
1. Fuse links
3. Remove bulb.
vmr2015-044-004_a
FUSE BOX 2
Rear Fuse Identification vmr2015-050_010_a
FUSE LINK IDENTIFICATION 1. Cover

2. Connector
Fuse 1 Main 16 awg
4. Properly reinstall removed parts in
links 2 Fan/accessories 16 awg the reverse order of their removal.
FUSE IN FUSE BOX 2 5. Validate headlight operation.
IDENTIFICATION
Headlight Beam Aiming
DPS/ACS
Turn adjustment knobs to adjust beam
Fuse 3 (dynamic power 40 A
height and side orientation to specifica-
steering)
tion.
Lights
Always check light operation after re-
placement.
vmr2015-050_008_a
LOW BEAM
1. Adjustment knobs
______________ 135
Taillight/Brake Light Bulb

Replacement
2. Rotate light bulb counterclockwise
to remove it from taillight.
vmo2015-005-050_a
TYPICAL — FRONT OF VEHICLE

1. Drive shaft boots
2. Drive shaft protector
vmr2015-050_014_a
3. Remove bulb socket from taillight.

Installation is the reverse of the re-
moval procedure.
Drive Shaft Boot and

Protector
Drive Shaft Boot and Protector
vmo2015-005-041_a
Inspection
TYPICAL — REAR OF VEHICLE
Visually inspect drive shaft protectors 1. Drive shaft boots
and boots conditions. 2. Drive shaft protector
Check protectors for damage or rub-
bing against shafts. Wheel Bearing
Check boots for cracks, tears, leaking Wheel Bearing Inspection
grease etc.
Repair or replace damaged parts as
necessary. Apply the parking brake.
Secure vehicle on jack stands.
Push and pull the wheels from the up-
per edge to feel the play.
See an authorized Can-Am dealer if
there is any play.
WARNING
injury or death.
136 ______________
Tire Inspection
Check tire for damage and wear. Re-
place if necessary.
Do not rotate tires. The front and rear
tires have a different size. The tires are
directional and their rotation must be
kept in a specific direction for proper
operation.
Tire Replacement
Tires replacement should be per-
formed by an authorized Can-Am
tmo2011-001-131_a dealer.
TYPICAL
WARNING
Wheels and Tires – Replace tires only with the same
Tire Pressure type and size as original tires.
– For unidirectional tread pat-
WARNING tern, ensure that the tires are
installed in the correct direction
Tire pressure greatly affects vehi- of rotation.
cle handling and stability. Insuf- – Tires should be replaced, by an
ficient pressure may cause tire to experienced person, in accor-
deflate and rotate on wheel. Over- dance with tire industry stan-
pressure may burst the tire. Al- dards and tools.
ways follow recommended pres-
sure. NEVER set tire pressure
below minimum. It could cause Wheel Removal
the tire to dislodge from the rim. Place vehicle on a level surface.
Since tires are low-pressure types, Engage 4WD mode.
a manual pump should be used.
Apply the parking brake.
Check pressure when tires are cold Loosen lug nuts then lift vehicle.
before using the vehicle. Tire pres- Secure vehicle on jack stands.
sure changes with temperature and
altitude. Recheck pressure if one of Remove lug nuts then remove wheel.
these conditions has changed.
Wheel Installation
For your convenience, a pressure
gauge is supplied in tool kit. At installation, it is recommended to
apply anti-seize lubricant on threads.
Refer to SPECIFICATIONS for proper
pressure. If tires are unidirectional, make sure to
install wheel according to tire rotation.
Although the tires are specifically de-
signed for off-road use, a flat may still Carefully tighten lug nuts in a criss-
occur. Therefore, it is recommended cross sequence then tighten to speci-
to carry a tire pump and a repair kit. fication.
______________ 137
TIGHTENING TORQUE Suspension

100 N•m ± 10 N•m Front Suspension Lubrication
Wheel lug nut
Lubricate front suspension arms at
grease fittings.
NOTICE Always use the recom-
mended wheel lug nuts according to SUSPENSION GREASE
the type of wheel. Using a different
lug nut could cause damage to the BRP SUSPENSION
rim or studs. recommended GREASE
product (P/N 293 550 033)
Rear Suspension Lubrication

Lubricate rear stabilizer bar links and
pivot bushing at grease fittings.
SUSPENSION GREASE
BRP SUSPENSION
recommended GREASE
product (P/N 293 550 033)
Suspension Inspection
vmo2008-001-002_a
TYPICAL — ALUMINUM WHEEL Shock Absorbers

1. Wheel lug nut (closed end type)
Inspect shock absorber for oil leaks or
other damage.
Steering
Check tightness of fasteners.
Steering Inspection See an authorized Can-Am dealer as
necessary.
Tie-Rod Ends
Place vehicle on a level surface. Ball Joints
Apply parking brake. Place vehicle on a level surface.
Lift vehicle. Apply parking brake.
Secure vehicle on jack stands. Lift vehicle.
Inspect tie-rod boots for cracks. Secure vehicle on jack stands.
Push and pull the wheels from the front Inspect ball joint boots for cracks.
or rear edge to feel the play. Push and pull the wheels from the up-
See an authorized Can-Am dealer if per and lower edge to feel the play.
there is an abnormal play or the boot is See an authorized Can-Am dealer if
cracked. there is an abnormal play or the boot is
cracked.
WARNING
The tie-rod end must be replaced if
the boot is cracked or shows an ab-
normal play.
138 ______________
Check the brake fluid level, the reser-

voir is full when the fluid reaches of the
top of window.
Visually inspect lever boot condition.
Check for cracks, tears, etc. Replace if
damaged.
tmo2011-001-131_a
TYPICAL
WARNING
The ball joint must be replaced if
the boot is cracked or it shows an
abnormal play. vmo2012-012-046_a
TYPICAL
Front suspensionArms
Rear Brake Reservoir
Check suspensionarms for cracks,
bending or other damage. Remove the seat.
See an authorized Can-Am dealer as With vehicle on a level surface, liquid
necessary. should be between MIN. and MAX.
level marks of brake pedal fluid reser-
Rear Trailing Arms voir.
Check trailing arms for distortion,
cracks or bending.
See an authorized Can-Am dealer if any
problem is detected.
Brakes
Brake Fluid Reservoir Level
Verification
With vehicle on a level surface, check vmo2015-005-026_b
brake fluid in reservoirs for proper 1. Rear brake fluid reservoir

level.
NOTE: A low level may indicate leaks Adding Brake FLuid
or worn brake pads. Clean filler cap.
Front Brake Reservoir
WARNING
Turn steering in the straight-ahead po-
sition to ensure reservoir is level. Clean filler cap before removing.
Remove screws retaining the reservoir

cap.
______________ 139
Remove reservoir cap.

Add fluid as required using a clean fun-
nel. Do not overfill.
NOTICE Brake fluid can damage
plastic and painted surface. Wipe
off and clean any spillage.
Reinstall reservoir cap and tighten
screws.
NOTE: Ensure filler cap diaphragm is
pushed inside the cap before closing
the brake fluid reservoir.

Always use brake fluid meeting the
specification DOT 4 only from a sealed
container.
WARNING
To avoid damage to the braking
system, do not use other brake
fluid types.
Brake Inspection
CAUTION The brakes can be

very hot after prolonged use of the
vehicle and can cause burns. Wait
for the brakes to cool down.
The brake inspection, maintenance
and repair should be performed by an
However, verify the following between
visits to your dealer:
– Brake fluid level
– Brake system for fluid leaks
– Brake cleanliness.
WARNING
The brake fluid replacement or
brake system maintenance and
repairs should be performed by an
140 ______________
VEHICLE CARE
Post-Operation Care Non Compatible Cleaning Products
When vehicle is used in salt-water en- NON-COMPATIBLE
vironment (beach area, launching and MATERIAL
CLEANING
loading boats etc.), rinsing the vehi- TYPE
PRODUCTS
cle with fresh water is necessary to
preserve vehicle and its components. ANY PETROLEUM
Metallic parts lubrication is highly rec- BASE CLEANING
ommended. Use XPS LUBE (P/N 293 PRODUCTS
600 016) or an equivalent. This must
be performed at the end of each oper- XP-S ATV
ating day. Finishing Spray
When vehicle is operated in muddy
conditions, rinsing the vehicle is rec- XP-S ATV Cleaning
ommended to preserve vehicle and its Kit (P/N 219 701 713)
components and to keep lights clean. (it contains the above
XP-S ATV Finishing
Vehicle Cleaning and Spray)
Protection
NOTICE Never use a high pres-
sure washer to clean the vehicle.
USE LOW PRESSURE ONLY (like a
garden hose).
Pay attention to certain areas where
mud or debris can accumulate and po-
tentially cause wear, interferences or
promote corrosion.
Wash the vehicle with a soapy water
solution.
NOTICE Never clean polypropy-
lene body parts with any petroleum
vbs2012-006-002_a
base cleaning products, as it will al-
ter the glossy finish. DO NOT USE ON POLYPROPYLENE
______________ 141
VEHICLE CARE
Compatible Cleaning Products

MATERIAL COMPATIBLE
TYPE CLEANING PRODUCT
XPS ATV Wash
Soapy water
vbs2012-006-001
SAFE FOR POLYPROPYLENE
142 ______________
STORAGE AND PRESEASON PREPARATION
When a vehicle is not in use for more
than (4) months, proper storage is a ne-
cessity.
When using your vehicle after storage,
a preparation is required.
See an authorized Can-Am dealer, re-
pair shop or person of your own choos-
ing to have your vehicle prepared for
either storage or the preseason.
______________ 143
STORAGE AND PRESEASON PREPARATION
This page is
intentionally blank
144 ______________
TECHNICAL
INFORMATION
______________ 145
VEHICLE IDENTIFICATION
The main components of your vehicle MFD. DATE FAB: 12/2003 1234 2
(engine and frame) are identified using VIN / NIV: 2BPS1234X2V000123 1
different serial numbers. It may some- MANUFACTURED BY / FABRIQUÉ PAR :
times become necessary to locate
MADE IN/FABRIQUÉ AU: MEXICO / MEXIQUE
these numbers for warranty purposes TYPE: ATV / VTT 704903901
or to trace your vehicle in the event of 704903901_a
loss. These numbers are also required
LABEL 2
by the authorized Can-Am dealer to 1. VIN (Vehicle Identification Number)
complete warranty claims properly. 2. Model
We strongly recommend that you take
note of all the serial numbers on your Engine Identification
vehicle and supply them to your insur-
ance company. Number (EIN)
Vehicle Identification
Number
vmr2015-005-001_a
vmo2014-020-004_a
TYPICAL BACK OF 450 ENGINE

1. Label 1 (on the frame under the seat in the 1. EIN (Engine Identification Number)
middle)
2. Label 2 (stamped onto frame behind RH
front wheel)
MFD. DATE FAB: 12/2003 1234 2

704 903 974
EN 15997
VIN / NIV: 2BPS1234X2V000123 1
Representative:
BRP Europe N.V.,
Skaldenstraat 125, TYPE:
Ghent, Belgium, 9042. ATV / VTT
704903974_a
LABEL 1
2. Model number
vmr2015-005-002_a
RH SIDE OF 570 ENGINE

146 ______________
NOISE EMISSION CONTROL SYSTEM REGULATION
(CANADA/UNITED STATES)
Tampering with Noise Control Sys-
tem Is Prohibited!
U.S. Federal law and Canadian provin-
cial laws may prohibit the following
acts or the causing there of:
1. The removal or rendering inoper-
ative by any person other than for
purposes of maintenance, repair or
replacement of any device or ele-
ment of design incorporated into
any new vehicle for the purpose of
noise control prior to its sale or de-
livery to the ultimate purchaser or
while it is in use or
2. The use of the vehicle after such
device or element of design has
been removed or rendered inoper-
ative by any person.
Among those Acts Presumed to
Constitute Tampering Are the Acts
Listed Below:
1. Removal or alteration or the punc-
turing of the muffler or any engine
component which conducts re-
moval of engine exhaust gases.
2. Removal or alteration or the punc-
turing of any part of the intake sys-
tem.
3. Replacing any moving parts of the
vehicle or parts of the exhaust or in-
take system, with parts other than
those specified by the manufac-
turer.
4. Lack of proper maintenance.
______________ 147
NOISE EMISSION AND VIBRATION VALUES (ALL
COUNTRIES EXCEPT CANADA/UNITED STATES)
MODEL 450 570
NOISE EMISSION AND VIBRATION VALUES1
83 dB @ 3600 RPM 81 dB @ 4000 RPM
Sound pressure (LpA) (Uncertainty (KpA) (Uncertainty (KWA)
3dB) 3dB)
Noise
95 dB @ 3600 RPM 96 dB @ 4000 RPM
Sound power level
(Uncertainty (KWA) (Uncertainty (KWA)
(LWA)
3dB) 3dB)
<2.5 m/s2 @ 3600 <2.5 m/s2 @ 4000
Hand-arm system
RPM RPM
Vibration
<0.5 m/s2 @ 3600 <0.5 m/s2 @ 4000
Whole body at seat
RPM RPM
1: Noise emission and Vibration values are measured in accordance with Standard EN 15997:2011 on
a paved surface, at Neutral.
148 ______________
The EC-Declaration of Conformity does not appear in this version of the
Operator's Guide.
Please refer to the printed version that was delivered with your vehicle.
ddd2009-001 EN
SPECIFICATIONS
450 Models
ENGINE 450
ROTAX 450, 4-stroke, Single Over Head
Engine type
Camshaft (SOHC), liquid cooled
Number of cylinder 1
Number of valves 4 valves (mechanical adjustment)
0.06 mm to 0.14 mm
Intake
(.0024 in to .0055 in)
Valve clearance
0.11 mm to 0.19 mm
Exhaust
(.0043 in to .0075 in)
Bore 94 mm (3.7 in)
Displacement 426.8 cm³ (26.04 in³)

Spark arrester approved by USDA
Exhaust system
Forest Service
Engine air filter Synthetic paper filter with foam
LUBRICATION SYSTEM 450

Type Wet sump with replaceable oil filter
Capacity 3 L (3.2 qt (U.S. liq.))
(oil change with filter) (engine/transmission)
XPS 4-stroke synth. blend
Lubrication
oil (P/N 293 600 121).
Engine oil XPS 4-stroke synthetic
oil (P/N 293 600 112).
Recommended
If not available, use a 4-stroke
SAE 5W 40 engine oil that meets
the requirements for API service
classification SJ, SL, SM or SN
150 ______________
SPECIFICATIONS
COOLING SYSTEM 450

Finland,
Norway Use Long life antifreeze (P/N 619
and 590 204)
Sweden
All other Use Long life antifreeze (P/N 219
Type
Coolant countries 702 685)
Alternative,
or if not
Ethyl glycol/distilled water
available
mix (50%/50%).
Capacity 2.9 L (3.1 qt (U.S. liq.))
TRANSMISSION 450
Type
Transmission)
GEARBOX 450
Type
neutral and reverse
ELECTRICAL SYSTEM 450

Without
400 W @ 6000 RPM
Quantity 1
Make and
NGK LMAR8D-J or equivalent
Spark plug type
0.7 mm to 0.9 mm
Gap
(.028 in to .035 in)
Forward 8000 RPM
______________ 151
SPECIFICATIONS

Voltage 12 Vdc
Nominal
Battery 18 A•h
rating
Power
starter 0.7 KW
output
High HS1 35 W
Headlights
Low HS1 35 W
Taillights P21/5W
Refer to FUSES in the
Fuses
MAINTENANCE section
FUEL SYSTEM 450

Electronic Fuel Injection (EFI), 46
Fuel delivery Type mm throttle body, 1 injector
per cylinder
Fuel pump Type Electrical (in fuel tank)
Idle speed 1250 RPM (not adjustable)
Inside
North 87 (R+M)/2 or higher
Fuel Minimum America
octane
rating Outside
North 92 RON or higher
America
152 ______________
SPECIFICATIONS
DRIVE SYSTEM 450

Capacity
XPS synthetic gear oil
Front differential oil/ Front (75W 90) (P/N 93 600 043)
rear final drive oil OR synthetic oil 75W 90 API GL5)
Type XPS synthetic gear oil (75W
140) (P/N 293 600 140)
Rear
or a 75W140 API GL-5 synthetic
gear oil
Straight gear Visco-Lok†
Base
auto-locking front differential
Front drive
All models except Straight gear Visco-lok† QE
Base auto-locking front differential
Rear drive Bevel Straight gear / final drive
Castrol CV joint grease (P/N 293
CV joint grease
550 062)
Propeller shaft grease (P/N 293
Propeller shaft grease
550 063)
STEERING 450
1-UP 205.7 cm (81 in)
Turning radius
2-UP 233.7 cm (92 in)
Camber angle (vehicle on ground) 0°
FRONT SUSPENSION 450

Double A-arm with dive-control
Suspension type
geometry
Quantity 2
Shock absorber
Type Oil
Preload adjustment type 5 positions cam
______________ 153
SPECIFICATIONS
REAR SUSPENSION 450

Trailing arm Independent (TTI)
Suspension type
with external stabilizer bar
Quantity 2
Shock absorber
Type Oil
BRAKES 450
Dual 214 mm cross drilled
Front brakes Type disc brakes with hydraulic
twin-piston calipers
Single 214 mm cross drilled
Rear brake Type disc brake with hydraulic
twin-piston caliper
Brake fluid
Type DOT 4
TIRES 450
1-UP 48.3 kPa (7 PSI)
Front
2-UP 48.3 kPa (7 PSI)
Pressure
1-UP 48.3 kPa (7 PSI)
Rear
2-UP 48.3 kPa (7 PSI)
Standard Front 635 x 203 x 305 mm (25 x 8 x 12 in)

DPS Rear 635 x 254 x 305 mm (25 x 10 x 12 in)
Tire size
Pro Front 660 x 203 x 305 mm (26 x 8 x 12 in)
Mossy Oak Rear 660 x 254 x 305 mm (26 x 10 x 12 in)
154 ______________
SPECIFICATIONS
WHEELS 450
Base Steel
Type All except base
Cast Aluminum
model
Front 305 x 152 mm (12 x 6 in)
Rim size
Rear 305 x 191 mm (12 x 7.5 in)
Wheel lug nut torque 100 N•m (74 lbf•ft)
DIMENSIONS 450
1-UP 211 cm (83 in)
Overall length
2-UP 231 cm (91 in)
1-UP 124 cm (49 in)
Overall height
2-UP 133 cm (52.5 in)
1-UP 129.5 cm (51 in)
Wheelbase
2-UP 149.9 cm (59 in)
Wheel track
All models
26.7 cm (10.5 in)
Ground clearance except Pro
Pro 29.2 cm (11.5 in)
LOADING CAPACITY AND WEIGHT 450

1-UP 308 kg (678 lb)
Dry weight
2-UP 324 kg (715 lb)
Total vehicle load allowed (including driver, all 1-UP 235 kg (517 lb)
Towing capacity 590 kg (1,300 lb)
Tongue capacity 23 kg (50 lb)
______________ 155
SPECIFICATIONS
570 Models
ENGINE 570
ROTAX® 570, 4-stroke, 2 cylinders
Engine type
0.06 mm to 0.14 mm
Intake
(.0024 in to .0055 in)
Valve clearance
0.11 mm to 0.19 mm
Exhaust
(.0043 in to .0075 in)
Spark arrestor approved by
Exhaust system
USDA Forest Service
LUBRICATION SYSTEM 570

Wet sump. Replaceable
Type
cartridge oil filter
2.0 L (2.1 qt (U.S. liq.))
filter)
XPS 4-stroke synth. blend
oil (P/N 293 600 121).
Engine oil XPS 4-stroke synthetic
oil(P/N 293 600 112).
Recommended
If not available, use a 5W40 motor
oil that meets the requirements
for API service classification
SJ, SL, SM or SN
156 ______________
SPECIFICATIONS
COOLING SYSTEM 570

Finland,
Norway Use Long life antifreeze (P/N 619
and 590 204)
Sweden
All other Use Long life antifreeze (P/N 219
Type
Coolant countries 702 685)
Alternative,
or if not
Ethyl glycol/distilled water
available
mix (50%/50%).
TRANSMISSION 570
Type
Transmission)
GEARBOX 570
Type
neutral and reverse

Recommended (P/N 293 600 140) or a 75W140
API GL-5 synthetic gear oil

Without
400 W @ 6000 RPM
Quantity 2
Make and
NGK DCPR8E or equivalent
Spark plug type
0.7 mm to 0.8 mm
Gap
(.028 in to .031 in)
Forward 8000 RPM
______________ 157
SPECIFICATIONS

Voltage 12 Vdc
Nominal
Battery 18 A•h
rating
Power
starter 0.7 KW
output
High HS1 35 W
Headlights
Low HS1 35 W
Taillights P21/5W
Refer to FUSES in the
Fuses
MAINTENANCE section
FUEL SYSTEM 570

Electronic Fuel Injection (EFI), 46
Fuel delivery Type mm throttle body, 1 injector
per cylinder
Fuel pump Type Electrical (in fuel tank)
Idle speed 1400 RPM (not adjustable)
Inside
North 87 (R+M)/2 or higher
Fuel Minimum America
octane
rating Outside
North 92 RON or higher
America
158 ______________
SPECIFICATIONS
DRIVE SYSTEM 570

Capacity
Front differential oil/ Front 90) (P/N 293 600 043)
rear final drive oil OR synthetic oil 75W 90 API GL5)
Type XPS synthetic gear oil (75W
140) (P/N 293 600 140)
Rear
synthetic gear oil
Straight gear Visco-Lok†
Base
auto-locking front differential
Front drive
All models except Straight gear Visco-lok† QE
Base auto-locking front differential
Rear drive Bevel straight gear / final drive
Castrol CV joint grease (P/N 293
CV joint grease
550 062)
Propeller shaft grease(P/N 293
Propeller shaft grease
550 063)
STEERING 570
1-UP 212 cm (83 in)
Turning radius
2-UP 239 cm (94 in)
Camber angle (vehicle on ground) 0°
FRONT SUSPENSION 570

Double A-arm with dive-control
Suspension type
geometry
Quantity 2
Shock absorber
Type Oil
______________ 159
SPECIFICATIONS
REAR SUSPENSION 570

Trailing arm Independent (TTI) with
Suspension type
external stabilizer bar
Quantity 2
Shock absorber
Type Oil
BRAKES 570
Dual 214 mm cross drilled
Front brakes Type disc brakes with hydraulic
twin-piston calipers
Single 214 mm cross drilled
Rear brake Type disc brake with hydraulic
twin-piston caliper
Brake fluid
Type DOT 4
TIRES 570
1-UP 48.3 kPa (7 PSI)
Front
2-UP 48.3 kPa (7 PSI)
Pressure
1-UP 48.3 kPa (7 PSI)
Rear
2-UP 48.3 kPa (7 PSI)
Base Front 635 x 203 x 305 mm (25 x 8 x 12 in)

DPS 635 x 254 x 305 mm (25 x
XT Rear
10 x 12 in)
Tire size
Mossy Oak† Front 660 x 203 x 305 mm (26 x 8 x 12 in)
Hunting
Edition 660 x 254 x 305 mm (26 x
Rear
Pro 10 x 12 in)
160 ______________
SPECIFICATIONS
WHEELS 570
Base Steel
Type All except base
Cast Aluminum
model
Front 305 x 152 mm (12 x 6 in)
Rim size
Rear 305 x 191 mm (12 x 7.5 in)
Wheel lug nut torque 100 N•m (74 lbf•ft)
DIMENSIONS 570
1-UP 211 cm (83 in)
Overall length
2-UP 231 cm (91 in)
1-UP 124 cm (49 in)
Overall height
2-UP 133 cm (52.5 in)
1-UP 129.5 cm (51 in)
Wheelbase
2-UP 149.9 cm (59 in)
Wheel track
All models
except
Mossy Oak
26.7 cm (10.5 in)
Hunting
Edition and
Ground clearance Pro
Mossy Oak
Hunting
29.2 cm (11.5 in)
Edition
Pro

1-UP 319 kg (704 lb)
Dry weight
2-UP 336 kg (741 lb)
______________ 161
SPECIFICATIONS
Total vehicle load allowed (including driver, all 1-UP 235 kg (517 lb)
Towing capacity 590 kg (1,300 lb)
Tongue capacity 23 kg (50 lb)
162 ______________
TROUBLESHOOTING
______________ 163
ENGINE DOES NOT TURN

1. Ignition switch is in the OFF position.
– Place switch to the ON position.
2. Emergency engine stop switch.
– Make sure that emergency engine stop switch is in ON position.
3. Gearbox is not set on PARK or NEUTRAL.
– Set gearbox either in PARK or in NEUTRAL or press the brake lever.
4. Burnt fuse.
– Check main, ignition or ECM fuse condition.
5. Weak battery or loose connections.
– Check charging system.
– Check connections and terminals condition.
– Have the battery checked.
6. Weak starter or loose connections.
– Check starter connections.
– Check starter relay.
ENGINE TURNS OVER BUT FAILS TO START

1. Flooded engine (spark plug wet when removed).
– (Drowned mode) If the engine does not start and it is fuel-flooded, this
special mode can be activated to prevent fuel injection and to cut ignition
while cranking. Proceed as follows:
• Insert key in ignition switch and turn to ON position.
• Move shift lever in park position.
• Press completely and HOLD throttle lever.
• Press the engine START button.
The engine should be cranked for 20 seconds. Release engine START but-
ton.
Release throttle lever and start/crank engine again to allow starting.
If it does not work:
• Clean the spark plug caps area then remove them.
• Remove the spark plugs.
• Unplug injector electrical connector.
• Crank engine several times.
• Install new spark plugs if possible or clean and dry spark plugs.
• Start engine as explained above.
If engine continues to flood, seek service from an authorized Can-Am dealer,
repair shop or person of your own choosing for maintenance, repair or
replacement. Please refer to the US EPA Emissions-related warranty con-
tained herein for information about warranty claims.
NOTE: Make sure to verify that there is no fuel in engine oil, if so, replace
engine oil.
164 ______________
ENGINE TURNS OVER BUT FAILS TO START (cont’d)

2. No fuel to the engine (spark plug dry when removed).
– Check fuel tank level.
– A failure of the fuel pump may have occurred.
– Check fuel pump fuse and relay.
own choosing for maintenance, repair or replacement. Please refer to the US
EPA Emissions-related warranty contained herein for information about war-
ranty claims.
3. Spark plug/ignition (no spark).
– Remove spark plug then reconnect to ignition coil.
– Start engine with spark plug grounded to the engine away from spark plug
hole. If no spark appears, replace spark plug.
– If trouble persists, seek service from an authorized Can-Am dealer, repair
shop or person of your own choosing for maintenance, repair or replace-
ment. Please refer to the US EPA Emissions-related warranty contained
herein for information about warranty claims.
4. Multifunction gauge CHECK ENGINE indicator lamp is on and display
shows CHECK ENGINE.
ranty claims.
CHECK ENGINE, seek service from an authorized Can-Am dealer, repair
shop or person of your own choosing for maintenance, repair or replace-
ment. Please refer to the US EPA Emissions-related warranty contained
herein for information about warranty claims.
ENGINE LACKS ACCELERATION OR POWER

1. Fouled or defective spark plug.
2. Lack of fuel to engine.
3. Engine is overheating. (CHECK ENGINE indicator light will turn on and HI
TEMP will appear in the multifunction display.)
– Refer to ENGINE OVERHEATS.
4. Air filter/housing clogged or dirty.
______________ 165
ENGINE LACKS ACCELERATION OR POWER (cont’d)

CHECK ENGINE or LIMP HOME, seek service from an authorized Can-Am
dealer, repair shop or person of your own choosing for maintenance, repair
or replacement. Please refer to the US EPA Emissions-related warranty
contained herein for information about warranty claims.
ENGINE OVERHEATS
1. Low coolant in cooling system.
– Check engine coolant, refer to ENGINE COOLANT in MAINTENANCE PRO-
CEDURES.
2. Dirty radiator fins.
– Clean radiator fins, refer to RADIATOR in MAINTENANCE PROCEDURES
section.
3. Cooling fan inoperative.
– Check cooling fan fuse or relay, refer to MAINTENANCE PROCEDURES
section. If the fuse is good, seek service from an authorized Can-Am dealer,
repair shop or person of your own choosing for maintenance, repair or
replacement. Please refer to the US EPA Emissions-related warranty con-
tained herein for information about warranty claims.
ENGINE BACKFIRE
1. Exhaust system leakage.
ranty claims.
2. Engine is running too hot.
3. Ignition timing is incorrect or there is an ignition system failure.
ranty claims.
ENGINE MISFIRE
1. Fouled/defective/worn spark plug.
– Clean/verify spark plug and heat range. Replace as required.
2. Water in fuel.
– Drain fuel system and refill with fresh fuel.
VEHICLE CANNOT REACH FULL SPEED

1. Engine.
166 ______________
VEHICLE CANNOT REACH FULL SPEED (cont’d)

2. Parking Brake.
– Ensure parking brake is completely removed.
3. Air filter/housing plugged or dirty.
CHECK ENGINE or LIMP HOME, seek service from an authorized Can-Am
dealer, repair shop or person of your own choosing for maintenance, repair
or replacement. Please refer to the US EPA Emissions-related warranty
contained herein for information about warranty claims.
SHIFT LEVER IS HARD TO MOVE

1. Gearbox gears are in a position that prevents the shift lever to work.
– Rock the vehicle back and forth to move the gears in the gearbox and allow
the shift lever to be set.
THE RPM INCREASES BUT THE VEHICLE DOES NOT MOVE

1. The gearbox is on PARK or NEUTRAL position.
– Select the R, HI or LO position.
3. Water in the CVT housing.
REDUCED POWER STEERING ASSIST

1. When DPS is subjected to sustained severe steering conditions, the assis-
tance provided by the DPS motor may be reduced to protect the system.
– Once the load is reduced, the normal steering assistance will return.
2. CHECK ENGINE INDICATOR LAMP is ON and display shows CHECK DPS
own choosing for maintenance, repair or replacement.
______________ 167
MULTIFUNCTION GAUGE MESSAGES
PILOT LAMP(S)
MESSAGE DESCRIPTION
ON
Displayed when brake is applied for more than 15 seconds
BRAKE None
(while riding).
Low battery voltage, check battery voltage and charging
LO BATT VOLT Check engine
system.
High battery voltage, check battery voltage and charging
HIGH BATT VOLT Check engine
system.
LOW OIL (1) Check engine Engine low oil pressure, stop engine immediately.
Engine is overheating, refer to ENGINE OVERHEATS in
HI TEMP Check engine
TROUBLESHOOTING section.
Serious fault on the engine that can change the normal
LIMP HOME Check engine operation of the engine, CHECK ENGINE indicator lamp
will also blink, refer to TROUBLESHOOTING section.
Engine fault, CHECK ENGINE indicator lamp will also be
CHECK ENGINE Check engine
ON, refer to TROUBLESHOOTING section.
Communication error between speedometer and engine
ECM NOT RECOGNIZED Check engine
control module (ECM).
CHECK DPS (models Indicates that the DPS (Dynamic Power Steering) does not
Check engine
with DPS) work properly. See an authorized Can-Am dealer.
MAINTENANCE
None Displayed in gauge when vehicle is due for a maintenance.
REQUIRED (2)
Throttle position sensor does not work properly. Seek
service from an authorized Can-Am dealer, repair shop or
TPS FAULT PRESS
person of your own choosing for maintenance, repair or
OVERRIDE BUTTON TO Check engine
replacement. Please refer to the US EPA Emissions-related
LIMP HOME
warranty contained herein for information about warranty
claims.
NOTICE (1) If the message and the check engine light stay on after engine
starting, stop engine. Check engine oil level. Refill if necessary. If the oil
level is good, seek service from an authorized Can-Am dealer, repair shop
or person of your own choosing for maintenance, repair or replacement.
Please refer to the US EPA Emissions-related warranty contained herein for
information about warranty claims. . Do not use the vehicle until repaired.
(2) To
erase the MAINTENANCE REQUIRED message, proceed as follows:
1. From main display (vehicle speed), press SET and HOLD.
2. Alternate between LOW beam and HIGH beam 3 times.
NOTE: Step 2 must be completed within 2 seconds.
168 ______________
WARRANTY
______________ 169
BRP LIMITED WARRANTY USA AND CANADA: 2018
CAN-AM® ATV
SCOPE OF THE LIMITED WARRANTY
Bombardier Recreational Products Inc. ("BRP")* warrants its 2018 Can-Am ATV
sold by authorized Can-Am ATV dealers (as hereinafter defined) in the United
States of America ("USA") and in Canada from defects in material or workmanship
for the period and under the conditions described below. This limited warranty will
become null and void if: (1) the ATV was used for racing or any other competitive
activity, at any point, even by a previous owner; or (2) the ATV has been altered
or modified in such a way so as to adversely affect its operation, performance or
durability, or has been altered or modified to change its intended use.
LIMITATIONS OF LIABILITY
THIS WARRANTY IS EXPRESSLY GIVEN AND ACCEPTED IN LIEU OF ANY
AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING
WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FIT-
NESS FOR A PARTICULAR PURPOSE TO THE EXTENT THAT THEY CANNOT
BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION
TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSE-
QUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS
WARRANTY SOME STATES/PROVINCES DO NOT ALLOW FOR THE DIS-
CLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A
RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU
SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS
WHICH MAY VARY FROM STATE TO STATE, OR PROVINCE TO PROVINCE.
Neither the distributor, any BRP dealer nor any other person has been authorized
to make any affirmation, representation or warranty regarding the product, other
than those contained in this limited warranty, and if made, shall not be enforceable
against BRP. BRP reserves the right to modify this limited warranty at any time, be-
ing understood that such modification will not alter the warranty conditions appli-
cable to the products sold while this warranty is in effect.
EXCLUSIONS – ARE NOT WARRANTED

The following are not warranted under any circumstances:
– Damage caused by failure to provide proper maintenance and/or storage, as de-
scribed in the Operator's Guide;
– Damage resulting from removal of parts, improper repairs, service, mainte-
nance, modifications or use of parts not manufactured or approved by BRP
Can-Am ATV dealer;
– Damage caused by abuse, abnormal use, neglect or operation of the product
in a manner inconsistent with the recommended operation described in the
Can-Am ATV Operator’s Guide;
– Damage resulting from accident, submersion, fire, theft, vandalism or any act of
God;
170 ______________
– Damages from rust, corrosion or exposure to the elements;
– Damage resulting from water or snow ingestion;
limitation towing, storage, telephone, rental, taxi, inconvenience, insurance
coverage, loan payments, loss of time, loss of income.
WARRANTY COVERAGE PERIOD

This limited warranty will be in effect from (1) the date of delivery to the first retail
consumer or (2) the date the product is first put into use, whichever occurs first and
for the applicable period below:
SIX (6) CONSECUTIVE MONTHS, for private use or commercial use owners. For
emission-related components; please also refer to the US EPA EMISSION-RE-
LATED WARRANTY contained herein.
CONDITIONS TO HAVE WARRANTY COVERAGE

been fulfilled:
from a Can-Am ATV dealer authorized to distribute Can-Am ATVs in the country
in which the sale occurred (“Can-Am ATV dealer”);
umented and signed by the purchaser;
– The 2018 Can-Am ATV must have undergone proper registration by an autho-
rized Can-Am ATV dealer;
– The 2018 Can-Am ATV must be purchased in the country in which the purchaser
resides;
BRP will not honor this limited warranty to any private use owner or commercial
are necessary in order to allow BRP to preserve both the safety of its products,
and also that of its consumers and the general public.
WHAT TO DO TO OBTAIN WARRANTY COVERAGE

The customer must cease using the Can-Am ATV upon the appearance of an anom-
aly. The customer must notify a servicing BRP dealer within three (3) days of the
appearance of a defect, and provide it with reasonable access to the product and
reasonable opportunity to repair it. The customer must also present to the autho-
rized BRP dealer, proof of purchase of the product and must sign the repair/work
order prior to starting the repair in order to validate the warranty repair. All parts re-
placed under this limited warranty become the property of BRP.
______________ 171
WHAT BRP WILL DO
BRP’s obligations under this warranty are limited to, at its sole discretion, repairing
parts found defective under normal use, maintenance and service, or replacing
such parts with new genuine Can-Am ATV parts without charge for parts and
labor, at any authorized BRP dealer during the warranty coverage period under the
conditions described herein. No claim of breach of warranty shall be cause for
cancellation or rescission of the sale of the Can-Am ATV to the owner.
ADDITIONAL SUPPLIER WARRANTIES

A GPS receiver may be supplied by BRP as standard equipment on certain 2018
Can-Am ATV's. The GPS receiver is covered under BRP’s limited warranty policy.
Additional warranty coverage if offered by the GPS receiver “supplier” that is
longer than BRP's limited warranty is to be dealt by the dealer or consumer directly
with the GPS receiver “supplier”.
TRANSFER
this limited warranty, subject to its terms and conditions, shall also be transferred
and be valid for the remaining coverage period provided BRP or an authorized
Can-Am ATV Distributor/Dealer receives a proof that the former owner agreed to
the transfer of ownership, in addition to the co-ordinates of the new owner.
CONSUMER ASSISTANCE
BRP suggests that you try to resolve the issue at the dealership level. We recom-
mend discussing the issue with the authorized dealer's service manager or owner.
* In the USA, products are distributed and serviced by BRP US Inc.

® Registered trademark of Bombardier Recreational Products Inc.
172 ______________
US EPA EMISSION-RELATED WARRANTY
Bombardier Recreational Products Inc. (“BRP”)* warrants to the ultimate pur-
chaser and each subsequent purchaser that this new vehicle, including all parts of
its exhaust emission control system and its evaporative emission control system,
meets two conditions:
1. It is designed, built, and equipped so it conforms at the time of sale to the ulti-
mate purchaser with the requirements of 40 CFR 1051 and 40 CFR 1060.
2. It is free from defects in materials and workmanship that may keep it from
meeting the requirements of 40 CFR 1051 and 40 CFR 1060.
Where a warrantable condition exists, BRP will repair or replace, as it elects, any
part or component with a defect in materials or workmanship that would increase
the engine’s emissions of any regulated pollutant within the stated warranty
period at no cost to the owner, including expenses related to diagnosing and
repairing or replacing emission-related parts. All defective parts replaced under
this warranty become the property of BRP.
For all emission-related warranty claims, BRP is limiting the diagnosis and repair of
emission-related parts to the authorized Can-Am dealers, unless for emergency re-
pairs as required by item 2 of the following list.
As a certifying manufacturer, BRP will not deny emission-related warranty claims
based on any of the following:
1. Maintenance or other service BRP or BRP's authorized facilities performed.
2. Engine/equipment repair work that an operator performed to correct an unsafe,
emergency condition attributable to BRP as long as the operator tries to restore
the engine/equipment to its proper configuration as soon as possible.
3. Any action or inaction by the operator unrelated to the warranty claim.
4. Maintenance that was performed more frequently than BRP specify.
5. Anything that is BRP fault or responsibility.
6. The use of any fuel that is commonly available where the equipment operates
unless BRP written maintenance instructions state that this fuel would harm
the equipment’s emission control system and operators can readily find the
proper fuel. See maintenance information section and fuel requirements of
fueling section.
Emission-Related Warranty Period

The emission-related warranty is valid for the following period whichever comes
first:
HOURS MONTHS KILOMETERS
Exhaust emission-related components 500 30 5000
Evaporative emission-related components N/A 24 N/A
______________ 173
Components Covered
The emission-related warranty covers all components whose failure would in-
crease an engine’s emissions of any regulated pollutant, including the following
listed components:
1. For exhaust emissions, emission-related components include any engine parts
related to the following systems:
– Air-induction system
– Fuel system
– Ignition system
– Exhaust gas recirculation systems
2. The following parts are also considered emission-related components for
exhaust emissions:
– Aftertreatment devices
– Crankcase ventilation valves
– Sensors
– Electronic control units
3. The following parts are considered emission-related components for evapora-
tive emissions:
– Fuel tank
– Fuel cap
– Fuel line
– Fuel line fittings
– Clamps*
– Pressure relief valves*
– Control valves*
– Control solenoids*
– Electronic controls*
– Vacuum control diaphragms*
– Control cables*
– Control linkages*
– Purge valves
– Vapor hoses
– Liquid/vapor separator
– Carbon canister
– Canister mounting brackets
– Carburetor purge port connector
4. Emission-related components also include any other part whose only purpose
is to reduce emissions or whose failure will increase emissions without signifi-
cantly degrading engine/equipment performance.
*As related to the evaporative emission control system
174 ______________
Limited Applicability
As a certifying manufacturer, BRP may deny emission-related warranty claims
for failures that have been caused by the owner’s or operator’s improper main-
tenance or use, by accidents for which the manufacturer has no responsibility,
or by acts of God. For example, an emission-related warranty claim need not be
honored for failures that have been directly caused by the operator’s abuse of the
engine/equipment or the operator’s use of the engine/equipment in a manner for
which it was not designed and are not attributable to the manufacturer in any way.
* In the USA, products are distributed and serviced by BRP US Inc.
______________ 175
BRP INTERNATIONAL LIMITED WARRANTY: 2018
CAN-AM® ATV
Bombardier Recreational Products Inc. ("BRP")* warrants its 2018 Can-Am
ATV sold by Can-Am ATV distributors or dealers authorized by BRP to distribute
Can-Am ATVs ("Can-Am ATV Distributor/Dealer") outside of the United States
of America ("USA"), Canada, member states of the European Economic Area
(which is comprised of the states of the European Union plus Norway, Iceland
and Liechtenstein) ("EEA"), Turkey, member states of the Commonwealth of
the Independent States (including Ukraine and Turkmenistan) ("CIS") and Turkey,
described below.
intended use.
GIVES YOU SPECIFIC RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY. (FOR PROD-
UCTS PURCHASED IN AUSTRALIA SEE CLAUSE 4 BELOW).

stances:
176 ______________
limitation towing, storage, transportation expenses, telephone, rental, taxi, in-
convenience, insurance coverage, loan payments, loss of time, loss of income;

for a period of:
SIX (6) CONSECUTIVE MONTHS for private use or commercial use.
FOR PRODUCTS SOLD IN AUSTRALIA ONLY

Nothing in these Warranty terms and conditions should be taken to exclude,
restrict or modify the application of any condition, warranty, guarantee, right or
remedy conferred or implied under the Competition and Consumer Act 2010
(Cth), including the Australian Consumer Law or any other law, where to do so
would contravene that law, or cause any part of these terms and conditions to be
void. The benefits given to you under this limited warranty are in addition to other
rights and remedies that you have under Australian law.
Our goods come with guarantees that cannot be excluded under the Australian
Consumer Law. You are entitled to a replacement or refund for a major failure
and for compensation for any other reasonably foreseeable loss or damage. You
are also entitled to have the goods repaired or replaced if the goods fail to be of
acceptable quality and the failure does not amount to a major failure.
______________ 177
been fulfilled:
umented;
– The 2018 Can-Am ATV must be purchased in the country or union of countries in
which the purchaser resides; and

days of the appearance of a defect, and provide it with reasonable access to the
to the authorized Can-Am ATV Distributor/Dealer proof of purchase of the product
property of BRP.
7) WHAT BRP WILL DO

178 ______________
8) TRANSFER
* For the territory covered by this limited warranty, products are distributed and serviced by
Bombardier Recreational Products Inc. or its affiliates.
______________ 179
BRP LIMITED WARRANTY FOR THE EUROPEAN
ECONOMIC AREA, THE COMMONWEALTH OF
THE INDEPENDENT STATES AND TURKEY: 2018
CAN-AM® ATV
Bombardier Recreational Products Inc. ("BRP")* warrants its 2018 Can-Am ATVs
sold by distributors or dealers authorized by BRP to distribute Can-Am ATVs
("Can-Am ATV Distributor/Dealer") in member states of the European Economic
Area (which is comprised of the member states of the European Union plus Nor-
way, Iceland and Liechtenstein) ("EEA"), in member states of the Commonwealth
of the Independent States (including Ukraine and Turkmenistan) ("CIS") and Turkey
described below.
intended use.
GIVES YOU SPECIFIC RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY.

stances:
180 ______________
limitation towing, transportation expenses, storage, telephone, rental, taxi, in-
convenience, insurance coverage, loan payments, loss of time, loss of income

for a period of:
TWENTY-FOUR (24) CONSECUTIVE MONTHS for private use.
SIX (6) CONSECUTIVE MONTHS for commercial use or rental use.
The product is used commercially when it is used in connection with any work or
employment that generates income during any part of the warranty period. The
product is also used commercially when, at any point during the warranty period,
it is licensed for commercial use.

been fulfilled:
umented;
______________ 181
– The 2018 Can-Am ATV must be purchased within the EEA by an EEA resident,
in the CIS for residents of the countries comprised in such area and in Turkey for
residents of Turkey; and
– Routine outlined in the Operator’s Guide must be timely performed in order
to maintain warranty coverage. BRP reserves the right to make warranty
coverage contingent upon proof of proper maintenance.

months of the appearance of a defect and provide it with reasonable access to the
to the authorized Can-Am ATV Distributor/Dealer, proof of purchase of the product
property of BRP.
7) WHAT BRP WILL DO

In the event that service is required outside of the EEA, CIS or Turkey, the owner
will bear responsibility for any additional charges due to local practices and
conditions, such as, but not limited to, freight, insurance, taxes, license fees,
8) TRANSFER
182 ______________
* In the EEA, products are distributed and serviced by BRP European Distribution S.A. and
other affiliates or subsidiaries of BRP.
______________ 183
ADDITIONAL TERMS AND CONDITIONS FOR FRANCE ONLY
The following terms and conditions are applicable to products sold in France only:
The seller shall deliver goods that are complying with the contract and shall be re-
sponsible for defects existing upon delivery. The seller shall also be responsible for
defects resulting from packaging, assembling instructions or the installation when
it is its responsibility per the contract or if accomplished under its responsibility. To
be compliant with the contract, the good shall:
1. Be fit for normal use for goods similar thereto and, if applicable:
• Correspond to the description provided by the seller and have the qualities
presented to the buyer though sample or model;
• Have the qualities that a buyer may legitimately expect considering the pub-
lic declarations of the seller, the manufacturer of its representative, including
in advertising or labeling; or
2. Have the characteristics mutually agreed upon as between the parties or be fit
for the specific use intended by the buyer and brought to the attention of the
seller and which accepted by the seller.
The action for failure to comply is prescribed after two years after delivery of the
goods. The seller is responsible for the warranty for hidden defects of the good
sold if such hidden defects are rendering the good unfit for the intended use, or
if they diminish its use in such a way that the buyer would not have acquired the
good or would have given a lesser price, had he known. The action for such hidden
defects shall be taken by the buyer within 2 years of the discovery of the defect.
184 ______________
CUSTOMER
INFORMATION
______________ 185
186 ______________
______________ 187
188 ______________
______________ 189
This page is
intentionally blank
190 ______________
______________ 191
192 ______________
ATV MODEL No.
VEHICLE
IDENTIFICATION NUMBER (V.I.N.)
ENGINE
IDENTIFICATION NUMBER (E.I.N.)
Owner:
NAME
No. STREET APT
CITY STATE/PROVINCE ZIP/POSTAL CODE
Purchase Date
YEAR MONTH DAY
Warranty Expiry Date

YEAR MONTH DAY
To be completed by the dealer at the time of the sale.
DEALER IMPRINT AREA
V00A2IL
Please verify with your dealer to ensure your vehicle has been registered with BRP.
WARNING
injury or death.

OUTLANDER Series / OUTLANDER MAX Series

2018
training course.
• DO NOT EXCEED VEHICLE SEATING CAPACITY
control if you carry more than a passenger.
Operator’s
Guide
if you carry a passenger.
SURFACE. You increase your risk of losing control
if you operate this vehicle on pavement.
• NEVER OPERATE THIS VEHICLE ON PUBLIC
Includes
ROADS. You can collide with another vehicle if you Safety, Vehicle
operate this vehicle on a public road. and Maintenance Information
STUNTS.
OUTLANDER Series/ TM
OUTLANDER MAX Series

TM TM
2018
WARNING
219 001 856 Read this guide thoroughly. It contains important safety information.
OPERATOR’S GUIDE OUTLANDER / MAX Series / ENGLISH
GUIDE DU COND. Séries OUTLANDER / MAX / ANGLAIS
Minimum recommended age: Operator: 16 years old. Keep this Operator’s Guide in the vehicle.
2 1 9 0 0 1 8 5 6 Original Instructions

2018 Can-Am Outlander 570 650 850 1000r Service Manual

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SAFETY NOTICE

CAUTION Indicates a hazardous situation

ment. TYPICAL — VEHICLE SERIAL NUMBER DECAL UNDER SEAT

1 TYPICAL — VEHICLE SERIAL NUMBER DECAL ON RH SIDE

BACK OF 450 ENGINE

Replacement or repair of any emission related

MANUAL INFORMATION MANUAL LAYOUT

This manual uses technical terms which may be

Section 06 ENGINE Page heading

Subsection title MAGNETO

Loctite 243 Drop represents a

Bold face number

Document number for 55 Page number

NOTICE Pay attention to torque specifications.

Remove starting pulley no. 2. TYPICAL Italic bold face type-

Bold face number following part

4.8 8.8 9.8 10.9 12.9

FASTENER FASTENER GRADE/TORQUE

FASTENER INFORMATION Threadlocker Application for

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

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

Threadlocker Application for Stud

1. Adjust screw to proper setting.

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

Application for Stripped Thread Repair 1 2

1. Clean shaft external contact surface.

Threadlocker Application for Case-In

1. Clean inner housing diameter and outer gasket

PERIODIC MAINTENANCE SCHEDULE

SEVERE DUSTY CONDITIONS

MAINTENANCE SCHEDULE LEGEND

EVERY 1 500 KM (1,000 MI) OR 50 HOURS (whichever comes first)

EVERY 3 000 KM (2,000 MI) OR 100 HOURS (whichever comes first)

EVERY 6 000 KM (4,000 MI) OR 200 HOURS (whichever comes first)

EVERY 12 000 KM (8,000 MI) OR 5 YEARS (whichever comes first)

Replace engine coolant

GENERAL – Riding on dry dirt covered surfaces

3. Check air filter dirty chamber for cleanliness.

1. Air filter cover

4. Remove air filter.

TYPICAL - SOME PARTS REMOVED FOR CLARITY

vmo2015-005-015_a Cleaning the Paper Filter

Cleaning the Foam Filter

TYPICAL - SOME PARTS REMOVED FOR CLARITY

Select a well-ventilated area and make sure the

CAUTION Never perform this operation

Installing the Engine Air Filter

start engine. TYPICAL — ALL MODELS

4. Remove carbon deposits from the spark ar-

TYPICAL NOTICE Use a soft brush and be careful to

2. Remove and discard the tail pipe retaining

Verifying the Engine Oil Level

1. Clean spark arrester

5. Inspect mesh of spark arrester for any damage.

For installation, reverse the removal procedure. TYPICAL - RH SIDE OF ENGINE

For all season, use:

Replacing the Engine Oil Filter

TYPICAL - SOME PARTS REMOVED FOR CLARITY

Allow oil to drain completely from the crankcase.

7. Reinstall remaining parts if applicable.

NOTICE Always use ethylene-glycol an-

Do not use tap water, straight antifreeze or 2. Remove pressure cap.

1. Leak indicator hose

Checking the Engine Coolant Specific